Plastic Spacer With Overlapping Gas-Impermeable Segments
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Solution Overview
Problem
Existing spacers made of metal for insulating glass units have high heat conductivity and poor gas diffusion resistance, while plastic spacers face issues with gas permeability and bonding with glass panes, leading to potential gas leaks and connection weaknesses, especially when bent to fit the shape of glass panes.
Innovation Solution
A spacer comprising multiple overlapping segments of substantially gas-impermeable material, integrated into a foil layer that maintains gas-impermeability even when bent, with optional sub-layers and polymeric materials to enhance insulation and bonding properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal foil is used for spacers, then gas diffusion resistance is improved, but heat conductivity is too high
Solution Approach 1:
The spacer combines plastic material with a foil layer containing overlapping gas-impermeable segments to create a composite structure that reduces heat conductivity while maintaining gas diffusion resistance. The plastic base provides thermal insulation while the foil segments provide gas barrier properties.
2Loss of energy
If plastic material is used for spacers, then heat conductivity is reduced, but gas diffusion resistance deteriorates
Solution Approach 1:
The invention creates a composite structure where plastic material serves as the heat-insulating base and a foil layer with overlapping gas-impermeable segments provides the gas barrier function, thus combining the advantages of both materials.
Solution Approach 2:
The foil layer is divided into multiple overlapping segments that collectively provide gas impermeability. These segments are arranged to ensure continuous coverage while allowing the underlying plastic to provide thermal insulation.
3Adaptability or versatility
If foil is bent to shape the spacer, then adaptability to glass pane shape is improved, but gas-impermeability is compromised due to cracks
Solution Approach 1:
The foil is divided into multiple overlapping segments that can flex and bend without cracking. The overlapping arrangement allows each segment to deform independently while maintaining continuous gas barrier coverage through the overlap zones.
Solution Approach 2:
The foil segments are designed as flexible thin films that can be bent to conform to the shape of glass panes while maintaining their gas-impermeable properties. The overlapping configuration provides flexibility and crack resistance.
4Loss of energy
If plastic spacers are used, then heat insulation is improved, but bonding strength with glass panes deteriorates
Solution Approach 1:
The composite structure combines plastic material for thermal insulation with a foil layer that provides improved bonding characteristics. The foil segments create additional bonding surfaces and potential chemical adhesion points between the spacer and glass panes.
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 reduces gas diffusion and maintains insulation integrity during bending, while improving the bonding between the spacer and glass panes, ensuring effective gas retention and structural stability.
Implementation Method 1
a layer (115) with gas-impermeable characteristics, wherein the layer comprises multiple overlapping segments of a substantially gas-impermeable material
Implementation Method 2
a good connection can be obtained between the glazing panes and the spacers due to glue being a good binder to both glass and metal
Data Source
Figure 1~2
Figure 3A~4C
Figure 5A~5D
AI summary
The present invention relates to a spacer for creating a spacing between glass panes, wherein said spacer is made of a plastic material. The spacer is elongated and comprises two side surfaces as well as a top surface and a bottom surface with a layer having gas-impermeable characteristics, wherein this layer comprises multiple overlapping segments of a substantially gas-impermeable material. Further, the present invention relates to a method of manufacturing such a spacer and a window comprising glass panes being mutually spaced by such a spacer. By letting the segments overlap, it is ensured that gas-impermeability of the spacer is significantly increased. Further, the overlapping of segments results in that a spacer with such a layer can be bent without compromising the gas-impermeability. When bending a spacer in corners to correspond to the shape of a glass pane, then the segments in the layer will still overlap, whereby gas-impermeability is maintained in the corners. Further, the overlapping ensures that a foil with such overlapping segments can be mounted across corners without comprising gas impermeability.