Insulating Glazing Spacer With Integrated Ribbon Cable
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Solution Overview
Problem
Insulating glazing with electrical supply lines faces challenges in achieving adequate sealing, leading to potential leaks due to the obstruction of automated filling processes and the presence of air bubbles, which are exacerbated by the complex geometry and spatial constraints around electrical connection cables.
Innovation Solution
A spacer with an integrated ribbon cable, where the cable is directly or indirectly connected to the polymer base body without cavities, ensuring a gas- and water-tight connection, allowing for automated filling without obstructing the filling process and reducing the risk of air pockets that can cause leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrical supply cables are routed around the spacer frame in the outer cavity, then electrical connections can be made, but the cables obstruct automated filling processes and create air bubbles that lead to leaks
Solution Approach 1:
The electrical supply line is integrated directly into the spacer structure, merging the electrical conduction function with the mechanical support and sealing function of the spacer. This eliminates the need for separate cables routed through the outer cavity, allowing automated filling without obstruction while maintaining sealing integrity through the unified structure.
Solution Approach 2:
The electrical supply line is extracted from the outer cavity routing and repositioned to run within the spacer structure itself. This removes the obstructing element from the filling path while maintaining electrical functionality, preventing air bubble formation and sealing failures.
2Ease of operation
If the supply cable passes through the primary sealant for bonding and sealing, then electrical power can be supplied, but this creates a potential point of failure for leaks
Solution Approach 1:
The electrical supply line is combined with the spacer structure, eliminating the need for cable penetration through the primary sealant. The integrated design maintains the continuity and integrity of the sealing system while providing electrical power through dedicated conductive paths within the spacer.
Solution Approach 2:
The electrical conduction function is extracted from the sealant material and assigned to dedicated conductive elements within the spacer structure. This separates the electrical function from the sealing function, preventing sealant compromise and maintaining reliable sealing.
3Extent of automation
If connecting cables are present in the outer cavity, then electrical connections can be made, but automated filling with secondary sealant becomes problematic and air bubbles cannot be avoided
Solution Approach 1:
The electrical connections are merged into the spacer structure, allowing automated filling of the outer cavity to proceed without obstruction. The integrated design eliminates physical barriers to the filling process while maintaining all necessary electrical connectivity functions.
Solution Approach 2:
The electrical supply lines are pre-positioned within the spacer structure before the automated filling process begins. This preliminary arrangement ensures that the filling operation can proceed automatically without encountering cables that would obstruct the nozzle or create air pockets.
Data Source
Figure 1~2a
Figure 2b
Figure 3a~3b
AI summary
The invention relates to a spacer (I) with an integrated ribbon cable (14) for insulating glazings, at least comprising: - a main part (5) which comprises two pane contact surfaces (7.1, 7.2), - a glazing interior surface (8), - an outer surface (9), - a hollow chamber (10), and - at least one ribbon cable (14) on the outer surface (9), said ribbon cable (14) being bonded to the outer surface (9).