US 12,442,244 B2
Vacuum insulated panel seal density
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. 4, 2023, as Appl. No. 18/376,490.
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 63/427,661, filed on Nov. 23, 2022.
Claims priority of provisional application 63/427,645, filed on Nov. 23, 2022.
Claims priority of provisional application 63/427,657, filed on Nov. 23, 2022.
Prior Publication US 2024/0167312 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 3/12 (2006.01); C03C 4/00 (2006.01); C03C 8/02 (2006.01); C03C 8/24 (2006.01); C03C 27/06 (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 3/122 (2013.01); C03C 4/0071 (2013.01); C03C 8/02 (2013.01); C03C 27/06 (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)] 50 Claims
OG exemplary drawing
 
1. A vacuum insulating panel comprising:
a first substrate;
a second substrate;
a plurality of spacers provided in a gap between at least the first and second substrates, wherein the gap is at a pressure less than atmospheric pressure;
a seal provided at least partially between at least the first and second substrates, the seal comprising a first seal layer having a Te/V ratio of at least about 1.5:1 in terms of wt. % and comprising from about 20-80 wt. % tellurium oxide, and a second seal layer; and
wherein the first seal layer has a density of from about 2.8-4.0 g/cm3, the second seal layer has a density of from about 3.0-4.2 g/cm3, and wherein the density of the second seal layer is at least about 0.20 g/cm3 greater than the density of the first seal layer.
 
31. A vacuum insulating panel comprising:
a first substrate;
a second substrate;
at least one spacer provided in a gap between at least the first and second substrates, wherein the gap is at a pressure less than atmospheric pressure;
a seal provided at least partially between at least the first and second substrates, the seal comprising a first seal layer and a second seal layer;
wherein the first seal layer has a density of from about 2.8-4.0 g/cm3, the second seal layer has a density of from about 3.0-4.2 g/cm3, and wherein the density of the second seal layer is at least about 0.20 g/cm3 greater than the density of the first seal layer; and
wherein the seal further comprises a third seal layer, wherein the first seal layer is located between at least the second and third seal layers; wherein for at least one location of the seal the first seal layer has a first thickness, the second seal layer has a second thickness, and the third seal layer has a third thickness, and wherein the first thickness is greater than the second thickness and less than the third thickness.
 
39. A vacuum insulating panel comprising:
a first substrate;
a second substrate;
at least one spacer provided in a gap between at least the first and second substrates, wherein the gap is at a pressure less than atmospheric pressure;
a seal provided at least partially between at least the first and second substrates, the seal comprising a first seal layer and a second seal layer;
wherein the first seal layer has a density of from about 2.8-4.0 g/cm3, the second seal layer has a density of from about 3.0-4.2 g/cm3, and wherein the density of the second seal layer is at least about 0.20 g/cm3 greater than the density of the first seal layer; and
wherein, for at least one location of the seal, an outer lateral edge of the first seal layer is spaced inwardly from an outer lateral edge of the second seal layer by an offset distance of at least about 0.5 mm.
 
45. A vacuum insulating panel comprising:
a first substrate;
a second substrate;
a plurality of spacers provided in a gap between at least the first and second substrates, wherein the gap is at a pressure less than atmospheric pressure;
a seal provided between at least the first and second substrates, the seal comprising a first ceramic seal layer, a second ceramic seal layer, and a third ceramic seal layer, and wherein the seal is substantially lead-free;
wherein the first seal layer has a density of from about 2.9-3.9 g/cm3, the second seal layer has a density of from about 3.0-4.2 g/cm3, and the third seal layer has a density of from about 3.0-4.2 g/cm3, and wherein the density of the second seal layer is at least about 0.20 g/cm3 greater than the density of the first seal layer;
wherein, for at least one location of the seal, the first seal layer has a first thickness, the second seal layer has a second thickness, and the third seal layer has a third thickness; and
wherein the first thickness is greater than the second thickness and less than the third thickness.
 
50. A vacuum insulating panel comprising:
a first substrate;
a second substrate;
a plurality of spacers provided in a gap between at least the first and second substrates, wherein the gap is at a pressure less than atmospheric pressure;
a seal provided at least partially between at least the first and second substrates, the seal comprising a first seal layer comprising at least 45 wt. % tellurium oxide and a second seal layer; and
wherein the first seal layer has a density of from about 2.8-4.0 g/cm3, the second seal layer has a density of from about 3.0-4.2 g/cm3, and wherein the density of the second seal layer is at least about 0.20 g/cm3 greater than the density of the first seal layer.