EP2780528B1

EP2780528B1 - Spacer profile comprising a reinforcement

Info

Publication number: EP2780528B1
Application number: EP13779742.9A
Authority: EP
Inventors: Jörg LENZ; Taher GAD; Fabian LINDNER; Florian HAMEISTER; Andreas Stumpf; Marek FRANK; Daniel BETKE; Norbert Deckers
Original assignee: Technoform Glass Insulation Holding GmbH
Current assignee: Technoform Glass Insulation Holding GmbH
Priority date: 2012-10-22
Filing date: 2013-10-18
Publication date: 2016-05-18
Anticipated expiration: 2033-10-18
Also published as: WO2014063801A1; CN104736788B; CN104736788A; EP2780528A1

Description

The present invention relates to spacer profiles and to insulating window units incorporating the spacer profiles.
Insulating window units or insulating glass/glazing (IGU) units having at least two glass/glazing panes, which are held apart from each other in the insulating glass unit, are well known. Such IGUs are used in window, door and façade elements. Insulating glass units are normally formed of an inorganic or organic glass or from other materials like Plexiglas. Usually, the separation of the glazing panes is secured by a spacer frame (see reference number 1 in Fig. 8a and 8b). A rectangular spacer frame is either assembled from four straight pieces using four corner connectors or is bent from one piece and closed by one straight connector at only one position.
Various designs have been utilized for insulating glass units that are intended to provide good heat insulation. According to one design, the intervening space between the panes is preferably filled with inert insulating gas, such as argon. Naturally, this filling gas should not be permitted to leak out of the intervening space between the panes. Moreover, nitrogen, oxygen, water, etc., contained in the ambient air should not be permitted to enter into the intervening space between the panes. Therefore, the spacer profile should be designed so as to prevent such diffusion into and out of the intervening space.
Furthermore, the heat transmission of the connection of the frame of window, door or façade elements including the IGU and of the connection of the glazing panes and the spacer frame, i.e., of the edge of the IGU, play a very important role for achieving low heat conduction in these elements. Insulating glass units, which ensure good heat insulation along this edge", fulfill "warm edge" conditions in accordance with the meaning of the term as utilized in the art.
Conventionally, spacer profiles were manufactured from metal. Such metal spacer profiles cannot, however, fulfill "warm edge" conditions. Thus, in order to improve upon such metal spacer profiles, the provision of synthetic material on the metal spacer profile has been described, e.g., in US 4,222,213 or DE 102 26 268 A1 .
Alternatively, a spacer, which exclusively consists of usual synthetic material having a low specific heat conductivity, could be expected to fulfill the "warm edge" conditions. However, such a spacer does not satisfy the requirements of diffusion impermeability and/or strength/rigidity etc.
Other known solutions include spacer profiles made of synthetic material that are provided with a metal film as a diffusion barrier and/or reinforcement layer as disclosed, e.g., in EP 0 953 715 A2 (family member US 6,192,652 ) or EP 1 017 923 (family member US 6,339,909 ).
Because metal is a better heat conductor than the suitable synthetic materials, it has been attempted, e.g., to design the heat conduction path between the side edges/walls of the spacer profile to be as long as possible (see EP 1 797 271 B1 ).
For improved gas impermeability, the spacer frame is preferably bent from a one-piece spacer profile, if possible by cold bending (at room temperature of approximately 20° C).
When the spacer profile is bent, in particular, when cold-bending techniques are used, there is a problem of wrinkle formation at the bend portions.
According to the solution known from EP 1 017 923 A1 , the space available in the chamber for the desiccating material is not satisfactory. According to the solutions known from Fig. 1 of EP 0 953 715 A2 , the wrinkle formation in the bend corner sections may be a problem. Moreover, when a spacer profile is intended to be utilized in a large frame, the re is a problem of sagging along unsupported portions of the spacer profile.
A composite spacer profile known from EP 0 601 488 A2 (family member US 5,460,862 ) comprises a stiffening support embedded in the wall of the profile that faces the intervening space between the panes in the assembled state. Another spacer profile known from DE 198 05 348 A1 (family member US 6,389,779 B1 ), comprises plastically deformable reinforcements extending in a longitudinal direction of the profile.
EP 1 529 920 B1 (family member US 6,989,188 B2 ) discloses a spacer profile having connecting segments between an outer wall and side walls of the spacer profile defining a concave recess. Spacers are also known from DE 10 2010 006127 A1 and DE 198 05 348 A1 .
Accordingly, a one-piece spacer profile should be cold-bendable into a spacer frame with a minimum of wrinkle formation, the heat conduction or transfer through the spacer should be minimized, and the sagging of the spacer should be minimized, which are competing if not opposing conditions.
Accordingly, it is an object of the invention to provide an improved spacer profile, which has enough stiffness to be used in large windows, and is cold-bendable into a one-piece spacer profile frame, and has a low heat conduction. Furthermore, it is an object to provide an insulating glazing unit having such a spacer profile
The object is achieved by a spacer profile according to claim 1 or an insulating glazing unit according to claim 11.
Further developments of the invention are given in the dependent claims.
Additional features and objects will be apparent from the description of the exemplary embodiments with consideration of the figures, which show in:

Fig. 1 a sectional view of the spacer profile according to a first embodiment of the present application;
Fig. 2 a sectional view of the spacer profile according to a second embodiment of the invention;
Fig. 3 a sectional view of the spacer profile according to a third embodiment of the invention;
Fig. 4 a sectional view of the spacer profile according to a fourth embodiment of the invention;
Fig. 5 a sectional view of the spacer profile according to a fifth embodiment not showing all claimed features;
Fig. 6 a sectional view of the spacer profile according to a sixth embodiment of the invention;
Fig. 7 a perspective cross-sectional view of glazing panes and a spacer profile according to the first embodiment of the present application;
Fig. 8a) and 8b) respectively perspective cross-sectional views of the configuration of the glazing panes and a spacer profile in a conventional insulating glazing unit, and
Fig. 9 a sectional view of the spacer profile according to a seventh embodiment of the invention.

