Silane-Terminated Sealant for Insulating Glass
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Solution Overview
Problem
Conventional secondary sealants used in insulating glass units pose health and environmental hazards, are costly, and face legislative restrictions due to the use of harmful chemicals like MDI, organo-mercury compounds, and polysulphide polymers, with one-part thermoplastic sealants offering poor durability and high energy consumption.
Innovation Solution
A two-part sealant composition comprising a silane terminated polyurethane or polyether polymer and a filler with residual water, combined with a plasticiser, which forms a cured sealant with 48-hour Shore A hardness between 25-70, providing mechanical strength and adhesion without the need for health and safety labelling, and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional two-part polyurethane sealants are used, then mechanical strength and adhesion are improved, but health and environmental hazards increase due to harmful chemicals like MDI and organo-mercury compounds
Solution Approach 1:
The invention changes the chemical composition parameters by replacing harmful MDI and organo-mercury compounds with safer alternatives like water-based or ammonia-based curing agents, while maintaining the mechanical strength through optimized polymer formulations and curing mechanisms
Solution Approach 2:
The invention uses readily available, non-toxic materials such as water or ammonia as curing agents instead of expensive and hazardous chemicals, making the sealant safer for environmental disposal while maintaining performance
2Strength
If conventional two-part polysulphide sealants are used, then mechanical strength is improved, but toxicity increases due to manganese dioxide, thiram, and polysulphide polymers
Solution Approach 1:
The invention extracts and removes toxic components such as manganese dioxide, thiram, and polysulphide polymers from the sealant formulation, replacing them with non-toxic alternatives while preserving the mechanical strength through different polymer chemistry
Solution Approach 2:
The invention uses safe, non-toxic materials that are easier and cheaper to manufacture and dispose of, replacing hazardous polysulphide-based systems with water-based or ammonia-based curing systems that pose no environmental threat
3Strength
If conventional polyurethane sealants are used, then mechanical strength is improved, but manufacturing cost increases due to expensive drying processes and health safety measures
Solution Approach 1:
The invention extracts and eliminates the need for expensive vacuum drying processes by using water or ammonia as curing agents that do not require moisture-sensitive material handling, thereby reducing manufacturing complexity and cost
Solution Approach 2:
The invention uses inexpensive, readily available curing agents like water or ammonia instead of costly polyurethane chemistry, eliminating the need for expensive drying equipment and health safety infrastructure
4Ease of operation
If one-part thermoplastic sealants are used, then ease of application is improved, but durability decreases and energy consumption increases
Solution Approach 1:
The invention changes the curing mechanism from simple thermal cooling to chemical curing through water or ammonia reaction, which provides superior cross-linking and durability while maintaining ease of application through ready-mixed formulations
Solution Approach 2:
The invention creates a composite sealant system combining thermoplastic ease of application with chemically cured durability, using polymer formulations that benefit from both thermal processing and chemical cross-linking for enhanced performance
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 two-part sealant composition meets European Standard EN1279 requirements, offering improved mechanical strength, adhesion, and environmental safety, while minimizing handling and manufacturing complexities, thus providing a cost-effective and safer alternative to existing sealants.
Implementation Method 1
The first part comprises a polymer selected from a silane terminated polyurethane or a silane terminated polyether
Implementation Method 2
the first and second parts are mixed to achieve a cured substance
Implementation Method 3
a plasticiser that is compatible with the polymer
Implementation Method 4
a filler comprising at least 0.5% by weight (as compared to the filler weight) of residual water, wherein the filler comprises at least one rheological filler
Data Source
AI summary
A two-part sealant composition, wherein this composition comprises a first part and a second part. The first part comprises a polymer selected from a silane-terminated polyurethane or a silane-terminated polyether, wherein this polymer is present in an amount of up to 100% by weight of the first part of the sealant composition. The second part comprises a plasticizer that it is compatible with the polymer and a filler comprising at least 0.5% by weight of residual water, wherein the filler comprises at least one rheological filler, and wherein the filler is present in an amount of 80-20% by weight of the second part of the sealant composition. The first and second parts are separated from one another, and the amount of polymer present in the first part makes up 4-50% by weight of the first and second parts taken together. In use, the first and second pans are mixed to achieve a cured substance having a 48 hour Shore A hardness in the range of 25-70.