Microwave heating equipment serves as the primary fusion mechanism in the production of solder-free Vacuum Insulated Glass (VIG). By utilizing microwave-absorbing materials, the equipment concentrates energy solely on the glass edges, reaching temperatures of approximately 550°C to permanently bond the sheets without intermediate solders.
This technology replaces traditional sealing pastes with direct glass-to-glass fusion. It creates a robust, eco-friendly seal while leaving the central vision area and its delicate coatings unaffected by the high heat.
The Mechanism of Solder-Free Sealing
The Role of Microwave Absorbers
Microwaves alone do not heat glass efficiently enough for fusion. The equipment employs microwave-absorbing materials, such as carbon blocks, to capture the energy.
Converting Energy to Heat
These absorbers convert microwave energy into intense thermal energy. This process targets the glass edges specifically, raising the temperature to approximately 550°C.
Direct Edge Fusion
At this temperature, the glass softens sufficiently to fuse. This enables a direct bond between the glass sheets, completely eliminating the need for glass powder, solder, or adhesive pastes.
Advantages Over Traditional Methods
Eliminating Material Costs
Traditional VIG production requires expensive sealing materials. Microwave heating removes this variable, significantly reducing the overall material cost of production.
Environmental Safety
Many sealing solders contain environmentally sensitive elements. This method allows for a lead-free manufacturing process, aligning with modern environmental and safety standards.
Understanding the Process Constraints
Reliance on Absorbing Materials
This is not a "beam-and-heat" process that works on bare glass. The system is entirely dependent on the precise application of microwave absorbers (like carbon blocks) to facilitate the heating process.
The Necessity of Localization
The system relies on a localized thermal field. The equipment must maintain strict control to ensure heat is generated only at the edges, requiring precise calibration to avoid thermal stress on the rest of the pane.
Preserving Glass Integrity
Protecting Mechanical Properties
Because the high heat is restricted to the edge, the structural integrity of the main glass area remains untouched. The equipment protects the mechanical properties of the pane from heat-induced degradation.
Safeguarding Performance Coatings
Modern VIG units rely on sensitive Low-E coatings for energy efficiency. The localized thermal field ensures these coatings are not damaged during the sealing process, maintaining the unit's thermal performance.
Making the Right Choice for Your Goal
- If your primary focus is Cost Reduction: Leverage direct fusion to eliminate the recurring expense of solders and glass powders.
- If your primary focus is Environmental Compliance: Adopt microwave heating to ensure a completely lead-free, solder-free production line.
- If your primary focus is Product Performance: Utilize the localized heating profile to protect sensitive Low-E coatings and glass temper.
Microwave heating transforms VIG manufacturing from a material-heavy assembly process into a clean, precise fusion technique.
Summary Table:
| Feature | Microwave Solder-Free Fusion | Traditional Solder Methods |
|---|---|---|
| Sealing Mechanism | Direct glass-to-glass fusion | Glass powder, solder, or paste |
| Operating Temp | ~550°C (Localized at edges) | Variable (Often full furnace heat) |
| Material Cost | Significantly lower (No solders) | High (Recurring solder expense) |
| Environmental Impact | Lead-free & Eco-friendly | Often contains sensitive elements |
| Coating Protection | Preserves Low-E coatings | Risk of coating degradation |
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References
- Wonyeong Jung, Seung Hwan Ko. Recent Progress in High-Efficiency Transparent Vacuum Insulation Technologies for Carbon Neutrality. DOI: 10.1007/s40684-024-00623-x
This article is also based on technical information from Kintek Furnace Knowledge Base .
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