Composite Spacer Profile Reinforcement for Warm Edge Insulating Glass
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Solution Overview
Problem
Conventional spacer profiles for insulating glass units face challenges in achieving 'warm edge' conditions due to high heat conduction, diffusion impermeability, and structural rigidity, particularly when cold-bent into large frames, leading to issues like wrinkle formation and sagging.
Innovation Solution
A spacer profile design featuring a profile body with a diffusion barrier layer and embedded steel wire reinforcements, optimized for minimal heat conduction and improved rigidity, allowing for cold-bending with reduced wrinkle formation and increased desiccant capacity, while maintaining diffusion impermeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal spacer profiles are used, then structural strength and rigidity are improved, but heat conduction increases preventing warm edge conditions
Solution Approach 1:
The spacer profile combines synthetic material (low heat conduction) with embedded metal reinforcement (high strength) and diffusion barrier layers (gas impermeability), creating a composite structure that simultaneously achieves warm edge conditions, structural strength, and diffusion protection
2Loss of energy
If synthetic material spacer profiles are used, then heat conduction is reduced fulfilling warm edge conditions, but diffusion impermeability and structural strength deteriorate
Solution Approach 1:
The synthetic material base provides low heat conduction for warm edge conditions, while embedded metal reinforcements and diffusion barrier layers provide the necessary structural strength and gas impermeability, combining advantages of different materials
3Productivity
If cold bending is used to form spacer frames, then manufacturing efficiency is improved, but wrinkle formation and sagging increase
Solution Approach 1:
Metal reinforcements are embedded in the spacer profile before cold bending, providing internal support that prevents wrinkle formation and sagging during the cold bending process and in the final assembled state
Solution Approach 2:
The combination of synthetic material and embedded metal reinforcement creates a composite structure that maintains rigidity during cold bending, enabling efficient manufacturing without defects
4Loss of energy
If the heat conduction path is extended to minimize heat transfer, then warm edge conditions are improved, but structural rigidity and resistance to sagging deteriorate
Solution Approach 1:
The spacer profile cross-section is segmented into multiple functional zones: synthetic material regions for thermal insulation, metal reinforcement regions for structural strength, and diffusion barrier layers for gas impermeability, allowing independent optimization of each function
Solution Approach 2:
The multi-material composite structure enables extended heat conduction paths through synthetic material while metal reinforcements provide structural rigidity to prevent sagging, achieving both warm edge conditions and structural integrity
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 spacer profile effectively minimizes heat transfer, prevents gas diffusion, and enhances structural integrity, enabling its use in large windows with reduced sagging and wrinkle formation, while meeting 'warm edge' and diffusion barrier standards.
Implementation Method 1
a diffusion barrier layer (40) extending on the outer wall (22), on the connection walls (28, 30) and on the side walls (24, 26)
Implementation Method 2
at least one steel wire (36, 38) extending in a longitudinal direction (z) with a constant cross section, which is embedded in the profile body (10)
Implementation Method 3
The first material is preferably a synthetic material, more preferably a polyolefin... the specific heat conductivity is less than or equal to about 0.3 W/(mK)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Spacer profile (1) for use as part of a spacer profile frame, extending in a longitudinal direction (z) and having a first width (b1) in a transverse direction (x) and a first height (h1) in a height direction (y) and comprising a profile body (10) which comprises an inner wall (20), an outer wall (22) having a second width (b2) in the transverse direction being smaller than the first width (bl), side walls (24, 26) connected to the inner wall (20) at inner corner portions (32, 34), wherein connection walls (28), which have concave outer surfaces, extend between the side walls (24, 26) and the outer wall (22) such that a chamber (35) is formed, a diffusion barrier layer (40) is provided, and at least one reinforcement (36, 38; 42, 44) provided in each of the inner comer portions (32, 34).