Embodiments of the present teachings will be described in greater detail below with reference to the figures. The same features/elements are marked with the same reference numbers in all figures. For the purpose of clarity, all reference numbers have not been inserted into all figures. The 3-dimensional x, y, z reference system shown in Figs. 1 and 8 applies to the profiles, the cross-sections and longitudinal directions shown in Figs. 1 to 8. The longitudinal direction corresponds to the direction z, the traverse direction corresponds to the direction x and the height direction corresponds to the direction y in relation to the profiles.
A spacer profile 1 according to a first embodiment and an insulating glazing unit, wherein the spacer profile 1 is used, will now be described with reference to Figs. 1 and 7. The spacer profile 1 is shown in cross-section perpendicular to the longitudinal direction z, i.e. along a slice in the x-y plane and extends with this constant cross-section in the longitudinal direction z. The spacer profile 1 has a first height h1 in the height direction y and a first width b1 in the traverse direction x and comprises a profile body 10, which is formed from a first material.
The spacer profile has an inner surface 12 extending in the traverse direction x with the first width b1 and facing inward toward the intervening space 53 between the glazing panes 51, 52 in the assembled state of the insulating glazing unit (see Fig. 7). On the opposite side in the height direction y, the spacer profile 1 has an outer surface 14, which has a second width b2 in the traverse direction x and faces away from the intervening space 53 between the glazing panes in the assembled state of the insulating glazing unit. The first height h1 of the spacer profile 1 is defined by the inner surface 12 and the outer surface 14. Furthermore, the spacer profile 1 has two side surfaces in the traverse direction x, which extend with a second height h2 in the height direction y and which are formed as attachment bases for attachment to the inner sides of the glazing panes 51, 52. In other words, the spacer profile 1 is preferably adhered to the respective inner side of the glazing panes 51, 52 via these attachment bases (see Fig. 7). The first width b1 is defined by the two side surfaces 16. The second height h2 of the side surfaces 16 is smaller than the first height h1 of the spacer profile 1. Furthermore, the spacer profile 1 has two connection surfaces 18 having a concave shape if seen from outside the spacer profile 1 extending between the outer surface 14 and the side surfaces 16. In other words, the side surfaces 16 and the outer surface 14 are connected by the connection surfaces 18 which are concave (= curved inwardly) with respect to the spacer profile 1. The side surfaces 16 and the inner surface 12 are directly connected. All of the above-described surfaces are connected with each other via curved portions, such that a smooth transition between the surfaces is achieved. Furthermore, the inner surface is formed slightly concave (seen form outside of the spacer profile).
The spacer profile 1 is formed of a profile body 10 comprising an inner wall 20 and an outer wall 22 separated by a first distance d1 in the height direction y, and two side walls which are separated by a second distance d2 in the traverse direction x. The inner wall 20 and the outer wall 22 extend essentially in the traverse direction x while the side walls 24, 26 extend essentially in the height direction y. The side walls 24, 26 are connected to the outer wall 22 via connection walls 28, 30. Furthermore, the side walls 24, 26 are connected to the inner wall 20 via inner corner portions 32, 34. The side walls 24, 26 are directly connected to the inner wall 20 via the inner corner portions 32, 34. That means, the inner corner portions 32, 34 are formed or constituted by portions of the side walls 24, 26 and the inner wall 20. Different thereto, the connection walls 28, 30 may not be formed from the edges of the respective side walls 24, 26 and the outer wall 22 but are additional walls which extend basically in an inclined direction with respect to the outer wall 22 and the side walls 24, 26. The connection walls 28, 30. extend in a direction between in parallel to the outer wall 22 and in parallel to the side walls 24,26. That means, an angle between a tangent to the connection wall 28, 20 and the outer wall 22 is preferably 0° to 90 °, more preferably larger than 0° and smaller than 90°. Furthermore, the connection walls 28, 30 are preferably connected to the edges of the outer wall 22 in the traverse direction x and to the edges of the side walls 24, 26 facing away from the inner wall 20. Accordingly, the outer wall 22 and the side walls 24, 26 are connected via the connection walls 28, 30.
Accordingly, a chamber 35 is formed by the inner wall 20, the side walls 24, 26, the connection walls 28, 30 and the outer wall 22.
The connection walls 28, 30 basically extend in the height direction y and at the same time in the traverse direction x to connect the side walls 24, 26 and the outer wall 22 in the shortest way. However, the connection walls 28, 30 are concave with respect to the chamber 35 such that they extend in form of a curve with a first radius R1 between the side walls 24, 26 and the outer wall 22. With other words, the connection walls 28, 30 are bended inwardly with respect to the chamber 35 and have basically the shape of a quadrant arranged outside the chamber 35.
The inner wall 20 has a first thickness t1, the side walls have a second minimum thickness t2 and the outer wall has a third minimum thickness t3. The minimum thickness of the connection walls 28, 30 preferably corresponds to the thickness of the outer wall 22. As the connection walls 28, 30, the inner wall 20, the outer wall 22 and the side walls 24, 26 are smoothly connected by curved portions, the thicknesses of the wall are higher in the transitions between the different walls or connection walls.
Furthermore, the inner wall 20 is also formed concave with respect to the chamber 35 such that the central portion of the inner wall 20 between the side walls 24, 26 is displaced in the height direction by a third distance d3 in a direction towards the chamber 35. Accordingly, the surface of the inner wall 20 facing towards the chamber 35 is displaced by the same third distance d3.
Furthermore, reinforcements 36, 38 made of a second material are provided in the inner corner portions 32, 34. With other words, the reinforcements 36, 38 are provided in the transition between the side walls 24, 26 and the inner wall 20. According to this embodiment, at least one of the reinforcements are steel wire 36, 38 extending in the longitudinal direction z with a constant cross section, which are embedded in the profile body 10 of the spacer profile 1. The center of the reinforcements 36, 38 is positioned with a fourth distance d4 from the inner surface 12 of the spacer profile 1 in the height direction y and with a fifth distance d5 in the traverse direction x from the side surfaces 16 of the spacer profile 1. Furthermore, the reinforcements 36, 38 are arranged with a minimum distance d6 between the surface of the reinforcemerits and the inner surface of the chamber 35.
