Plastic Spacer With Embedded Mesh For Multi-Pane Glazing
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Solution Overview
Problem
Existing spacers for multi-pane insulating glazing lack sufficient strength and exhibit high thermal conductivity, with existing reinforcement methods either failing to provide adequate stability or leading to moisture issues due to detachment of materials during thermal expansion.
Innovation Solution
Incorporating a metal or non-metal mesh within the plastic spacer body during the extrusion process, which provides reinforcement without the detachment issues seen with metal foils and allows for reduced wall thickness without compromising strength, thereby reducing thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the wall thickness of the spacer main body is reduced to lower thermal conductivity, then the insulating performance is improved, but the mechanical strength and stability deteriorate
Solution Approach 1:
The patent applies composite materials by embedding a metal mesh (aluminum, steel, or stainless steel) within the plastic matrix of the spacer main body. This creates a composite structure where the metal mesh provides high mechanical strength and stiffness, enabling the use of thinner plastic walls while maintaining structural integrity. The metal mesh acts as a reinforcement skeleton that carries mechanical loads, allowing the plastic walls to be made thinner for reduced thermal conductivity without compromising strength.
2Strength
If glass fibers are admixed with the plastics material for reinforcement, then the mechanical strength is improved, but the material becomes very brittle and the wall thickness cannot be reduced
Solution Approach 1:
The patent replaces fiber-reinforced plastic composites with a metal mesh-reinforced plastic composite. The metal mesh provides reinforcement while maintaining the ductility and flexibility of the plastic matrix, avoiding the brittleness issue associated with glass fiber admixture. The mesh structure distributes stresses evenly throughout the plastic material, preventing stress concentration points that would lead to brittle failure.
3Strength
If a metal foil is embedded in the main body for reinforcement, then the mechanical strength is improved, but the plastic becomes detached from the metal foil during thermal expansion causing moisture problems
Solution Approach 1:
The patent uses a metal mesh with an open porous structure rather than a solid metal foil. This mesh structure allows the plastic material to interpenetrate and mechanically interlock with the metal wires, creating a unified composite structure that prevents detachment during thermal expansion. The open structure of the mesh accommodates dimensional changes of both the metal and plastic components, maintaining intimate contact and preventing moisture ingress pathways.
4Strength
If fibers are added to the plastic material for reinforcement, then the mechanical strength is improved, but the heat transfer of the spacer is increased
Solution Approach 1:
The patent applies local quality by concentrating the reinforcement function in a localized metal mesh structure rather than distributing fibers throughout the entire plastic volume. The metal mesh is positioned strategically within the plastic matrix to provide reinforcement only where structurally necessary, while leaving the surrounding plastic material intact to maintain its low thermal conductivity properties. This localized reinforcement approach avoids the widespread heat conduction pathways that would be created by distributed fiber networks.
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 embedded mesh enhances the spacer's stability and reduces thermal conductivity, preventing bending and moisture problems while allowing for thinner profiles without increasing heat transfer, thus improving insulating properties.
Implementation Method 1
a metal mesh, which is embedded in the main body
Implementation Method 2
A reduced wall thickness has the result that the thermal conductivity of the main body is reduced
Implementation Method 3
the outer face and an inner face, which respectively connect the two abutment surfaces, the main body being made of plastic and having at least one metal layer on the outer face
Data Source
AI summary
A spacer for multi-pane insulating glazing, comprising a main body, which has mutually parallel abutment surfaces for panes, and an outer face and an inner face, which respectively connect the two abutment surfaces, the main body being made of plastic and having at least one metal layer on the outer face. The spacer also has a metal or a non-metal mesh, which is embedded in the main body.