Localized Edge Heating for Vacuum Insulating Glass Seals
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Solution Overview
Problem
Conventional vacuum insulating glass (VIG) unit manufacturing techniques require high temperatures and long heating times, which can cause tempered glass to lose its temper strength and potentially deform or break, and can also affect low-E coatings, necessitating a more efficient edge sealing method.
Innovation Solution
Localized heating using a two-dimensional array of near-infrared heat sources is applied to the edges of the VIG unit to melt the frit, while maintaining the rest of the unit at a lower intermediate temperature, reducing the overall heating time and energy consumption, and utilizing a staged heating and cooling process in a multi-zone oven.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional high temperature heating (approximately 500°C) is applied to the entire VIG unit for edge seal formation, then the frit melts and forms a hermetic seal, but the tempered glass loses its temper strength and may deform or break
Solution Approach 1:
The patent applies localized heating only to the peripheral edges of the VIG unit where the frit seal is located, rather than heating the entire unit. This is achieved through a heating arrangement that concentrates thermal energy at the edges, allowing the frit to melt and form a hermetic seal while the central tempered glass areas remain at lower temperatures and retain their temper strength
Solution Approach 2:
The heating process is segmented into different zones: a high-temperature zone at the peripheral edges for frit melting, and a lower-temperature zone for the central glass areas. This spatial segmentation allows different parts of the unit to experience different temperature conditions appropriate to their functional requirements
2Reliability
If conventional high temperature heating is applied for extended periods, then complete frit melting and seal formation is achieved, but energy consumption increases and processing time is extended
Solution Approach 1:
By concentrating heating energy only at the peripheral edges where frit sealing is required, rather than heating the entire VIG unit, the patent significantly reduces total energy consumption while achieving complete frit melting and hermetic seal formation in the same or shorter time periods
3Reliability
If conventional high temperature heating is applied, then the frit melts and forms a hermetic seal, but low-E coatings on the glass substrates are adversely affected
Solution Approach 1:
The localized heating arrangement confines high temperatures to the peripheral edges where frit sealing occurs, while the central areas containing low-E coatings remain at lower temperatures. This spatial differentiation protects the temperature-sensitive low-E coatings from thermal degradation while still achieving complete frit melting and hermetic seal formation at the edges
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 method allows for the formation of a structurally sound hermetic edge seal that preserves at least 50% of the tempered glass's original strength, reduces the risk of glass deformation or breakage, and minimizes the impact on low-E coatings, while consuming less energy and saving time.
Implementation Method 1
Localized heating using a two-dimensional array of near-infrared heat sources is applied to the edges of the VIG unit to melt the frit
Implementation Method 2
The unit is pre-heated to one or more intermediate temperature(s)... and the unit is cooled
Implementation Method 3
utilizing a staged heating and cooling process in a multi-zone oven
Data Source
AI summary
Certain example embodiments of this invention relate to edge sealing techniques for vacuum insulating glass (VIG) units. More particularly, certain example embodiments relate to techniques for providing localized heating to edge seals of units, and/or unitized ovens for accomplishing the same. In certain example embodiments, a unit is pre-heated to one or more intermediate temperatures, localized heating via at least one substantially two-dimensional array of heat sources is provided proximate to the peripheral edges of the unit so as to melt frits placed thereon, and cooled. In certain non-limiting implementations, the pre-heating and/or cooling may be provided in one or more steps. An oven for accomplishing the same may include multiple zones for performing the above-noted steps, each zone optionally including one or more chambers. Accordingly, in certain example embodiments, a temperature gradient proximate to the edges of the unit is created, thereby reducing the chances of breakage and/or at least some de-tempering of the substrates.