Furthermore, the profile body 10 is firmly bonded (e.g., fusion and/or adhesive bonding) with a one-piece diffusion barrier layer 40. When the terms "diffusion impermeability" or "diffusion barrier" are used with respect to the spacer profiles and/or the materials forming the spacer profile, vapor diffusion impermeability as well as gas diffusion impermeability for the gases relevant herein, are meant to be encompassed within the meaning thereof. That means for the diffusion out of the intervening space that less than 1 % of the gas volume in the intervening space can escape per year. The spacer profile is diffusion impermeable in this sense and fulfils standard EN 1279 parts 2 and 3. The diffusion barrier layer 40 is formed from a third material and preferably formed as a film. The diffusion barrier layer is formed on the surfaces of the outer wall 22, connection walls 28, 30 and side walls 24, 26 facing away from the chamber 35. These surfaces are the "outer surfaces" of the respective walls. Accordingly, the outer surface of the inner wall 20 corresponds to the inner surface 12 of the spacer profile 1. Thus, the outer surface 14 and the connection surfaces 18 are constituted by the diffusion barrier layer 40 as the diffusion barrier layer 40 is the outermost layer. Furthermore, also the side surfaces 16 are at least partly constituted by the diffusion barrier layer 40. The diffusion barrier layer 40 extends on the side walls 24, 26 up to a seventh distance d7 from the inner surface 12 in the height direction y. Afterwards, the diffusion barrier layer extends within the side walls 24, 26 up to a eighth distance d8 from the inner surface 12. At the eighth distance d8 from the inner surface 12, the diffusion barrier layer 40 is bent by 90° into the traverse direction x and extends in the traverse direction x into the inner wall 20 with a third width b3. Accordingly, the diffusion barrier layer ends in a profiled end portion 42, 44 which has in this embodiment the shape of an "L". As the diffusion barrier layer 40 is made of metal material, the profiled end portions 42, 44 also act as reinforcements.
The region of the profile body (accommodation region), in which the profiled end portions are located (are accommodated), preferably should be clearly above the mid-line of the profile in the height direction. In such case, the dimension (length) of the accommodation region from the inner side of the spacer profile in the y-direction should not extend over more than 40% of the height of the spacer profile. By providing the profiled end portions in this region, the rigidity and bendability of the spacer profile is improved while the wrinkle formation in the process of bending is reduced.
On the other hand, for purely ornamental reasons, the diffusion barrier layer preferably should not be visible through the window panes of the assembled insulating window unit. Therefore, the film preferably should be covered at the inner side of the spacer profile by the material of the profile body.
In summary, the profiled end portion should preferably be close to the inner surface.
The term "profiled" as used herein preferably does not mean that the end portions are exclusively a linear elongation of the diffusion barrier layer 40, but instead that a two dimensional profile is formed in the two-dimensional view of the cross section in the x-y plane, which profile is formed, for example, by one or more bends and/or angles in the end portion.
Each L-shaped profiled end portion 42, 44 encloses one reinforcement 36, 38 from two directions. Namely, each reinforcement 36, 38 is enclosed by the L-shaped end portion 42, 44 of the diffusion barrier layer 40 such that the diffusion barrier layer 40, in case it extends within the respective wall, may be arranged between the reinforcement and the approximate side surface 16 or inner surface 12. Accordingly, each reinforcement 36, 38 is enclosed by the diffusion barrier layer 40 in a direction facing away from the chamber 35. With other words, the reinforcements 36, 38 overlap with the diffusion barrier layer 40 (or its profiled end portions 42, 44) in the height direction y. Furthermore, the reinforcements 36, 38 overlap with the diffusion barrier layer 40 (or its profiled end portions 42, 44) in the traverse direction x.
Furthermore, openings 46 may be formed in the inner wall 20 so that the inner wall 20 is not formed to be diffusion-proof. In addition or in the alternative, to achieve a non-diffusion-proof design, it is also possible to select the material for the entire profile body and/or the inner wall, such that the material permits an equivalent diffusion without the formations of such openings 46, 48. However, the formation of the opening of 46, 48 is preferable. Accordingly, a moisture exchange between the chamber 35, which is adapted to be filled with hygroscopic material and the intervening space 53 between the glazing panes in the assembled state is preferably ensured.
As can be seen from Fig. 1, the spacer profile 1 has its largest width at the height of the inner surface 12 in the height direction y and in a portion of the side walls 24, 26, where the diffusion barrier layer 40 extends within the same in the height direction y. In the area between the inner wall 12 and the outer wall 22, a step-like transition with a thickness or width of a sixth thickness h3 is created. The step-like transition is formed because the diffusion barrier layer 40 extends in a straight manner on the side of the side walls 24, 26, facing away from the chamber 35 but is provided in one area within the side wall 24, 26 and in another are on the side wall 24, 26. With other words, the side walls 24, 26 have a larger width in the traverse direction x in a portion in which the diffusion barrier layer 40 extends within the same than in a portion where the diffusion barrier layer 40 does not extend within the same. It is noted that the term "side surfaces" includes all surfaces extending straight in the height direction y. Accordingly, the side surfaces are formed in the portion of the side walls where the diffusion barrier is provided on the outer side of the side walls as well as in the portions where the diffusion barrier extends within the side walls. Accordingly, in the first case, the diffusion barrier layer forms the side surfaces and in the second case, the side walls for the side surfaces. The space created by this little step, when the spacer profile 1 is positioned between the glazing panes 51, 52, allows the presence of an adhesive material (primary sealing compound) 61 between the side surfaces 16 and the panes 51, 52 in the portion with the smaller thickness (t2), whereas the side surfaces 16 in the portion with the larger thickness (t2 + h3) can directly contact the window panes, which, however, is not preferred for small thicknesses of h3 smaller than 0,3 mm.
