Vacuum Insulated Glazing Edge Sealing Without Frit Foaming
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Solution Overview
Problem
Existing methods for manufacturing vacuum insulated glass (VIG) units face issues with manufacturing speed, end product quality, and foaming of edge seal materials during the sealing process, which affects the integrity and efficiency of the vacuum seal.
Innovation Solution
A method involving the use of glass frit powder material heated to a softening temperature, applied to glass sheets, and then re-heated without foaming, allowing for a dense edge sealing that effectively evacuates the gap between the glass sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If edge seal material is heated to melt and adhere to glass sheets, then sealing quality is improved, but gaseous inclusions form causing foaming and expansion
Solution Approach 1:
The patent applies glass frit powder to the glass sheets before placing them in the vacuum chamber, rather than heating and melting the seal material after evacuation. This preliminary application allows the seal material to be in place before vacuum sealing, preventing foaming that would occur if heating happened after evacuation.
Solution Approach 2:
The patent changes the temperature parameter by not heating the glass sheets above the softening point of the glass frit during vacuum sealing. Instead, the glass frit is applied in a softened state at lower temperatures, avoiding the vigorous foaming that occurs with high-temperature heating in vacuum.
2Object-generated harmful factors
If heating is conducted slowly to defoam internal gases, then foaming is reduced, but manufacturing time increases
Solution Approach 1:
The glass frit powder is applied to the glass sheets before vacuum sealing, eliminating the need for slow heating to defoam. The seal material is already in position when vacuum is applied, allowing rapid sealing without foaming issues.
Solution Approach 2:
The patent skips the slow heating and defoaming process entirely by applying the glass frit powder directly to the glass sheets before evacuation. The vacuum sealing proceeds rapidly without the need for prolonged heating cycles.
3Reliability
If edge seal material is heated in vacuum chamber, then sealing is achieved, but gases vigorously foam causing incomplete joining
Solution Approach 1:
The glass frit powder is applied to the glass sheets before placing them in the vacuum chamber and before heating. This ensures the seal material is already in position and can bond effectively without vigorous foaming that would occur with in-chamber heating.
Solution Approach 2:
The patent uses glass frit powder with specific compositional parameters that allow it to soften and bond at lower temperatures without vigorous foaming. The powder form and composition are optimized to prevent gas release issues during vacuum sealing.
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 results in a stronger, high-quality VIG unit with reduced foaming, enabling faster and less complex manufacturing, and maintaining the vacuum seal for extended periods.
Implementation Method 1
heating a glass frit powder material to a softening temperature (Tfrit-powder) to soften the glass frit powder material
Implementation Method 2
re-heating the applied glass frit powder material by use of at least one heat source
Implementation Method 3
evacuating the gap between the paired glass sheets in a vacuum chamber
Data Source
AI summary
A vacuum insulated glass (VIG) unit, and a window having the same, the VIG unit including paired glass sheets separated by support structures maintaining a gap between the paired glass sheets, a dense edge sealing peripherally arranged creating a sealed cavity between the paired glass sheets, a getter placed in the gap between the glass sheets, where the pressure in the sealed cavity is no higher than 0.001 mbar, where at least one of the first glass sheet and the second glass sheet includes a low-emission coating, where the edge sealing is made from low temperature glass frit powder material, and includes less than 0.1 wt % lead, less than 1 wt % solvent and less than 1 wt % binder, where gaseous inclusions in the edge sealing constitutes less than 5% of the total volume, and where the glass frit powder material includes tellurium oxide and vanadium oxide.