WO2024038179A1

WO2024038179A1 - Spacer profile comprising an outer layer of acid-treated polymer, a composite barrier foil, a method of making such spacers and use of acid-treated polymers in spacer profiles for insulating glass units

Info

Publication number: WO2024038179A1
Application number: PCT/EP2023/072781
Authority: WO
Inventors: Peter Pedersen
Original assignee: Rolltech A/S
Priority date: 2022-08-18
Filing date: 2023-08-18
Publication date: 2024-02-22

Abstract

The invention relates to a spacer profile that can be of various designs and having an outer surface of a polymeric material having a roughness Ra of at least 0.25 µm. The invention further relates to multilayer diffusion barrier foils for use in spacers having an outer layer, which is an acid-treated polymeric material, or an outer layer of a polymeric material having a roughness Ra of at least 0.25 µm.

Description

Title:

an outer of acid-treated

barrier foil, a method of makinq such and use of acid-treated polymers in

units.

Within the field of insulating window units or insulating glass units (IGU), spacer profiles are used to separate the panes. Various designs exist for insulating glass units and according to some designs, the intervening space between the panes are filled with an inert gas e.g. argon. It is desired that the gas in the intervening space does not leak from the space while at the same time it is desired that oxygen, vapor, moisture or similar heat conducting gasses do not enter the intervening space, as it reduced the resistance to heat conduction. Usually the spacer profiles and/or the sealing(s) around the spacer are the most leaky positions in the IGU.

The spacer profiles for the IGU are of various designs and with various outer surfaces. Among the designs, are the traditional spacer profiles which are a folded metal foil, the hybrid spacer profiles being made of a polymeric material with reinforcements of various kinds and flexible spacer profile being made of materials such as silicone. The spacer profiles can have barrier foils, composite barriers with multiple layers of various materials and/or other barrier-improving features. This means that there is a great variety of the outer surface of the spacer profiles which needs to be able to form a tight sealing with the sealant and/or the panes.

Manufacturers of IGU’s use several kinds of primary and secondary sealants or adhesives to adhere the spacer profile to the panes and/or to form a sealant on the side of the spacer profile not facing the intervening space between the panes. Examples of such sealants or adhesives are poly-isobutyl, polysulfides, hot melt secondary sealants, silicones, polyurethanes etc.

For a manufacturer of spacer profiles, it is a challenge that it is not always known which kind of sealants a costumer intends to use. This means that the manufacturer might face a situation, where a customer has used a sealant which is not fully compatible with the outer surface of the spacer profile, thus resulting in a risk that separation occurs between the spacer and the sealants especially with the secondary sealant provided on the side directly opposite to the intervening space between the panes. Currently, there is a challenge that some secondary sealants tend to lose their adherence to the spacer profile when exposed to moisture. For a manufacturer of spacer profiles, one solution is having several versions of essentially the same spacer profile in order to provide a spacer that can be used together with the sealant chosen by an IGU manufacturer.

EP 3511507A illustrates various spacer profiles having the problem that he outer surface is not necessarily compatible with the secondary sealants. WO 2021/151705A1 is another example of such spacer profiles. The spacer profiles of WO 2021/151705A1 are pacer profiles having foils as the outer layer. US 11668132 B2 focusses on improving the direct connection between the panes and the spacer profile. However, US 11668132 B2 does not address the problem of compatibility with secondary sealants. It teaches that the outer surface must be smooth, i.e. having an extremely low roughness and in any case a roughness being less than 0.2 pm.

Thus, there is a need for spacer profiles having an outer surface that is compatible with most or all of the traditionally used primary and secondary sealants - especially compatibility with the secondary sealants. The person skilled in the art would understand that with compatible is meant that there is a good connection, adhesion or bonding between the sealants and the surface and one that also lasts when aged.

SUMMARY OF INVENTION

The problem is elegantly solved by providing a spacer profile for IGU units with an outer layer of an acid-treated polymeric material or a polymeric material with a roughness R_a of at least 0.25 pm. In a preferred solution, silica flakes are embedded in the outer layer and extend from the surface.

According to the invention, there is provided a spacer profile for use as part of a spacer profile frame, which is suitable for being mounted in and/or along an edged area of an insulating glazing unit so as to surround an intervening space between glazing panes, the spacer profile comprising a spacer body extending in a longitudinal direction (Z), said spacer body comprising: an inner wall facing the intervening space between and extending in a transverse direction (X) an outer wall separated from the inner wall by a first distance two side walls extending in a hight direction (Y) and separated by a second distance optionally two outer connection walls extending between the side walls and the outer wall optionally two inner connection walls extending between the side walls and the inner wall

- where the inner wall, the side walls and the outer wall define a chamber suitable for desiccants optionally the two outer connection walls and/or the two inner connection walls are part of the defining of the chamber

- where the outer wall has an outer wall outer surface facing away from the chamber

- where the side walls have side walls outer surfaces facing away from the chamber characterized in that the spacer body at least on the outer wall as an outermost outer layer and has a layer of an acid-treated polymeric material.

Acid-treatment of polymeric material creates a lasting roughness and modification of the surface of the polymeric material that improves the binding to the secondary sealants typically used during manufacturing of IGUs. Other modifications of polymeric materials for increasing the roughness do not have the same lasting improvement.

In a preferred embodiment, the spacer body further comprises a diffusion barrier positioned at least on the outer wall outer surface. When a diffusion barrier is used, the outermost outer layer of an acid-treated polymeric material is then used as the outer layer of the diffusion barrier or is being applied on the outer side of the diffusion barrier.