The first material of the profile body 10 is preferably an elastic-plastic deformable, poor heat-conducting (insulating) material.
Herein, the term "elastic-plastic deformable" preferably means that elastic restoring forces are active in the material after a bending process, as is typically the case for synthetic materials for which only a part of the bending takes place with a plastic, irreversible deformation. Further, the term "poor heat conducting" preferably means that the specific heat conductivity (thermal conductivity) λ is less than or equal to about 0.3 W/(mK).
The first material is preferably a synthetic material, more preferably a polyolefin and still more preferably polypropylene, polyethylene terephthalate, polyamide or polycarbonate. An example of such a polypropylene is Novolen® 1040K. The term synthetic material encompasses also bio products, e.g. bio polymers which are, for example, at least partly formed of renewable resources. The first material preferably has an E-modulus of less than or equal to about 2200 N/mm² and a specific heat conductivity λ less than or equal to about 0.3 W/(mK), preferably less than or equal to about 0.2 W/(mK). The first material may be strengthened by providing fibres therein. For example, glass fibre (for example, 10% to 30%, preferably, 15% to 25%, e.g. 20%) and/or carbon fibre (for example, 1% to 10%, preferably, 2% to 7%, e.g. 3.5 %) may be provided which are dispersed within the synthetic material of the profile body. Furthermore, also silicates, in particular, sheet silicates may be provided.
The second material of the reinforcements 36, 38 is preferably, as stated above, metal, e.g. steel. Preferably, the steel wire are brass coated so that a primer can be used to improve adhesion to the synthetic material of the profile body 10. Preferably, steel wire with a high tensile strength up to 1100 N/mm², more preferably up to 2000 N/mm², and further more preferably up to 2750 N/mm² or higher are used. This type of steel is called spring steel. Due to the high tensile strength, the wire may be very thin. Preferably the diameter of the used steel wire is between 0,01 and 2,00 mm, more preferably between 0,1 and 1 mm and even more preferred between 0,4 and 0,5 mm, for example 0,4 mm.
Alternatively the reinforcements may be made of plastic and/or fiber strands/wires/yarns or similar elongated wire-shaped elements or fibrous bundles of metal and/or composite fiber plastics materials. For example, glass fibers or a mixture of polymer and glass fiber is used. Preferably, the second material is a mixture of the first material, which has been used for the profile body, with glass fibers. Such a mixture allows a strong adhesion of the second material to the first material. Alternatively or additionally, carbon fibers, carbon nanotubes, liquid crystal polymers and mixtures of such materials with conventional synthetic materials may be used.
The third material of the diffusion barrier layer 40 is preferably a plastic deformable material. Herein, the term "plastic deformable" preferably means that practically no elastic restoring forces are active after deformation. This is typically the case, for example, when metals are bent beyond their elastic limit (apparent yield limit). Preferably, the third material is a metal, more preferably stainless steel or steel having a corrosion protection of tin (such as tin plating) or zinc. If necessary or desired, a chrome coating or a chromate coating may be applied thereto.
The above-used term "firmly bonded", preferably means that the profile body 10 and the diffusion barrier layer 40 are durably connected with each other, e.g. by co-extrusion of the profile body 10 together with the diffusion barrier layer and/or, if necessary, by the application of an adhesive material. Preferably the cohesiveness of the connection is sufficiently large that the materials are not separable in the "Peel" test according to DIN 53282.
Furthermore, the diffusion barrier layer additionally or alternatively acts as a reinforcement.
Its fourth thickness (material thickness) t4 is preferably less than or equal to 0.30 mm, more preferably less than or equal to 0.20 mm, still more preferably less than or equal to 0.15 mm, still more preferably less than or equal to 0.12 mm, and still more preferably less than or equal to 0.10 mm. Moreover, the fourth thickness t4 preferably is greater than or equal to 0.10 mm, preferably greater than or equal to 0.08 mm, still preferably greater than or equal to 0.05 mm and still preferably greater than or equal to 0.03 mm. These values can be freely combined as limits of thickness ranges. The maximum thickness is chosen so as to correspond to the desired specific heat conductivity and stability or rigidity and cold-bendability. If the layer is made thinner, the "warm edge" conditions will be increasingly fulfilled. If the layer is made thicker, the rigidity of the spacer profile 1 is increased. In each of the embodiments shown in the figures, the layer preferably has a thickness in the range of 0.05 mm to 0.13 mm.
The preferred third material for the diffusion barrier layer is steel and/or stainless steel having a specific heat conductivity λ less than or equal to about 50 W/(mK), more preferably less than or equal to about 25 W/(mK) and still more preferably less than or equal to 15 W/(mK). The E-modulus of the second material preferably falls in the range of about 170-240 kN/mm² and is preferably about 210 kN/mm². The breaking elongation of the second material is preferably greater than or equal to about 15%, and more preferably greater than or equal to about 20% and more preferably greater than or equal to 30%. Furthermore preferably, the breaking elongation is between 30% and 60%, more preferably between 35 % and 50%, as for example 37%, 40% or 45%.
The tensile strength of the third material is preferably between 750 N/mm² and 1300 N/mm², more preferably between 850 N/mm² and 1200 N/mm², and further more preferably between 890 N/mm² and 1150 N/mm², as for example 900 N/mm², 944 N/mm², 1000 N/mm², 1100 N/mm² and 1150 N/mm².
One preferable material has the combination of a breaking elongation between 30% and 40% and a tensile strength between 890 N/mm² and 950 N/mm², as for example a breaking elongation of 37% and a tensile strength of 944 N/mm². An example for such a material is "1.4372" (or 1.4372 2 H) steel. Preferably such a material has a thickness of approximate 0.1 min. Another preferable material has the combination of a breaking elongation between 40% and 50% and a tensile strength between 1050 N/mm² and 1130 N/mm², as for example a breaking elongation of 45% and a tensile strength of 1100 N/mm². An example for such a material is "1.4310" steel (or "1.4310 2 H" steel). Preferably such a material has a thickness of approximate 0.08 mm. Preferably, the third material is a steel which is thermally and mechanically treated.
