Multi-Layer Edge Seal for Insulating Glass Units
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Solution Overview
Problem
Insulating glass units (IGUs) face issues with moisture penetration, thermal performance, and structural integrity due to seal failures, especially with metal spacers, which lead to reduced service life and increased production costs.
Innovation Solution
An insulating glass unit with a three-layer edge seal comprising a first thermoplastic material, a second thermoplastic material, and a thermoset plastic material, where the first thermoplastic material defines the distance between glass panes, the second thermoplastic material provides excellent sealing, and the thermoset plastic material enhances mechanical strength and adhesion, reducing thermal conductivity and improving stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal space bar is used to hold glass panes, then structural strength is improved, but thermal conductivity increases creating thermal bridges that reduce insulating capability
Solution Approach 1:
The patent applies composite materials by combining thermoplastic and thermoset plastic materials in a multi-layer edge seal system. The thermoplastic material provides flexibility and initial sealing, while the thermoset plastic material provides structural strength and low thermal conductivity, creating a composite structure that simultaneously achieves mechanical integrity and thermal insulation without metal components.
2Loss of energy
If a thermoplastic spacer is used instead of metal, then thermal conductivity is reduced, but structural strength becomes insufficient
Solution Approach 1:
The patent merges the functions of multiple materials into a unified edge seal system. The thermoplastic material and thermoset plastic material are combined in specific layers, where the thermoplastic provides flexibility and moisture sealing, while the thermoset plastic provides structural reinforcement, together achieving both low thermal conductivity and sufficient structural strength.
Solution Approach 2:
By creating a composite edge seal structure with thermoplastic and thermoset plastic materials, the system achieves properties that neither material could provide alone - the thermoplastic offers flexibility and vapor sealing while the thermoset plastic contributes structural rigidity and strength.
3Reliability
If sealant materials are used to bond glass panes and provide moisture resistance, then moisture penetration is reduced, but flexibility to accommodate thermal expansion may be limited
Solution Approach 1:
The patent applies local quality by assigning different functional properties to different layers of the edge seal. The thermoplastic material layer provides flexibility and elasticity to accommodate thermal expansion and movement, while the thermoset plastic material layer provides rigid structural support and enhanced moisture resistance, with each layer optimized for its specific function.
4Loss of energy
If multiple layers of different plastic materials are used in the edge seal, then thermal performance and sealing properties are improved, but device complexity increases
Solution Approach 1:
The edge seal is segmented into distinct functional layers: a thermoplastic material layer for flexibility and moisture sealing, and a thermoset plastic material layer for structural strength. This segmentation allows each layer to be optimized for its specific function while working together as an integrated system, achieving complex performance requirements through modular layering.
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 significantly enhances thermal performance, extends the service life of IGUs by up to 5 years, reduces production costs, and minimizes moisture penetration, while maintaining mechanical stability and flexibility to accommodate thermal expansion.
Implementation Method 1
the first thermoplastic material defines the distance between the at least two glass panes and defines a first layer of the edge seal, the first layer of the edge seal being situated within the interpane space and adhering to the surfaces of the at least two parallel glass panes
Implementation Method 2
the second thermoplastic material is contacting the first thermoplastic material and defines a third layer of the edge seal, the third layer of the edge seal being situated within the interpane space and adhering to the surface of the at least two parallel glass panes
Implementation Method 3
the thermoset plastic material is contacting the second thermoplastic material, the thermoset plastic material adhering at least to a first glass surface on the two parallel glass panes not facing the interpane space
Implementation Method 4
The present invention provides an insulating glass unit having improved thermal properties. A thermoplastic material with low thermal conductivity is used as a spacer between the glass panes
Data Source
Figure 1a~1b
Figure 2a~2b
AI summary
An insulating glass unit comprising at least two parallel glass panes (1), a space between the at least two parallel glass panes being the interpane space (2), said at least two parallel glass panes being held structurally together along their perimeters by an edge seal, the edge seal extending along the whole perimeter of the at least two glass panes, whereby the interpane space is sealed from the outside by the edge seal, the edge seal comprising: a first thermoplastic material (3), a second thermoplastic material (4) and a thermoset plastic material (5), wherein the first thermoplastic material (3) defines the distance (6) between the at least two glass panes (1) and defines a first layer of the edge seal, the first layer of the edge seal being situated within the interpane space and adhering to the surfaces of the at least two parallel glass panes facing the interpane space, wherein the second thermoplastic material (4) is contacting the first thermoplastic material (3) and defines a second layer of the edge seal, the second layer of the edge seal being situated within the interpane space and adhering to the surface of the at least two parallel glass panes facing the interpane space, and wherein the thermoset plastic material (5) is contacting the second thermoplastic material (4), the thermoset plastic material adhering to at least a first glass surface on the two parallel glass panes not facing the interpane space, said first glass surface (7) defining the thickness of each of the two glass panes, the thermoset plastic material defining a third layer of the edge seal. The invention moreover relates to a process for manufacturing an insulating glass unit.