Multiple Glazing Spacer Composition for Low-Temperature Corner Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing multiple glazing technology faces issues with spacer deformation during melt-molding, leading to reduced productivity and molding accuracy, particularly at corner portions, due to the spacer deforming immediately after extrusion and failing to fill corners properly.
Innovation Solution
A thermoplastic resin composition for the spacer is used, comprising butyl-based rubber, crystalline polyolefin, a drying agent, and an inorganic filler, with specific molecular weight ranges and ratios, and a loss tangent that monotonically increases without peaks, allowing molding at 150°C or lower to suppress deformation and improve molding speed and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If the spacer is molded at lower temperature to reduce energy consumption and deterioration, then the sealing material can be molded at lower temperature, but the spacer significantly deforms immediately after extrusion and productivity cannot be improved
Solution Approach 1:
The patent changes the molecular weight parameters of the butyl-based rubber (number average molecular weight: 45,000-60,000; weight average molecular weight: 200,000-225,000; Mw/Mn ratio: 4.0-5.0) and adjusts the loss tangent characteristics (monotonically increasing without peak from 90°C to 190°C) to achieve optimal balance between low-temperature moldability and post-extrusion deformation resistance, enabling both energy reduction and maintained productivity
Solution Approach 2:
The patent creates a composite thermoplastic resin composition containing butyl-based rubber (50-98 wt%), crystalline polyolefin (2-50 wt%), drying agent, and inorganic filler, where the specific combination and proportions of materials work synergistically to provide both low-temperature processability and structural stability after extrusion
2Use of energy by stationary object
If the spacer is molded at lower temperature to reduce energy consumption, then energy consumption can be reduced, but molding speed must be restricted and productivity cannot be improved
Solution Approach 1:
The patent optimizes the melt viscosity parameter at molding temperature (150°C: 0.6-3.5 kPa·s) by controlling the molecular weight distribution of butyl-based rubber and the composition ratios, enabling fast molding speed at low temperature without causing excessive deformation after extrusion
3Use of energy by stationary object
If the spacer is molded at lower temperature to reduce energy consumption, then energy consumption can be reduced, but molding accuracy at corner portions cannot be improved
Solution Approach 1:
The patent adjusts the loss tangent characteristics (monotonically increasing from 90°C to 190°C without peak) and molecular weight parameters to control the flow and filling behavior of the spacer material at corner portions during low-temperature molding, ensuring accurate filling without deformation while maintaining low energy consumption
Solution Approach 2:
The patent ensures uniform molecular weight distribution and composition throughout the spacer material, particularly optimizing the properties to ensure consistent filling and deformation resistance at critical corner portions during low-temperature molding processes
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 enables molding at low temperatures, reducing deformation and improving productivity and production stability by ensuring accurate shaping and efficient filling of the spacer, particularly at corner portions.
Implementation Method 1
the butyl-based rubber has a loss tangent at 190°C at 1Hz of 1.25 or more and 1.42 or less; the loss tangent monotonically increases without having a peak in a temperature range of 90°C to 190°C
Implementation Method 2
a melt viscosity at 150°C is 0.6 kPa·s or more and 3.5 kPa·s or less
Data Source
Figure 1~3
Figure 4
Figure 5(a)~5(c)
AI summary
To improve molding speed and molding accuracy at corner portions, and thereby to improve productivity and production stability. A multiple glazing having two or more glass plates spaced apart to face one another via a spacer so as to form an air layer between the glass plates, wherein the spacer is formed of a thermoplastic resin composition having a JIS A hardness at 25°C of 10 or more and 90 or less; the thermoplastic resin composition contains a butyl-based rubber, a crystalline polyolefin, a drying agent and an inorganic filler; a proportion of the crystalline polyolefin to the total amount of the butyl-based rubber and the crystalline polyolefin is 2 wt% or more and 12 wt% or less; a proportion of the crystalline polyolefin to the total amount of the thermoplastic resin composition is 1 wt% or more and 5 wt% or less; the butyl-based rubber includes two or more types of butyl-based rubbers differing in the molecular weight; the butyl-based rubber has a number average molecular weight of 45000 or more and 60000 or less; the butyl-based rubber has a weight average molecular weight of 200000 or more and 225000 or less; and a ratio of the weight average molecular weight to the number average molecular weight of the butyl-based rubber is 4.0 or more and 5.0 or less.