Alternatively, the third material is a steel film of "1.4301" or "1.4016" steel according to DIN EN 10 088-2 having a thickness of 0.05 mm. Another example is made of a tin plate film is a film made of Antralyt E2, 8/2, 8T57 having a thickness of 0.125 mm.
As it is shown in Fig. 7, the side surfaces 16 formed as an attachment basis are adhered with the inner sides of the glazing panes 51, 52 using an adhesive material (primary sealant compound 61), e.g. a butyl-sealant compound based on polyisobutylene. The intervening space 53 between the glazing panes 51, 52 is thus defined by the two glazing (e.g. window or door) panes 51, 52 and the spacer profile 1. The inner surface 12 of the spacer profile 1 faces toward the intervening space 13 between the window panes 51, 52. On the outer surface 14 facing away from the intervening space 53 between the glazing panes 51, 52 in the height direction y, a mechanically stabilizing sealing material (secondary sealant compound) 62, for example based on polysulfide, polyurethanes or silicone, is introduced into the remaining empty space between the inner sides of the window panes in order to fill the empty space. This sealant compound also protects the diffusion barrier layer from mechanical or other corrosive/degrading influences.
The spacer profile 1 shown in Fig. 1 is designed to be used as a part of a spacer profile frame. Such a spacer profile frame can be formed by cold-bending the spacer profile 1 and connecting the open ends of the spacer profile 1 by a connector, preferably a linear connector. This way of forming a spacer profile frame is not shown in the drawings. Alternatively, linear portions of the spacer profile 1 can be connected to a spacer profile frame using corner connectors (not shown). These ways of forming spacer profile frames are well known in the art and not further explained here. When assembling an insulating glazing unit, a spacer profile frame is formed of the spacer profile 1 and attached to one of the glazing panes 51, 52 as shown in Fig. 7. The attachment is formed by using an adhesive material 61 as already explained above.
The spacer profile is preferably manufactured by a co-extrusion process, wherein all of the above-described parts are co-extruded together in one co-extrusion process. Alternatively, as also described above, for example, adhesive is used to fix the respective parts on each other. As the reinforcements 36, 38, which are formed as wire, are covered (or enclosed, or overlap with) by the profiled end portions 42, 44 of the diffusion barrier layer 40, the position of the reinforcement 36, 38 is well defined also in the process of bending the spacer profile. Accordingly, the process reliability of the bending process is improved. Furthermore, the risk that the reinforcements 36, 38 touch the side surfaces 16 or inner surface 12 due to manufacturing errors or variations in the manufacturing process (for example, extrusion process or bending process) of the spacer profile such that the reinforcements 36, 38 become visible or in touch with the sealant compound can be eliminated.
Furthermore, compared to the so-called "wave spacer" (see, for example, EP 1 797 271 B1 ) the amount of steel needed for the diffusion barrier layer 40 is reduced. At the same time, the heat transmission through the third steel material of the diffusion barrier layer is reduced significantly in comparison with a known spacer having a rectangular form wherein the connection walls 28, 30 are replaced by normal corner portions. Furthermore, the design of the inner corner portions 28, 30 allows nearly the same thermal value PSI as the known Wave Spacer has.
In case of using the mechanically and thermally treated 1.4310 steel or similar steel materials, the stiffness provided by the diffusion barrier layer can be significantly increased. Therefore, the rigidity of the whole spacer is also improved. Furthermore, the mechanically and thermally treated high-rigid stainless steel allows a thinner material compared to conventional materials such that the amount of steel which is used for producing the profile is reduced.
In case of using such high rigid stainless steel for the diffusion barrier layer, the diffusion barrier layer provides the main contribution to the rigidity of the spacer profile.
The usage of steel wire with a high tensile strength up to 2,700 N/mm² creates high rigidity of the spacer profile 1. As such rigid steel wire allows the use of very thin steel wire (diameter of 0.4 to 0.5 mm, for example), the wire is prevented from breaking during the bending of the frame. Accordingly, less material can be used while, at the same time, the thermal influence of the steel wire to the spacer profile is reduced.
Due to the new form of the connection walls 28, 30 between the side walls 24, 26 and the outer wall 22, the hollow cross-section has been increased. In other words, the volume of the chamber 35 is increased compared to the wave spacer form. This allows to fill more hygroscopic material (desiccant) per meter of the spacer profile. This allows to fill only two sides of the spacer frame with the desiccant instead of filling all four sides. Accordingly, a 16mm spacer profile according to this application can be filled with more than 20g/meter of the desiccant.
Furthermore, compared to the known "Wave Spacer", the optimized shape of the connection walls 28, 30 reduces the amount of needed secondary sealant compound because the recesses, as provided on the outer side of the wave spacer due to the wave form of the connection walls, do not exist in the present spacer profile.
Furthermore, due to the convex shape of the inner wall, a defined final shape when bending the spacer profile is achieved, as the inner wall always collapses inside the corner when bending the spacer.
Accordingly, the amount of the first and third material which are used for 1m of the spacer profile is reduced in comparison the conventional spacers such that the spacer profile according to the present application comprise cheaper manufacturing costs. Furthermore, the spacer profile provides a better rigidity about the x axis and about the y axis. Furthermore, the reinforcements (steel wire) are protected by the metal film (diffusion barrier layer) and well embedded inside the profile body 10 made of synthetic material. As the reinforcements are positioned at a position most away from the center of the spacer profile but within the synthetic material of the spacer profile and enclosed by the diffusion barrier layer, the above mentioned rigidity is as large as possible. Furthermore, as the inner corner portions 32, 34 have naturally a larger wall thickness in the cross section perpendicular to the longitudinal direction z, the reinforcements can be embedded therein without additionally increasing the thickness, as it is the case in conventional spacer profiles with reinforcements.
