Composite Edge Seal for Insulating Glass Thermal Management
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Solution Overview
Problem
Existing edge seal systems for insulating glass and solar modules face issues with thermal insulation due to metal spacers being good heat conductors, and silicone-based secondary sealants can lead to deformation or movement of thermoplastic spacers under external influences, causing optical defects and gas leakage.
Innovation Solution
A polymer-modified primary sealant with olefinic polymers, inert fillers, desiccants, and UV stabilizers, combined with a silicone-based secondary sealant, forms a stable bond through chemical interactions, preventing deformation and enhancing adhesion to glass and other materials, thus creating a durable edge seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal spacers are used to maintain glass pane distance, then the spacer provides structural support and maintains geometry, but the metal spacer conducts heat well which reduces thermal insulation performance
Solution Approach 1:
The patent uses a composite edge seal system combining thermoplastic spacer material with both primary sealant (polyisobutylene-based) and secondary sealant (silicone-based). This composite structure provides structural support while the thermoplastic material has lower thermal conductivity than metal, improving thermal insulation performance.
Solution Approach 2:
The patent changes the material parameter of the spacer from metal to thermoplastic, fundamentally altering the thermal conductivity parameter. The thermoplastic material maintains the required mechanical strength for structural support while significantly reducing heat conduction to improve the overall K-value of the insulating glass unit.
2Ease of operation
If silicone-based secondary sealant is used to bond the edge seal, then the sealant provides flexible bonding and sealing, but the silicone can cause deformation or movement of thermoplastic spacers under external influences like UV radiation and temperature changes
Solution Approach 1:
The patent introduces a primary sealant layer as an intermediary between the thermoplastic spacer and the silicone-based secondary sealant. This primary sealant (polyisobutylene-based) acts as a buffer that prevents direct contact between the silicone and thermoplastic spacer, eliminating the harmful chemical interactions while maintaining the flexible bonding function of the secondary sealant.
Solution Approach 2:
The primary sealant is applied beforehand to protect the thermoplastic spacer from the harmful effects of the silicone-based secondary sealant. This protective layer prevents UV-induced degradation and chemical incompatibility issues before the secondary sealant is applied, ensuring long-term stability of the edge seal system.
3Reliability
If a dual sealant system with primary and secondary sealants is used, then the seal provides comprehensive protection against moisture and gas, but the manufacturing process becomes complicated and cost-intensive
Solution Approach 1:
The primary sealant performs multiple functions: it bonds the thermoplastic spacer to the glass panes, provides initial sealing against moisture and gas, and serves as a protective intermediary layer. The secondary sealant provides additional sealing and bonding. This multi-functional design justifies the dual sealant system by consolidating multiple requirements into a coordinated two-layer approach.
Solution Approach 2:
The sealing function is segmented into two distinct layers with specific分工: the primary sealant handles the critical interface between spacer and glass, while the secondary sealant provides external sealing and bonding. This segmentation allows each layer to be optimized for its specific function, improving overall reliability while making the manufacturing process more systematic and controllable.
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 solution provides a stable edge seal that withstands high temperatures, UV radiation, and external influences, preventing deformation and gas leakage, even after prolonged weathering cycles and UV exposure, ensuring reliable thermal insulation and gastightness.
Implementation Method 1
A polymer-modified primary sealant with olefinic polymers, inert fillers, desiccants, and UV stabilizers, combined with a silicone-based secondary sealant, forms a stable bond through chemical interactions
Implementation Method 2
A desiccant (e.g. a molecular sieve) is contained additionally within the hollow spacer in order to keep the air or gas trapped between the panes dry
Implementation Method 3
A polymer-modified primary sealant with olefinic polymers, inert fillers, desiccants, and UV stabilizers, combined with a silicone-based secondary sealant, forms a stable bond through chemical interactions, preventing deformation and enhancing adhesion to glass and other materials
Implementation Method 4
A polymer-modified primary sealant with olefinic polymers, inert fillers, desiccants, and UV stabilizers, forms a stable edge seal that withstands high temperatures, UV radiation, and external influences
Data Source
AI summary
An edge seal for manufacturing two-pane or multi-pane insulating glass or solar modules having a primary sealant and a secondary sealant has the following overall composition:a) 30-60 wt. %, preferably 40-50 wt. %, olefinic polymers, Mn 400-600,000 D, preferably 5,000-300,000 Db) 2-35 wt. %, preferably 5-25 wt. %, modified polymerc) 5-40 wt. %, preferably 10-30 wt. %, fine-particle, inert fillersd) 5-25 wt. %, preferably 10-15 wt. %, desiccants and water scavengers 0-3 wt. % aging resistors, in particular anti-oxidants or UV stabilizers.