Vacuum-Insulated Glass Windows Using Laser-Formed Integral Spacers
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Solution Overview
Problem
Vacuum-insulated glass windows with discrete spacers are aesthetically unpleasing and increase manufacturing complexity and cost due to the need for spacer placement and fixation between glass panes.
Innovation Solution
Integrally forming glass-bump spacers from the same material as the glass panes, using high-repetition-rate UV lasers to induce photo-absorption and locally heat the glass, allowing the spacers to protrude and maintain the necessary separation distance between panes, thereby eliminating the need for discrete spacers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If discrete spacers are used between glass panes, then the panes are effectively separated and maintained at a consistent distance, but the spacers are visible through the window making it unsightly and add manufacturing complexity
Solution Approach 1:
The spacer function is merged with the glass pane itself by forming protrusions directly on the glass surface. This eliminates discrete spacer components and their associated placement and fixation steps, while the protrusions remain invisible or minimally visible when viewed through the window, thus resolving both aesthetic and manufacturing complexity issues.
Solution Approach 2:
The glass pane is modified locally by forming protrusions at specific locations on its surface. These localized protrusions provide the spacing function only where needed, while the rest of the glass surface remains smooth and aesthetically pleasing. This local modification approach maintains visual clarity while achieving the mechanical spacing function.
2Reliability
If discrete spacers are placed and fixed between panes, then the panes are prevented from contacting each other, but this process adds cost and complexity to manufacturing
Solution Approach 1:
The spacer functionality is combined with the glass pane structure itself through the formation of protrusions. This eliminates the need for separate spacer components and their associated placement and fixation processes, significantly simplifying manufacturing while ensuring reliable pane separation through the integrated protrusion structures.
Solution Approach 2:
The glass pane provides its own spacing function through the protrusions formed on its surface. Instead of requiring external spacer components to be added during assembly, the glass pane itself serves the dual purpose of providing both structural integrity and spacing maintenance, thereby reducing manufacturing steps and costs.
3Length of stationary object
If visible spacers are used to maintain gap distance, then the panes are properly spaced, but the window appearance is compromised
Solution Approach 1:
The glass surface is locally modified with protrusions at specific positions to provide the necessary gap distance. These localized protrusions maintain consistent spacing while minimizing visual impact, as they are small and can be positioned to be less noticeable when viewed through the window, thus balancing spacing requirements with aesthetic considerations.
Solution Approach 2:
Instead of adding separate spacer elements between the panes, the solution inverts the approach by forming protrusions directly on the glass pane surface. This reversal of the traditional spacer concept allows the glass itself to provide the spacing function, eliminating the need for visible intermediate elements and improving overall appearance.
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 provides a visually seamless vacuum-insulated glass window with reduced manufacturing complexity and cost, while maintaining effective thermal and acoustic insulation properties by ensuring a consistent and controlled gap between the glass panes.
Implementation Method 1
using high-repetition-rate UV lasers to induce photo-absorption and locally heat the glass
Implementation Method 2
Vacuum-insulated glass (VIG) windows typically consist of two or more glass panes with a vacuum in between, which provides improved thermal and noise insulating properties
Data Source
AI summary
Vacuum-insulated glass (VIG) windows (10) that employ glass-bump spacers (50) and two or more glass panes (20) are disclosed. The glass-bump spacers are formed in the surface (24) of one of the glass panes (20) and consist of the glass material from the body portion (23) of the glass pane. Thus, the glass-bump spacers are integrally formed in the glass pane, as opposed to being discrete spacer elements that need to be added and fixed to the glass pane. Methods of forming VIG windows are also disclosed. The methods include forming the glass-bump spacers by irradiating a glass pane with a focused beam (112F) from a laser (110). Heating effects in the glass cause the glass to locally expand, thereby forming a glass-bump spacer. The process is repeated at different locations in the glass pane to form an array of glass-bump spacers. A second glass pane is brought into contact with the glass-bump spacers, and the edges (28F, 28B) sealed. The resulting sealed interior region (40) is then evacuated to a vacuum pressure of less than one atmosphere.