The length (d7 - d8) of the path along which the diffusion barrier layer 40 extends within the side walls 24, 26 in the height direction y is increased. The steel of the reinforcement layer cannot be seen from outside the insulating glassing unit, especially in the case of insulating glass units with three or more glass panes or in the case of "structural glazing" facades. Furthermore, the amount of secondary sealant compound can be reduced.
All details concerning the first embodiment also apply to the other described embodiments, except when a difference is expressly noted or is shown in the figures.
A second embodiment of the spacer profile 1 is shown in Fig. 2. The embodiment differs from the first embodiment essentially by further comprising undulations or notches 50 formed into the outer surface 14 of the spacer profile 1. As the diffusion barrier layer 40 constitutes the outer surface 14, the undulations 50 are formed in the diffusion barrier layer 40. As the diffusion barrier layer is firmly bonded to the walls of the spacer profile 1, the notches 50 extend into the outer wall 22. The notches 50 are, in this embodiment, provided in the transition between the outer wall 22 and the connection walls 28, 30. The notches 50 have a fifth thickness t5 in the height direction y.
As the notches 50 are provided in the diffusion barrier layer 40 made of metal material, the notches 50 significantly increase the stiffness of the spacer profile 1. This effect is further improved by arranging the notches in a position which is the farthest away from the central area of the spacer profile. Due to the higher stiffness, sagging of the spacer profile when used in a large window is reduced.
A third embodiment of the spacer profile is shown in Fig. 3. This embodiment differs from the second embodiment essentially in that further notches or grooves 52 are provided in the profiled end portions 42, 44 of the diffusion barrier layer 40. The notches 52 are provided with a ninth distance d9 from the corresponding side surface 16 and have a sixth thickness t6 in the height direction y, which preferably corresponds to the fifth thickness t5 of the above-described notches 50 in the outer wall 22.
Due to these additional notches, also the stiffness of the inner wall is significantly increased such that sagging is further reduced. Furthermore, winkle formation of the inner wall is reduced in a bending process. Furthermore, the reinforcements 36, 38 are, at least partly, further enclosed from a third direction such that an inward movement of the reinforcements 36, 38 is also prevented.
Accordingly, securing the position of the reinforcements 36, 38 is further improved and the rigidity of the whole spacer profile 1 is further increased in this embodiment.
A fourth embodiment of the spacer profile 1 is shown in Fig. 4. This embodiment differs from the third embodiment essentially in that the notches 50 in the outer wall 22 or in the diffusion barrier layer 40 on the outer wall 22 are not provided.
However, the advantages with respect to the inner wall and the reinforcements as described with respect to the third embodiment are also provided in this embodiment.
A fifth embodiment of the spacer profile 1, which does not show all claimed features, is shown in Fig. 5. This embodiment differs from the first embodiment essentially in that the reinforcements are not formed by steel wire but are formed by the profiled end portions 42, 44 of the diffusion barrier layer 40 only. Accordingly, in this embodiment, it is preferred to use as a third material for the diffusion barrier layer 40, a steel material having a high rigidity (for example, the thermally and mechanically treated A 1.4310 steel material). By using such a material, the reinforcements can be formed by the diffusion barrier layer. In other words, in this embodiment, the reinforcements are integrally formed with the diffusion barrier layer 40.
This allows to simplify the manufacturing process and to reduce the costs of the spacer profile 1. Furthermore, the heat transmission through metal parts is reduced.
A sixth embodiment of the spacer profile 1 is shown in Fig. 6. This embodiment differs from the second embodiment in that the diffusion barrier layer extends in the height direction y on the side walls 24, 26 up to the distance d7 from the inner surface 12, wherein the distance d7 in this embodiment is shorter than the distance d7 in the first to fifth embodiments.
A seventh embodiment of the spacer profile 1 is shown in Fig. 9. The seventh embodiment differs from the second embodiment in that the profiled end portions 42, 44 of the diffusion barrier layer 40 respectively comprise three bends 54, 55, 56.
Starting at the reinforcement layer 40 extending on the side wall 24, 26 and going in the direction to the inner wall 20, the first bend 54 is about 45° towards the interior of the respective sidewall 24, 26 and has approximately the seventh distance d7 from the inner surface 12. With other words, the first bend 54 is approximately located at the step-like transition where in thickness of the side walls 24, 26 increases as stated above.
The second bend 55 basically immediately follows the first bend 54 and is about 45° in the opposite direction of the first bend 54. Accordingly, after the second bend 55, the diffusion barrier layer 40, or more precisely, its profiled end portion 42, 44, extends basically in parallel to the diffusion barrier layer 40 before the first bend 54 (that is, when extending on the surface of the respective side wall 24, 26). In this embodiment, a seventh thickness h31 of the material covering the reinforcement layer 40 in the direction to the side surfaces 16 is, accordingly, increased with respect to thickness provided by the sixth thickness h3 of the step like transition in the first embodiment, for example. Thus, the increase is achieved by the first and second bends 54, 55 making the reinforcement layer 40 to extend deeper within the side walls 24, 26. The sixth thickness h31 is achieved by the bends 54, 55 and by the step like transition in this embodiment.
Finally a 90° bend directing the diffusion barrier layer 40 to extend into the inner wall 20 as in the second embodiment is provided as a third bend 56. In other words, after the first and second bend 54, 55, the profiled end portion 42, 44 extends in the height direction y until it is bent inwardly with a radius of preferably 0.1 mm to 1 mm by approximately 90°. After the third bend 56, the profiled end portion 42, 44 extends with the above eighth distance d8 from the inner surface 12 in the traverse direction x. Thus, the profiled end portion 42, 44 extends in this embodiment in the traverse direction x into the inner wall 20 with a fourth width b4 from the portion of the profiled end portions 42, 44 extending between the second bend 55 and the third bend 56.
