Vacuum Insulated Panel Tube Mounting to Prevent Seal Cracking
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Solution Overview
Problem
Conventional vacuum insulating panels face issues with seal structures for evacuation tubes, leading to breakage and cracking, which compromises hermeticity and results in premature window failures.
Innovation Solution
The design incorporates specific bore configurations and support structures for evacuation tubes, utilizing different bore sizes and support surfaces to minimize tilting during seal formation, along with laser-sealed tube seals to enhance adhesion and hermeticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional seal structures for evacuation tubes are used, then the manufacturing process is simple, but the seal structure breaks and cracks leading to loss of hermeticity
Solution Approach 1:
The seal structure is divided into multiple segments including a first seal portion, a second seal portion, and a third seal portion, each providing different functions. The first seal portion provides the seal, the second seal portion reinforces against cracking, and the third seal portion provides additional support, collectively preventing breakage while maintaining hermeticity.
Solution Approach 2:
The patent applies preliminary reinforcement to the seal structure by adding the second and third seal portions before the evacuation tube is installed. This preliminary action prevents crack formation and propagation during subsequent manufacturing and operation, ensuring hermeticity is maintained throughout the product lifecycle.
2Reliability
If the evacuation tube is loosely supported, then the manufacturing process is fast, but the tube tilts during seal formation causing breakage
Solution Approach 1:
The patent provides localized support at critical positions along the evacuation tube rather than uniform support throughout. The first support surface, second support surface, and third support surface are positioned at specific locations to prevent tilting during seal formation, balancing stability requirements with manufacturing efficiency.
Solution Approach 2:
The patent introduces intermediary support structures (support surfaces and spacers) between the evacuation tube and the surrounding structure. These intermediaries prevent direct contact that could cause tilting, while also providing the necessary stability during seal formation without significantly slowing manufacturing.
3Reliability
If the bore diameter is large, then the evacuation tube installation is easy, but the tube tilts more during sealing
Solution Approach 1:
The patent addresses the tilting problem by adding dimensional constraints through multiple support surfaces positioned at different heights and locations. The first, second, and third support surfaces create a three-dimensional support system that prevents tilting in multiple directions, maintaining alignment even with larger bore diameters that facilitate easier tube installation.
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
This approach improves evacuation tube seal adhesion, maintains hermeticity, reduces glass breakage and crack formation, enhances moisture resistance, and increases thermal stability and durability while facilitating faster manufacturing.
Implementation Method 1
The gap between the substrates may be at a pressure less than atmospheric pressure to provide insulating properties. Providing a vacuum in the space between the substrates reduces conduction and convection heat transport
Implementation Method 2
reducing conduction and convection heat transport, and thus provides insulating properties
Implementation Method 3
reducing conduction and convection heat transport
Implementation Method 4
reducing radiative energy with a low-emissivity (low-E) coating provided on one of the substrates
Implementation Method 5
using a laser to form the tube seal
Implementation Method 6
using a laser to form the tube seal, the tube seal being supported on at least a first support surface at a base of the first bore
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 pressure less than atmospheric pressure; an evacuation tube extending at least partly into an aperture in one of the substrates; and an evacuation tube seal at least partially surrounding the tube. Relationship(s) between the tube, and bore(s) in the substrate for mounting the tube, may be designed to reduce tube tilting.