Laminated Vacuum Insulated Glass Unit Compression Bonding
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Solution Overview
Problem
Existing methods for laminating vacuum insulated glass (VIG) units face challenges such as surface roughness, thermal deflection, and inefficient bonding, which affect the quality and yield of laminated VIG units.
Innovation Solution
A method involving a lamination assembly with a VIG unit and a lamination layer, where the assembly is subjected to compression pressure and heating. This process helps in smoothing the lamination layer, adapting it to surface variations, and ensuring proper bonding between the VIG unit and the further sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If compression pressure is applied to the lamination assembly, then bonding strength between the lamination layer and glass sheets is improved, but surface roughness and thermal deflection may occur
Solution Approach 1:
The patent applies heating to change the physical state of the lamination layer, making it more pliable and adaptable to surface variations. This parameter change (temperature increase) allows the lamination layer to conform to the glass sheet surface under compression pressure, improving bonding strength while accommodating surface roughness rather than exacerbating it.
Solution Approach 2:
The patent introduces a cushioning layer between the compression source and the lamination assembly to distribute and moderate the compression pressure. This beforehand cushioning prevents excessive or uneven pressure that could cause thermal deflection or surface distortion, while still providing sufficient pressure for bonding.
2Manufacturing precision
If heating is applied to soften the lamination layer for bonding, then lamination quality is improved, but thermal deflection of the VIG unit occurs
Solution Approach 1:
The patent applies heating locally and selectively to specific areas of the lamination assembly rather than uniformly heating the entire VIG unit. This localized heating approach softens the lamination layer where bonding is needed while minimizing thermal exposure to the glass sheets, thereby reducing thermal deflection while maintaining lamination quality.
Solution Approach 2:
The cushioning layer serves as a thermal buffer that moderates heat transfer to the glass sheets. This beforehand cushioning prevents excessive heat penetration that could cause thermal deflection, while still allowing sufficient heat to reach the lamination layer for softening and bonding.
3Productivity
If fast lamination process is implemented to meet manufacturing capacity demands, then productivity is improved, but lamination quality and bonding control may be compromised
Solution Approach 1:
The patent prepares the lamination layer in advance by pre-heating or pre-positioning it on the glass sheet before the actual bonding process. This preliminary action reduces the time and complexity required during the main lamination step, enabling faster production cycles while maintaining bonding quality through controlled conditions.
Solution Approach 2:
The patent optimizes processing parameters such as temperature, pressure, and time to achieve rapid yet controlled bonding. By carefully selecting and adjusting these parameters, the process achieves fast cycle times suitable for high-volume manufacturing while maintaining consistent lamination quality and bonding strength.
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 method provides a fast and controlled lamination process, improving the yield and quality of laminated VIG units by ensuring strong bonding and minimizing surface roughness and thermal deflection issues.
Implementation Method 1
the lamination assembly is heated
Implementation Method 2
the heated and thus softened lamination layer
Implementation Method 3
The one or more clamping body displacers is operated to provide a compression pressure to the lamination assembly by means of the clamping surfaces
Data Source
AI summary
The present disclosure relates to a method of providing a laminated vacuum insulated glass (VIG) unit (1), wherein the method comprises: providing a lamination assembly (10) comprising a vacuum insulated glass (VIG) unit (11) comprising at least two, tempered glass sheets (11a, 11b) separated by a plurality of support structures (12) distributed in a gap (13) between the tempered glass sheets (11a, 11b), and a lamination layer (2) arranged between one of the tempered glass sheets (11a, 1b) of the vacuum insulated glass (VIG) unit (11) and a further sheet (3), arranging the lamination assembly (10) between clamping bodies (7, 8) providing clamping surfaces (4, 5), wherein at least one of said clamping surfaces (4, 5) is configured to be displaced by one or more clamping body displacers (6, 21) to change the distance between the clamping surfaces (4, 5), and operating the clamping body displacers (6, 21) to provide a compression pressure (F) to the lamination assembly (10) by means of the clamping surfaces (4, 5), and heating the lamination assembly (10). The disclosure additionally relates to a system for providing laminated vacuum insulated glass (VIG) units (1), and use of such a system.