The radii of the first and second bends are preferably between 0.05 mm and 1 mm, more preferably between 0.10 and 0.5 mm, as for example, 0.11 mm or 0.15 mm. The radii can be different to each other. The fourth width b4 is preferably between 1 mm and 2.5 mm, more preferably between 1.75 mm and 2.1 mm as, for example, 1.85 mm, 1.95 mm or. 2 mm. The fifth thickness h31 in the traverse direction x is preferably between 0,1 mm and 2,5 mm, more preferably between 0,15 mm und 1 mm, and further more preferably between 0,17 mm and 0,5 mm, as for example, 0,20 mm or 0,25 mm. The displacement of the reinforcement layer 40 is preferably between 0,05 mm and 1,5 mm, more preferably between 0,1 mm und 0,5 mm as for example, 0,15 mm or 0,20 mm.
The profiled end portions according to the seventh embodiment may be combined with any one of the previously described embodiments. For example, the profiled end portions according to the seventh embodiment may comprise the above described notches 50, 52.
By providing the further bends as described above, the thickness of the wall material between the respective side surface 16 and the reinforcement layer (or profiled end portions) is increased. Accordingly, the spacer profile can be bent more easily without the risk of wrinkle formation in this specific part of the spacer.
Further possible modifications are discussed below. Obviously, each of the above-mentioned embodiments can be combined with each other. This means, the above-described combinations of reinforcements, notches and so on is not necessarily required to achieve the claimed invention. In particular, the notches 50, 52 may be arranged anywhere on the outer walls 22 or anywhere on the L-shaped end portions of the diffusion barrier layer. Furthermore, the direction of notching may also be in the opposite direction, as, for example, not into the outer wall but in a direction opposite to the chamber 35. Furthermore, also the reinforcements may be provided on different positions, such as, for example, the outer wall or the connection walls between the side walls and the outer walls, or the side walls. Furthermore, the reinforcements may also be provided within the middle portion of the inner wall.
Furthermore, the reinforcements may be provided not constantly in the longitudinal direction z but in sections. This means, the reinforcement wires may be co-extruded only at portions, at which the spacer profile is bent later-on. Furthermore, the form of the connection walls is not limited to the form described above. This means, also straight connection walls being inclined to the outer wall and the side walls are encompassed by the present teachings as well as convex and concave shapes. This means, the convex shape of the inner wall is not necessarily required.
The notches 50 on the outer surface are advantageous in particular in the process of manufacturing the spacer profile because the diffusion barrier layer can be held in position by these notches when extruding the spacer profile 1. Accordingly, this advantage may be achieved by providing notches 50 anywhere in the diffusion barrier layer in portions where the diffusions barrier layer forms one of the outer surfaces of the spacer profile. Accordingly, in this respect, also only one notch would be sufficient.
The spacer profile may be manufactured in different colors. In case of using suitable materials, especially PP, the coloring material may be provided "inside" the PP and no film or coated surfaces are necessary, which may be subject to visible scratches. Different colors of different portions such as a difference between the indoor and outdoor sides are possible. The diffusion barrier layer 40 may be formed and positioned in the spacer profile 1 such that the diffusion barrier layer 40 does not form the outer surfaces of the spacer profile 1.
The insulating glass units can be used for doors, windows, facade elements, indoor partition walls, roofs and the like. The material of the glazing panes is not limited to glass but can be other transparent or semi-transparent glazing materials like Plexiglas or others.
The first width b1 is preferably between 4 mm and 40 mm, more preferably between 5 mm and 20 mm and further more preferably between 10 mm and 16 mm, e.g., 10 mm, 12 mm or 16 mm.
The second width b2 is smaller than the first width b1 and is preferably between 3 mm and 25 mm, more preferably between 4 mm and 15 mm, and further more preferably between 9 mm and 12 mm, e.g. 9 mm, 9.7 mm or 10 mm.
The third width b3 is preferably between 1 mm and 5 mm, more preferably between 1 mm and 4 mm, e.g., 1.5 mm, 2.05 mm or 2.5 mm.
The first height h1 is preferably between 2 mm and 20 mm, more preferably between 3 mm and 15 mm and further more preferably between 5 mm and 10 mm, e.g., 5 mm, 7 mm or 8 mm, and usually about 7 mm.
The second height h2 is preferably between 1 mm and 12 mm, more preferably between 2 mm and 10 mm, e.g., 4 mm, 5 mm or 6 mm.
The sixth thickness h3 is preferably between 0.01 mm and 1 mm, more preferably between 0.02 mm and 0.1 mm, e.g. 0.05 mm or 0.1 mm
The first thickness t1 is preferably between 0.1 mm and 3 mm, more preferably between 0.2 mm and 1.5 mm and further more preferably between 0.5 mm and 1 mm, e.g. 0.8 mm, 0.9 mm or 1 mm.
The second thickness t2 preferably corresponds to the first thickness t1.
The third thickness t3 preferably corresponds to the first thickness t1.
The fourth thickness t4 is, as described above, preferably in the range of 0.1 mm.
The fifth thickness t5 and the sixth thickness t6 of the notches 50, 52 are preferably between 0.01 mm to 1 mm, more preferably between 0.1 mm and 0.8 mm, e.g. 0.2 mm.
The third distance d3 is preferably between 0.01 mm and 1 mm, more preferably between 0.1 mm and 0.9 mm and further more preferably between 0.15 mm and 0.5 mm, e.g. 0.2 mm or 0.4 mm.
The fourth distance d4 is preferably between 0.2 mm and 3 mm, more preferably between 0.5 mm and 2 mm, e.g. 0.8 mm, 1 mm or 1.2 mm.
The fifth distance d5 is preferably between 0.2 mm and 2 mm, more preferably between 0.3 mm and 1 mm, e.g. 0.4 mm, 0.5 mm or 0.6 mm.
The sixth distance d6 is preferably between 0.2 mm and 2 mm, more preferably between 0.3 mm and 1 mm, e.g. 0.4 mm, 0.5 mm or 0.6 mm.
