Layered Vacuum Panel Seal to Limit Glass De-Tempering
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Solution Overview
Problem
Conventional vacuum insulated glass panels face issues such as significant de-tempering of glass substrates, lack of durability, hermiticity problems, slow processing times, and high manufacturing costs due to thermal heating methods and laser perimeter heating techniques.
Innovation Solution
A vacuum insulating panel with a multi-layer edge seal structure, comprising a main seal layer and primer layers, is designed to reduce induced transient thermal stress and improve hermiticity, durability, and manufacturing efficiency. The edge seal structure includes a main seal layer with a specific thickness and width, and primer layers with higher melting and softening points to provide strong mechanical bonding and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal heating methods are used to form the edge seal, then the seal hermiticity is improved, but significant de-tempering of glass substrates occurs and processing time increases
Solution Approach 1:
The seal structure is divided into multiple layers with different functions: a first seal layer for hermetic sealing, a second seal layer for mechanical bonding, and a third seal layer for additional sealing. This segmentation allows each layer to be optimized for its specific function, achieving hermiticity without requiring prolonged thermal heating that would cause de-tempering
Solution Approach 2:
Different regions of the seal have different thicknesses and material properties. The first seal layer has a specific thickness range (0.5-2.0 mm) optimized for hermetic sealing, while the second and third layers have different thicknesses optimized for mechanical bonding and structural integrity. This local differentiation enables the seal to achieve both hermiticity and durability without excessive thermal processing
2Productivity
If laser perimeter heating is used to form the edge seal, then sealing speed is improved, but induced transient thermal stress increases causing de-tempering and reduced durability
Solution Approach 1:
The seal is segmented into multiple layers that can be applied and cured sequentially at lower temperatures. The first seal layer provides hermetic sealing at lower temperatures, while subsequent layers provide mechanical bonding. This eliminates the need for high-temperature laser heating that causes thermal stress and de-tempering
Solution Approach 2:
The edge seal uses a composite structure with multiple seal layers having different material properties and thicknesses. This composite approach allows the system to achieve both hermetic sealing and mechanical strength without requiring the high temperatures that cause glass de-tempering and loss of durability
3Device complexity
If a single-layer seal is used, then device complexity is reduced, but seal hermiticity and durability are insufficient
Solution Approach 1:
The seal is divided into three distinct layers, each with specific thicknesses and functions. The first layer (0.5-2.0 mm) provides hermetic sealing, the second layer provides mechanical bonding, and the third layer provides additional sealing and structural support. This segmentation achieves superior hermiticity and durability while maintaining reasonable manufacturing complexity
Solution Approach 2:
Each seal layer has locally optimized thickness and material properties tailored to its specific function. The first layer has greater thickness for hermetic sealing, while subsequent layers have optimized thicknesses for mechanical bonding and structural integrity. This local optimization achieves high reliability without requiring excessive structural complexity
4Strength
If increased thermal heating is applied to improve seal bonding, then mechanical bonding strength is improved, but de-tempering of glass increases and manufacturing cost increases
Solution Approach 1:
The bonding function is distributed across multiple seal layers rather than requiring a single high-temperature bonding step. The second and third seal layers provide mechanical bonding at lower temperatures, eliminating the need for increased thermal heating and associated manufacturing costs
Solution Approach 2:
The multi-layer seal structure uses composite materials with different thermal and mechanical properties. This allows the system to achieve strong mechanical bonding through the combined effect of multiple layers at lower temperatures, reducing manufacturing costs while maintaining bonding strength
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 proposed solution effectively maintains the thermal tempering of glass substrates, reduces de-tempering rates, enhances the durability and hermiticity of the vacuum insulating panel, and improves manufacturing efficiency, leading to cost-effective production of high-quality panels.
Implementation Method 1
Providing a vacuum in the space between the substrates reduces conduction and convection heat transport, and thus provides insulating properties
Implementation Method 2
The edge seal structure includes a main seal layer with a specific thickness and width, and primer layers with higher melting and softening points to provide strong mechanical bonding and heat dissipation
Implementation Method 3
primer layers with higher melting and softening points to provide strong mechanical bonding
Implementation Method 4
primer layers with higher melting and softening points to provide strong mechanical bonding and heat dissipation
Data Source
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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 and second substrates, the seal including a first seal layer, a second seal layer, and a third seal layer, wherein the first seal layer may be located between at least the second and third seal layers; wherein, for at least one location of the seal, the first seal layer has a first thickness, the second seal layer has a second thickness, and the third seal layer has a third thickness; and wherein the first thickness may be greater than the second thickness and less than the third thickness.