Vacuum Insulated Panel Seal Thickness for Glass Stress Control
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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, slow processing times, and durability problems due to thermal stress and hermeticity issues, which hinder their commercial viability and compliance with safety standards.
Innovation Solution
A vacuum insulating panel design with a multi-layer edge seal structure, utilizing a main seal layer and primer layers with controlled thickness and thermal expansion coefficients, combined with laser heating to minimize thermal stress and ensure hermeticity, durability, and compliance with safety codes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sealing methods are used to create hermetic seals in vacuum insulated panels, then the panels can maintain vacuum, but significant thermal stress and de-tempering of glass substrates occur during manufacturing
Solution Approach 1:
The patent changes the physical-chemical parameters of the sealant material by using a multi-layer ceramic composition with specific thickness ratios. The first ceramic seal layer (50-150 μm) contains different oxide compositions than the second layer (100-300 μm), creating a gradient structure that modifies thermal expansion behavior and stress distribution during heating, thereby maintaining hermeticity while reducing thermal stress on glass substrates
Solution Approach 2:
The patent employs a composite multi-layer ceramic seal structure where the first ceramic seal layer and second ceramic seal layer have different material compositions and thicknesses. This composite structure combines materials with complementary properties to achieve both hermetic sealing and thermal stress management, preventing de-tempering while maintaining vacuum integrity
2Ease of manufacture
If traditional edge seal structures are used, then manufacturing is simpler, but thermal stress gradients cause durability problems and hermeticity issues
Solution Approach 1:
The patent segments the edge seal into multiple distinct ceramic layers with different functions and compositions. The first ceramic seal layer provides initial sealing and stress management, while the second ceramic seal layer provides structural integrity and additional hermeticity. This segmentation allows each layer to be optimized for its specific function, improving overall reliability without excessive manufacturing complexity
Solution Approach 2:
The patent applies local quality by giving different regions of the seal (first layer vs. second layer) different material compositions and thicknesses tailored to their specific functional requirements. The first layer is thinner and compositionally optimized for stress management during heating, while the second layer is thicker and optimized for long-term structural stability and hermeticity
3Reliability
If thicker seal layers are used to improve hermeticity, then vacuum maintenance is better, but thermal stress and processing time increase
Solution Approach 1:
The patent optimizes the thickness parameter of each seal layer to achieve the minimum effective thickness required for hermeticity while reducing thermal mass. The first ceramic seal layer is kept thinner (50-150 μm) to minimize thermal stress and processing time, while the second layer (100-300 μm) provides sufficient structural support and long-term sealing, achieving hermeticity without excessive processing time
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, and enhances durability and hermeticity, enabling cost-effective and efficient production of vacuum insulated panels that meet safety standards.
Implementation Method 1
combined with laser heating to minimize thermal stress and ensure hermeticity
Implementation Method 2
edge seal structure, utilizing a main seal layer and primer layers with controlled thickness and thermal expansion coefficients, combined with laser heating
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
gap is at a pressure less than atmospheric pressure
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 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.