The seventh distance d7 is preferably ≥ 0.5mm, more preferably 1 mm, more preferably ≥ 1.5 mm but at the same time preferably ≤ h2 - 2.5 mm, more preferably ≤ h2 - 3 mm. In other words, h2 - d7 is preferably ≥ 2.5 mm, more preferably ≥ 3 mm, but at the same time d7 should be most preferably 1.5 mm.
The eighth distance d8 is preferably between 0.1 mm and 2 mm, more preferably between 0.2 mm and 1 mm, e.g. 0.4 mm, 0.5 mm or 0.6 mm.
The thickness of the reinforcement 36, 38 is preferably between 0.05 mm and 2 mm, more preferably between 0.1 mm and 1 mm, as for example 0.2 mm, 0.4 mm or 0.5 mm.
The first Radius R1 of the concave connection wall is preferably between 1 mm and 10 mm, more preferably between 1.3 mm and 5 mm, and further more preferably between 1.5 mm and 2 mm, as for example 1.6 mm, 1.7 mm or 1.8 mm.

List of reference signs:

1	spacer profile
10	spacer profile body
12	inner surface
14	outer surface
16	side surfaces
18	connection surfaces
20	inner wall
22	outer wall
24, 26	side walls
28, 30	connection walls
32, 34	inner corner portions
35	chamber
36, 38	reinforcements
40	diffusion barrier layer
42, 44	profiled end portions
46, 48	openings
50, 52	notches
54	first bend
55	second bend
56	third bend

Claims

A spacer profile (1) for use as part of a spacer profile frame, which is suitable for being mounted in and/or along an edge area of an insulating glazing unit (50) surrounding an intervening space (53) between glazing panes (51, 52), the spacer profile (1) extending in a longitudinal direction (z) and having, in a cross section (x-y) perpendicular to the longitudinal direction (z), a first width (b1) in a transverse direction (x), which is perpendicular to the longitudinal direction (z), and a first height (h1) in a height direction (y), which is perpendicular to the longitudinal direction (z) and to the transverse direction (x), wherein the spacer profile (1) comprises
a profile body (10) made of synthetic material, the profile body (10) comprising an inner wall (20) extending in the transverse direction (x) and being arranged to face towards the intervening space (53) in the assembled state of the spacer profile frame, an outer wall (22) extending parallel to the inner wall (20) and having a second width (b2) in the transverse direction being smaller than the first width (b1) and spaced by a first distance (d1) from the inner wall (20) in the height direction (y) smaller than the first height (h1), side walls (24, 26) extending in the height direction and spaced by a second distance (d2) in the transverse direction (x) smaller than the first width (b1) and being connected to the inner wall (20) at inner corner portions (32, 34),
connection walls (28, 30) extending between the side walls (24, 26) and the outer wall (22) such that a chamber (35) is formed by the sidewalls (24, 26), the inner wall (20), the outer wall (22), and the connection walls (28, 30), and
a diffusion barrier layer (40) firmly bonded with the profile body (10) and being made of metal material and extending, in a cross section (x-y) perpendicular to the longitudinal direction (z), in one piece on the outer surface of the outer wall (22), on the outer surfaces of the connection walls (28, 30) and on at least a part of the outer surfaces of the side walls (11, 12), characterized in that
at least two reinforcements (36, 38; 42, 44) are provided in each of the inner corner portions (32, 34),
the first reinforcement of the at least two reinforcements (36, 38; 42, 44) is made of wire (36, 38),
the diffusion barrier layer (40) comprises profiled end portions (42, 44), which are provided in the inner corner portions (32, 34), as the second reinforcement of the at least two reinforcements (36, 38, 42, 44), and
each first reinforcement made of wire (36, 38) overlaps with the corresponding profiled end portion (42, 44) seen in the height direction (y) and in the transverse direction (x), such that each first reinforcement made of wire (36, 38) is enclosed by the corresponding profiled end portion (42, 44) in a direction facing away from the chamber (35).
The spacer profile (1) according to claim 1, wherein the at least one reinforcement made of wire (36, 38) is made of metal material.
The spacer profile (1) according to claim 1 or 2, wherein the diffusion barrier layer (40), continuous to the parts extending on the outer surfaces of the side walls (24, 26) in a direction to the profiled end portions (42, 44), extends within the side walls (24, 26) in a height direction (y).
The spacer profile (1) according to any one of claims 1 to 3, wherein the diffusion barrier layer (40) comprises at least one notch (50, 52).
The spacer profile (1) according to claim 4, wherein the at least one notch (50, 52) is provided in each of the profiled end portions (42, 44) and/or in the outer wall (22) adjacent to the connection walls (28, 30), respectively.
The spacer profile (1) according to any one of claims 1 to 5, wherein the outer surface of the inner wall has a concave shape.
The spacer profile (1) according to any one of claims 1 to 6, wherein the connection walls (28, 30) have a concave outer surface.
The spacer profile (1) according to any one of claims 1 to 7, wherein the radius (R1) of the concave connection walls (28, 30) is larger than 1.5 mm.
The spacer profile (1) according to any one of claims 1 to 8 as far as being dependent on claim 3, wherein diameter of the wire (36, 38) is between 0.1 mm and 1 mm.
The spacer profile (1) according to any one of claims 1 to 9, wherein the reinforcement (36, 38) has a tensile strength of at least 2500 N/mm².
Insulating glazing unit comprising:
at least two glazing panes (51, 52) arranged to oppose each other with a separation distance therebetween so as to form an intervening space (53) between the glazing panes (51, 52), and a spacer profile frame formed from a spacer profile (1) according to any one of claims 1 to 10 and at least partially defining the intervening space (53) between the glazing panes (51, 52), wherein the side walls (24, 26) of the spacer profile (1) are, as attachment bases, adhered with a diffusion-proof adhesive material (61) essentially along their entire length and at least partly in the height direction with the inner sides of the glazing panes (51, 52) that face thereto.