IGU Spacer Channels for Electrochromic Window Power Isolation
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Solution Overview
Problem
Conventional metal spacers in insulated glass units (IGUs) often cause electrical shorting issues with electrochromic devices due to their conductive nature, which can lead to failure of the electrochromic windows.
Innovation Solution
The use of spacers with notched profiles and channels to accommodate bus bar leads and wires, preventing direct contact with the spacer and ensuring electrical insulation, along with the integration of hollow spacers with wires passing through to provide power to electrochromic devices without shorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metal spacers are used in IGUs, then structural strength and sealing are improved, but electrical shorting occurs with electrochromic devices
Solution Approach 1:
The spacer is divided into multiple segments or components: a main body portion providing structural support and sealing, and separate insulating elements (such as insulating caps, insulating barriers, or segmented structures) that prevent electrical contact. This segmentation allows the spacer to simultaneously provide mechanical strength while maintaining electrical insulation between the electrochromic device and conductive parts.
Solution Approach 2:
An insulating intermediary material or structure is introduced between the metal spacer and the electrochromic device. This intermediary could be an insulating coating on the spacer, an insulating gasket, or an insulating barrier layer that physically separates conductive elements, preventing direct electrical contact while allowing the spacer to maintain its structural and sealing functions.
2Stability of the object's composition
If metal spacers are used to ensure structural integrity, then sealing performance is improved, but electrical conductivity causes shorting issues
Solution Approach 1:
The spacer structure incorporates different material properties in different locations: the main body retains metal construction for structural strength and sealing, while specific local areas (contact surfaces, edges near electrochromic devices, or specific zones) are modified with insulating coatings, insulating inserts, or geometric features that prevent electrical contact. This local differentiation allows simultaneous achievement of sealing integrity and electrical insulation.
Solution Approach 2:
The spacer employs composite construction combining metal portions for structural strength and sealing with insulating materials (such as plastic coatings, polymer inserts, or composite structures) in strategic locations. This composite approach allows the spacer to exhibit both mechanical properties of metal and electrical insulation properties of non-conductive materials in the same component.
3Ease of operation
If wires are passed through solid spacers to power electrochromic devices, then electrical connection is achieved, but direct contact with spacer causes shorting
Solution Approach 1:
The wire is nested within an insulating conduit or protective sheath that passes through the spacer. Alternatively, the wire is routed through a hollow cavity or channel in the spacer that is lined with insulating material. This nested configuration allows the wire to maintain electrical connection to the electrochromic device while being physically isolated from conductive parts of the spacer, preventing shorting.
Solution Approach 2:
An insulating intermediary structure (such as an insulating bushing, insulating grommet, or insulating channel lining) is placed between the wire and the metal spacer. This intermediary maintains the wire's electrical connectivity function while preventing direct electrical contact between the wire and conductive spacer portions, thereby avoiding shorting issues.
Data Source
AI summary
This disclosure describes insulated glass units (IGUs) that incorporate electrochromic devices. More specifically, this disclosure focuses on different configurations available for providing an electrical connection to the interior region of an IGU. In many cases, an IGU includes two panes separated by a spacer. The spacer defines an interior region of the IGU and an exterior region of the IGU. Often, the electrochromic device positioned on the pane does not extend past the spacer, and some electrical connection must be provided to supply power from the exterior of the IGU to the electrochromic device on the interior of the IGU. In some embodiments, the spacer includes one or more holes (e.g, channels, mouse holes, other holes, etc.) through which an electrical connection (e.g., wires, busbar leads, etc.) may pass to provide power to the electrochromic device.