Strain Relief Structure for Electrochromic Window Seal Integrity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrochromic devices in insulated glass units (IGUs) are prone to moisture ingress, leading to degradation and failure, especially due to compromised seals between wires and secondary sealants during handling and over time, which compromises the adhesion and creates pathways for moisture to reach the electrochromic device.
Innovation Solution
The implementation of a strain relief structure between the glass panes of the IGU, which provides additional strain relief and secures wires in place, combined with compatible materials and coatings for the wires and secondary sealants, and a circuitous route for moisture to travel, minimizes the risk of moisture entry by maintaining the integrity of the seal and reducing wire movement during handling and curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wires are routed through the secondary seal to power the electrochromic device, then the device can be powered and controlled, but the seal is compromised and moisture can ingress through the wire-seal interface
Solution Approach 1:
A strain relief structure serves as an intermediary component between the wires and the secondary seal. This structure includes a cavity that receives the wires and a sealant barrier that prevents moisture from traveling along the wires into the IGU interior. The intermediary structure allows wires to pass through while maintaining seal integrity by providing a dedicated pathway with moisture blocking features.
Solution Approach 2:
The strain relief structure segments the wire penetration area into distinct zones: a cavity for wire accommodation, a sealant barrier for moisture blocking, and an anchor portion for structural support. This segmentation allows each zone to perform its specific function - wires are contained in the cavity, moisture is blocked by the sealant barrier, and the structure is secured by the anchor portion.
2Stability of the object's composition
If wires are secured firmly to the glass lite to prevent movement during handling, then handling stability is improved, but strain on the wires and seal adhesion is increased
Solution Approach 1:
The strain relief structure provides beforehand cushioning for the wires by providing a cavity that absorbs movement and strain. The flexible sealant barrier and the cushioning portion work together to accommodate wire movement during handling without transmitting excessive strain to the wire-seal interface or the wires themselves.
Solution Approach 2:
The strain relief structure acts as an intermediary between the rigid glass lite and the flexible wires. It provides a compliant interface that allows wire movement without compromising the seal or the wire integrity, mediating between the stability requirements of the glass and the flexibility requirements of the wires.
3Ease of manufacture
If the secondary seal is applied directly over the wires to seal the IGU, then sealing is simplified, but moisture can travel along the wires to the interior
Solution Approach 1:
The flexible sealant barrier serves as an intermediary moisture blocking element between the secondary seal and the wires. It is applied over the wires within the strain relief structure cavity, creating a first line of defense against moisture travel. The secondary seal then applies over this barrier, creating a multi-layer moisture protection system.
Solution Approach 2:
The flexible sealant barrier is applied preliminarily over the wires before the secondary seal is applied. This preliminary action creates a moisture barrier at the critical wire-seal interface, preventing moisture from traveling along the wires into the IGU interior while still allowing the secondary seal to be applied in a relatively simple manner.
4Manufacturing precision
If a rigid strain relief structure is used to hold wires in place, then wire positioning is improved, but the structure cannot accommodate movement and may compromise the seal
Solution Approach 1:
The strain relief structure transitions from a static rigid form to a dynamic compliant system. The flexible sealant barrier and cushioning portion can deform and adapt to wire movement during handling, while still maintaining wire positioning and seal integrity. This dynamic behavior allows the structure to accommodate both precision positioning and movement flexibility.
Solution Approach 2:
The strain relief structure combines multiple materials with different properties: a rigid or semi-rigid anchor portion for structural support and positioning, a flexible sealant barrier for moisture blocking and movement accommodation, and a cushioning portion for strain absorption. This composite material approach allows the single structure to provide both precision positioning and movement adaptability.
Data Source
AI summary
Embodiments herein relate to methods and apparatus for preventing and mitigating the ingress of moisture into an interior region of an IGU. Various techniques are disclosed including, for example, the use of a strain relief structure around wires passing through a secondary seal, improved materials for coating the wires, and additional/improved layers for bonding the secondary seal to tape provided around a spacer.