Compression-Injection Patch for Insulating Glass Unit Spacer Sealing
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Solution Overview
Problem
The fenestration industry lacks effective methods for sealing discontinuities and breaches in insulating glass units, leading to unreliable and ineffective seals that compromise thermal insulation and durability, particularly at spacer joints, splices, capillary tube insertion points, and gas-fill holes.
Innovation Solution
A compression-injection patch method using a sealant-coated patch with a flexible backing layer, applied with pressure and optionally heat, to inject sealant into spacer discontinuities, ensuring a hermetic seal across the spacer width and between glass lites, using tools tailored for different joint types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a wrapped cover (adhesive-coated vapor barrier film or aluminum foil coated with PIB) is applied over the spacer discontinuity, then the position of the spacer ends is maintained until sealant is added, but the seal becomes unreliable and ineffective
Solution Approach 1:
The patch is pre-coated with sealant material before application to the spacer discontinuity. This preliminary preparation ensures that the sealant is already in place and properly positioned, eliminating the need for subsequent sealant application steps and ensuring reliable sealing from the outset.
Solution Approach 2:
The patch acts as an intermediary carrier that delivers the sealant directly to the discontinuity site. The patch material itself serves as the medium through which the sealant is transferred and positioned, ensuring precise placement and immediate sealing effectiveness.
2Adaptability or versatility
If custom sealing methods are used for each specific spacer/sealant combination, then the seal can be tailored to specific requirements, but the process becomes complex and lacks general guidelines
Solution Approach 1:
The patch system is designed with universal applicability across different spacer and sealant combinations. The patch can accommodate various discontinuity types (joints, splices, capillary tube insertion points, gas-fill holes, fastener locations) and works with different sealant materials, providing a single standardized solution that eliminates the need for custom procedures for each specific combination.
Solution Approach 2:
The patch system allows for parameter adjustments in terms of patch size, shape, and sealant coating thickness to accommodate different discontinuity types and requirements, while maintaining the same fundamental application process and methodology.
3Ease of manufacture
If the patch is applied without compression-injection, then the application process is simpler, but the sealant does not reliably penetrate into the discontinuity to achieve hermetic sealing
Solution Approach 1:
The patch is pre-coated with an adequate thickness of sealant material before application. This preliminary preparation ensures that sufficient sealant is available to penetrate into the discontinuity when compression is applied, guaranteeing hermetic sealing without requiring complex injection equipment or multi-step processes.
Solution Approach 2:
The compression-injection process uses mechanical pressure (analogous to pneumatic/hydraulic principles) to force the sealant from the patch into the discontinuity. The applied compression drives the sealant material into the spacer joint, ensuring complete penetration and reliable hermetic sealing.
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
This method reliably achieves a durable, hermetic seal that minimizes air intrusion and gas loss, enhancing thermal insulation and durability, and meets stringent industry standards like EN1279, with improved argon retention and increased pass rates in laboratory testing.
Implementation Method 1
a compression-injection patch that carries sealant and is applied over the spacer discontinuity with pressure to inject the sealant of the patch into the discontinuity
Implementation Method 2
The sealant can be a polyisobutylene (PIB) in one configuration of the patch
Data Source
Figure 1
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AI summary
A method for applying a patch to a spacer discontinuity or other seal breach includes the step of applying pressure to the patch during the application of the patch to cause sealant carried by the patch to be injected into the spacer discontinuity. This step can be performed with or without the application of heat. Pressure is applied to the patch long enough to position the sealant entirely across the gap between the lites such that the sealant wets out against both interior glass surfaces. Pressure is also applied to the patch long enough to inject sealant into openings defining the discontinuity. A sealant is then applied over the entire patch. The structure of the patch and the patched IG unit are provided.