Vacuum Insulated Panel Edge Seal Density for Hermeticity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional vacuum insulated glass panels face issues such as significant de-tempering of glass substrates, high manufacturing costs, and durability problems due to thermal stress and hermeticity issues, which hinder their commercial viability.
Innovation Solution
A vacuum insulating panel with a multi-layer ceramic edge seal, utilizing a main seal layer and primer layers with controlled thermal expansion coefficients, is formed using a laser to minimize thermal stress and ensure hermeticity, while maintaining the glass substrates' compressive and tensile stress within safety limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sealing methods are used to create hermetic edge seals, then sealing is achieved, but significant de-tempering of glass substrates occurs and thermal stress problems arise
Solution Approach 1:
The seal is divided into multiple layers with different materials and properties. The first seal layer has different thermal expansion characteristics than the second seal layer, allowing each layer to accommodate thermal stress differently while collectively providing hermetic sealing, thus preventing de-tempering of the glass substrates
Solution Approach 2:
The patent changes the physical and chemical parameters of the seal layers by controlling the density difference between the first and second seal layers. This parameter control allows the seal to withstand thermal stress without causing significant de-tempering of the glass substrates while maintaining hermeticity
2Reliability
If conventional sealing methods are used, then sealing is achieved, but durability problems occur due to thermal stress
Solution Approach 1:
The multi-layer seal structure segments the thermal stress distribution, with each layer having different mechanical properties. This segmentation prevents stress concentration that would lead to durability problems, while maintaining long-term hermeticity under thermal cycling conditions
Solution Approach 2:
The seal uses composite materials with different thermal and mechanical properties in each layer. This composite structure enhances durability by distributing thermal stress across layers with complementary properties, preventing failure under prolonged thermal exposure
3Reliability
If conventional sealing methods are used, then sealing is achieved, but manufacturing costs are high
Solution Approach 1:
The patent replaces conventional high-temperature thermal sealing processes with a controlled laser firing process. This substitution allows precise localized heating that achieves hermetic sealing while minimizing overall thermal exposure, reducing manufacturing costs by eliminating the need for expensive high-temperature furnaces and lengthy processing times
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution maintains the glass substrates' thermal tempering, enhances durability and hermeticity, and reduces manufacturing costs by minimizing thermal stress and de-tempering, ensuring compliance with safety standards and efficient production.
Implementation Method 1
using a laser (e.g., near-IR laser) to fire and/or sinter the first seal layer
Implementation Method 2
fire and/or sinter the first seal layer, so that after evacuation of the gap to a pressure less than atmospheric pressure the first seal layer may have a density of from about 2.8-4.0 g/cm3
Implementation Method 3
Providing a vacuum in the space between the substrates reduces conduction and convection heat transport, and thus provides insulating properties
Implementation Method 4
the gap is at a pressure less than atmospheric pressure
Implementation Method 5
reducing radiative energy with a low-emissivity (low-E) coating provided on one of the substrates
Data Source
AI summary
A vacuum insulating panel may include: a first substrate; a second substrate; a plurality of spacers provided in a gap between at least the first and second substrates, wherein the gap is at a pressure less than atmospheric pressure; a seal provided between at least the first substrate and the second substrate, the seal comprising a first seal layer; wherein the first seal layer comprises tellurium oxide and vanadium oxide; wherein the first seal layer comprises, on a wt. %, more tellurium oxide than vanadium oxide, and has a density of from about 2.8-4.0 g/cm3.