Vacuum Insulated Panel Sealing With Laser-Activated Ti-Al-V Getter
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Solution Overview
Problem
Conventional vacuum insulated glass panels face issues such as significant de-tempering of glass substrates, high manufacturing costs, lack of durability, and hermeticity problems due to thermal stress and cracks, leading to safety and performance concerns.
Innovation Solution
A vacuum insulating panel with a Ti-Al-V crystalline phase getter material, activated via laser treatment, and a multi-layer edge seal structure with graded thermal expansion coefficients, allowing for efficient and durable sealing without significant de-tempering, maintaining compressive and tensile stresses, and ensuring hermeticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sealing methods are used to create vacuum insulated panels, then hermeticity can be achieved, but significant de-tempering of glass substrates and thermal stress gradients occur leading to durability issues
Solution Approach 1:
The patent changes the thermal expansion parameter by introducing a multi-layer seal structure with graded thermal expansion coefficients. The first seal layer has a thermal expansion coefficient matched to the glass substrate, while the second seal layer has a different coefficient, creating a gradient that reduces thermal stress and prevents de-tempering during vacuum creation and operation.
Solution Approach 2:
The patent uses composite seal structures with multiple layers having different material properties. The first seal layer and second seal layer are made of different materials with different thermal expansion coefficients, creating a composite structure that accommodates thermal stresses while maintaining hermeticity, thus preventing glass substrate de-tempering.
2Reliability
If conventional getters are used in vacuum insulated panels, then sorption function is provided, but the getter material does not achieve optimal sorption performance
Solution Approach 1:
The patent changes the physical and chemical parameters of the getter material by forming a Ti-Al-V crystalline phase through laser treatment. This crystalline phase has optimized parameters for sorption efficiency, significantly improving the getter's ability to absorb residual gases and maintain vacuum compared to conventional amorphous or differently-composed getter materials.
Solution Approach 2:
The patent utilizes phase transition by transforming the getter material from its initial state to a Ti-Al-V crystalline phase through laser treatment. This phase transition creates a more effective sorption structure, enhancing the getter's productivity and sorption efficiency in maintaining the vacuum environment.
3Ease of manufacture
If traditional manufacturing processes are used for vacuum insulated panels, then basic panel structure is achieved, but manufacturing costs and time are high
Solution Approach 1:
The patent merges multiple manufacturing steps into a single laser treatment process. The laser treatment simultaneously activates the getter material to form the Ti-Al-V crystalline phase and treats the seal layers to achieve proper bonding and stress distribution, eliminating the need for separate thermal processing steps and significantly improving manufacturing efficiency.
Solution Approach 2:
The patent replaces conventional thermal processing mechanisms with laser-based energy delivery. The laser provides localized, controlled energy input that achieves getter activation and seal layer treatment more efficiently than traditional oven or furnace methods, reducing manufacturing time and energy consumption while maintaining structural integrity.
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 high compressive and tensile stresses in glass substrates, reduces thermal stress gradients, enhances durability, and improves hermeticity, while reducing manufacturing costs and time, ensuring compliance with safety standards and thermal stability.
Implementation Method 1
laser treating and/or activating the getter in a manner causing the getter material to comprise a Ti—Al—V crystalline phase
Implementation Method 2
causing the getter material to comprise a Ti—Al—V crystalline phase which was not present in the getter material prior to the laser treating and/or activating
Implementation Method 3
a getter comprising getter material, wherein the new crystalline phase may improve sorption of the getter
Implementation Method 4
improve sorption of the getter in the vacuum insulating panel
Implementation Method 5
Providing a vacuum in the space between the substrates reduces conduction and convection heat transport
Implementation Method 6
The gap between the substrates may be at a pressure less than atmospheric pressure to provide insulating properties
Data Source
AI summary
A vacuum insulating panel includes first and second substrates (e.g., glass substrates), a hermetic edge seal, a pump-out port, and spacers sandwiched between at least the two substrates. The gap between the substrates may be at a pressure less than atmospheric pressure to provide insulating properties. The panel may include a getter. The getter may be laser activated in a manner which causes the getter to transform and realize a Ti—Al—V phase (e.g., Al3V0.333Ti0.667) of crystallite material. The getter may be a thin film getter and/or may be elongated in shape.