Insulated Window Spacer With Slim Corrugated Metal Bridges
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Solution Overview
Problem
Insulated window spacers face challenges in reducing heat loss while maintaining structural integrity and reliability, with existing solutions potentially increasing the risk of leakage and failure.
Innovation Solution
The use of slim, high-strength metal bridges with a corrugated or undulated shape, combined with separate metal sidewalls, reduces heat conduction and allows for flexible production and enhanced sealing properties by using different materials for the bridges and sidewalls, and incorporating desiccant or foam for improved insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional spacers with thicker bridges are used, then structural strength is improved, but heat loss increases
Solution Approach 1:
The patent applies this principle by using thin bridge members (0.05-0.15mm thickness) instead of thick rigid structures. The bridges are made sufficiently thin to reduce thermal conduction while maintaining structural integrity through alternative design features like corrugated profiles and proper spacing arrangement.
Solution Approach 2:
The patent changes the thickness parameter of the bridge members to 0.05-0.15mm, which is significantly thinner than conventional spacers. This parameter change directly reduces heat conduction while the structural strength is compensated through material selection and geometric optimization.
2Loss of energy
If slim bridge members are used to reduce heat loss, then heat conduction is reduced, but structural reliability deteriorates
Solution Approach 1:
The patent uses composite construction by joining multiple thin bridge members and sidewalls together to form an assembly that provides both thermal insulation and structural strength. The composite structure distributes mechanical loads across multiple components rather than relying on a single thick bridge.
Solution Approach 2:
The spacer is segmented into separate components (bridges and sidewalls) that are joined together. This segmentation allows each component to be optimized independently - thin bridges for thermal performance and properly designed joints for structural reliability.
3Adaptability or versatility
If separate parts are joined to form the spacer, then production flexibility is improved, but device complexity increases
Solution Approach 1:
The patent merges separate bridge members and sidewalls into a unified spacer assembly through joining operations. This merging allows the spacer to be produced from pre-fabricated components that can be easily replaced or modified, providing production flexibility while the joining process creates a functionally simple sealed unit.
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
This configuration minimizes heat transfer, enhances the structural strength and sealing capabilities of the spacer, and allows for easier production and modification, reducing the risk of leakage and failure while maintaining reliability.
Implementation Method 1
slim, high-strength metal bridges with a corrugated or undulated shape... reduces heat conduction
Data Source
Figure 1~6b
Figure 7~12
AI summary
A spacer assembly comprising a first sidewall 1 and a second sidewall 2 and a first bridge 3 and a second bridge 4. The first bridge 3 and second bridge 4 and the first sidewall 1 and the second sidewall 2 are separate members joined permanently to form a spacer preferably by welding. The bridge 3 and/or 4 have reduced thickness to reduce the heat loss and employ substantially high strength metal material. The bridge 3,4 and sidewall 1,2 may also employ different metal materials.