Vacuum Insulated Glass Spacer Design for Thermal Stress Reduction
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Solution Overview
Problem
Vacuum insulated glass (VIG) faces challenges in achieving long-term stability and a tight seal, particularly with glass-glass connections being rigid, which limits pane size and thermal insulation, and evacuation processes are inefficient.
Innovation Solution
The solution involves a novel design of spacers distributed along stress lines to reduce thermal stresses, using a combination of materials and configurations such as spiral and hexagonal patterns, and magnetic fixing elements to eliminate adhesives and enhance positioning, along with production methods like punching and laser cutting for spacer creation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass-glass connection by glass solder is used, then a rigid bordering bond is achieved, but large geometrical dimensions cannot be combined with good thermal insulating values
Solution Approach 1:
The patent employs a composite bordering bond structure combining glass solder and metal solder (aluminum, zinc, or their alloys). The glass solder provides chemical bonding to the glass, while the metal solder provides mechanical strength and flexibility. This composite approach allows large pane dimensions while maintaining good thermal insulation by creating a flexible yet strong seal that accommodates thermal expansion and contraction.
2Adaptability or versatility
If glass-metal-glass connection is used, then flexible gas-tight bond suitable for high vacuum is achieved, but long-term stability and tight seal over time are challenging
Solution Approach 1:
The patent applies preliminary protective measures by coating the metal solder with protective layers (such as glass powder or ceramic coatings) before final assembly. This preliminary protection prevents oxidation and degradation of the metal during storage and installation, ensuring long-term stability. The evacuation opening is also prepared in advance with sealing surfaces that are pre-coated or pre-treated to ensure reliable vacuum sealing over time.
Solution Approach 2:
The bordering bond uses a composite structure with glass solder providing chemical adhesion to glass, metal solder providing flexibility and mechanical strength, and protective coatings preventing degradation. This multi-material composite approach maintains both flexibility for vacuum sealing and long-term reliability by protecting each component's strengths while mitigating their weaknesses.
3Ease of manufacture
If spacers are arranged in conventional patterns, then simple manufacturing is achieved, but thermal stresses are not effectively reduced
Solution Approach 1:
The patent arranges spacers along curved stress lines rather than straight conventional patterns. The stress lines follow the natural curvature of stress distribution in the glass pane, creating arc-shaped or spiral patterns of spacer placement. This curved arrangement better follows the actual stress flow paths, effectively reducing thermal stresses while remaining manufacturable through template-guided placement.
4Reliability
If evacuation opening is sealed after vacuum production, then vacuum space is achieved, but the sealing means projects beyond nominal dimensions
Solution Approach 1:
The patent designs the evacuation opening and sealing mechanism to be nested within the existing bordering bond structure. The evacuation opening is created through the metal solder layer, and the sealing means (such as a sealing ring or adhesive) is applied within the confines of the border seal, ensuring that no component projects beyond the nominal panel dimensions while still achieving reliable 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 significantly reduces thermal stresses and enhances the stability and service life of VIG units by allowing flexible gas-tight bonds and efficient evacuation, improving thermal insulation and reducing mechanical loading.
Implementation Method 1
designed for the vacuum-tight closure of the evacuation tube
Implementation Method 2
a spacer device which is designed to set the spacings of the glass plates
Data Source
AI summary
The invention relates to a vacuum insulated glass, which comprises two or more glass plates, which can be evacuated, which are oriented in parallel and which are sealed air-tight at the outer edge, with respect to the interior formed by means of spacers, by means of strip-shaped connecting elements attached to the entire perimeter, in particular metal strips connected to each other in a vacuum-tight manner, having the following features: a) the spacers each comprise at least two segments (7, 9) associated with each other, b) the spacers are arranged on closed distribution lines, which are arranged at a distance from each other and extend substantially parallel to the perimeter of the glass plate in question and run out in a defined manner in a curve in the corner regions of the glass plate, c) the segments (7, 9) are made of different materials, and d) the segments (7, 9) have a coating and/or structuring on the surfaces that do not come in contact with the glass plates (5, 6). The invention further relates to a method for producing the vacuum insulated glass.