US 12,377,640 B2
Method of making vacuum insulated panel with optimized laser speed
Scott V. Thomsen, Glen Arbor, MI (US); and Jun Huh, Ann Arbor, MI (US)
Assigned to LuxWall, Inc., Ypsilanti, MI (US)
Filed by LuxWall, Inc., Ypsilanti, MI (US)
Filed on Oct. 6, 2023, as Appl. No. 18/377,335.
Claims priority of provisional application 63/540,729, filed on Sep. 27, 2023.
Claims priority of provisional application 63/427,670, filed on Nov. 23, 2022.
Claims priority of provisional application 63/427,645, filed on Nov. 23, 2022.
Claims priority of provisional application 63/427,661, filed on Nov. 23, 2022.
Claims priority of provisional application 63/427,657, filed on Nov. 23, 2022.
Prior Publication US 2024/0166559 A1, May 23, 2024
This patent is subject to a terminal disclaimer.
Int. Cl. E06B 3/66 (2006.01); B01J 20/02 (2006.01); B23K 26/20 (2014.01); B23K 26/324 (2014.01); C03B 23/24 (2006.01); C03C 3/062 (2006.01); C03C 4/00 (2006.01); C03C 8/02 (2006.01); C03C 27/06 (2006.01); C03C 27/08 (2006.01); E06B 3/663 (2006.01); E06B 3/673 (2006.01); F16J 15/06 (2006.01); B23K 26/57 (2014.01); B23K 103/00 (2006.01); E06B 3/677 (2006.01)
CPC E06B 3/6612 (2013.01) [B01J 20/0211 (2013.01); B01J 20/0214 (2013.01); B01J 20/0248 (2013.01); B23K 26/206 (2013.01); B23K 26/324 (2013.01); C03B 23/245 (2013.01); C03C 3/062 (2013.01); C03C 4/0071 (2013.01); C03C 8/02 (2013.01); C03C 27/06 (2013.01); C03C 27/08 (2013.01); E06B 3/66304 (2013.01); E06B 3/66333 (2013.01); E06B 3/66342 (2013.01); E06B 3/673 (2013.01); E06B 3/67334 (2013.01); E06B 3/6736 (2013.01); F16J 15/062 (2013.01); B23K 26/57 (2015.10); B23K 2103/52 (2018.08); B23K 2103/54 (2018.08); C03C 2204/00 (2013.01); C03C 2207/00 (2013.01); E06B 2003/66338 (2013.01); E06B 3/6775 (2013.01)] 32 Claims
OG exemplary drawing
 
1. A method of making a vacuum insulating panel, the vacuum insulating panel comprising a first glass substrate, a second glass substrate, a plurality of spacers provided in a gap between at least the first and second glass substrates, and a seal provided at least partially between at least the first and second glass substrates, the seal comprising a first seal layer and a second seal layer; wherein the method comprises:
firing and/or sintering second seal material to form the second seal layer;
providing first seal material for the first seal layer in a location contacting the second seal layer;
wherein the second seal layer comprises bismuth oxide and boron oxide, and where the second seal layer comprises from about 1-40 mol % bismuth and from about 3-40 mol % boron on an elemental basis, and wherein the second seal layer comprises at least two times more boron than bismuth on an elemental basis in terms of mol %;
laser heating, using a laser beam from a laser, the first seal material in order to form the first seal layer;
wherein said laser heating comprises causing the laser beam to move at a lateral speed from about 5-70 mm/second relative to the substrates and the first seal material so that the laser beam at least partially passes through at least one of the glass substrates and impinges upon at least the second seal layer in order to heat the second seal layer and fire and/or sinter the first seal material thereby forming the first seal layer, in a manner so that at least one of (i) induced transient thermal stress in the first seal layer does not exceed about 25 MPa, and/or (ii) the first seal layer has a density of from about 2.8-4.0 g/cm3; and
after forming the first seal layer, evacuating the gap to a pressure less than atmospheric pressure.