In a preferred embodiment, the diffusion barrier is a multilayer diffusion barrier foil as described in another embodiment of the invention.

In a preferred embodiment, the outermost outer layer is an acid-treated polymeric foil.

In a preferred embodiment, the outermost outer layer is a TCA-treated PET foil.

In a preferred embodiment, the outermost outer layer material is a PET foil with a minimum surface tension of 45 dyne/cm, preferably a PET foil with a minimum surface tension of 50 dyne/cm or more preferable a PET foil with a minimum surface tension of 58 dyne/cm.

Acid treatment of polymeric materials changes the surface tension of the polymeric materials. There are other ways of changing the surface tension of polymeric materials than acid treatment, e.g. plasma treatment. The inventor has found that PET foils with a minimum surface tension as specified above are particularly compatible with most of the secondary sealants used in IGU.

In a preferred embodiment, silicon oxide is deposited on the acid-treated PET foil. The silicon oxide can be in form of flakes embedded in the surface of the TCA-treated PET foil and locked into the outer surface of the PET foil. This has the advantage that the surface area is increased and good bonding sites for the primary and secondary sealants are achieved. Further, silanes typically present in the secondary sealant are believed to form bindings to the silica flakes. Thereby, a tighter connection between the secondary sealants and the spacer profiles is achieved.

It is especially preferred that silicon oxide is deposited on a TCA-treated PET foil, and it is particularly preferred that the silica flakes are extending from the surface.

In a preferred embodiment, at least the inner wall and part of the side walls are made of a polymeric material. It is especially preferred that the spacer body further comprises reinforcements such as wires, multiple bended diffusion barriers, added metallic layers and the like. The advantages of this combination are that the polymeric material reduces the heat conductivity, and the reinforcement layer provides stiffness to the relatively flexible polymeric material. Thereby, both a good heat insulation and a good stiffness of the spacer profile are achieved.

According to the invention, there is also provided a spacer profile for use as part of a spacer profile frame, which is suitable for being mounted in and/or along an edged area of an insulating glazing unit so as to surround an intervening space between glazing panes, the spacer profile comprising a spacer body extending in a longitudinal direction (Z), said spacer body comprising: an inner wall facing the intervening space between and extending in a transverse direction (X) an outer wall separated from the inner wall by a first distance two side walls extending in a hight direction (Y) and separated by a second distance optionally two outer connection walls extending between the side walls and the outer wall optionally two inner connection walls extending between the side walls and the inner wall

- where the inner wall, the side wall and the outer wall define a chamber suitable for desiccants; optionally the two outer connection walls and/or the two inner connection walls are part of the defining of the chamber

- where the side walls have side walls outer surfaces facing away from the chamber characterized in that the spacer body at least on the outer wall as an outermost outer layer has a layer of polymeric material having a roughness Ra of at least 0.25 pm.

Preferably, the R_a is at least 0.30 pm, more preferably at least 0.35 pm and even more preferred at least 0.40 pm and most preferred at least 0.7 pm.

Preferably both the outer wall outer surface and at least part of the side surfaces have as the outermost outer layer a layer of polymeric material having a roughness Ra of at least 0.25 pm more preferably at least 0.35 pm and even more preferred at least 0.40 pm and most preferred at least 0.7 pm.

For some purposes, an even higher R_a is preferred. Here, an R_a of at least 1.0 pm is preferred, and more preferred is an R_a of at least 1.3 pm and even more preferred of at least 1.50 pm.

The advantage of more roughness is a better surface to adhere on and thereby a stronger connection to the sealants. The advantage of also increasing the roughness of both the outer wall outer surface and the side surfaces is that both the connection to the primary and to the secondary sealants are improved.

Suited R_a of the polymeric material can be selected from R_a of at least 0.25 pm, at least 0.30 pm, at least 0.35 pm, at least 0.40 pm, at least 0.45 pm, at least 0.50 pm, at least 0.55 pm, at least 0.60 pm, at least 0.65 pm, at least 0.70 pm, at least 0.75 pm, at least 0.80 pm, at least 0.85 pm, at least 0.90 pm, at least 0.95 pm, at least 1.0 pm, at least 1.1 pm, at least 1 .2 pm, at least 1.3 pm, at least 1.4 pm, at least 1.5 pm, at least 1 .6 pm, at least 1.7 pm and at least 2.0 pm. In a preferred embodiment, the polymeric material is a polar polymeric material.

In a preferred embodiment ,the polar polymeric material is selected from the group consisting of polyethylene teraphtelat (PET), Polyurethane, Polycarbonate (PC), Polymethyl metacrylate (PMMA), Polyvinyl acetate, acrylate elastomers, polyvinyl butyral, Poly styrene, polyvinyl alcohol and polychloroprene.

The person skilled in the art would understand that each of the above-mentioned polar polymers has multiple variations within each polymer.

In a most preferred embodiment, the polar polymeric material is a PET.

In a preferred embodiment of the spacer profile that at least on the outer wall has an outermost outer layer of a layer of polymeric material having a roughness Ra of at least 0.25 pm; at least the inner wall and part of the side walls are made of a polymeric material. It is especially preferred that the spacer body further comprises reinforcements such as wires, multiple bended diffusion barriers, added metallic layers and the like. The advantages of this combination are that the polymeric material reduces the heat conductivity, and the reinforcement layer provides stiffness to the relatively flexible polymeric material. Thereby, both a good heat insulation and a good stiffness of the spacer profile are achieved.

According to the invention, there is also provided a spacer profile for use as part of a spacer profile frame, which is suitable for being mounted in and/or along an edged area of an insulating glazing unit so as to surround an intervening space between glazing panes, the spacer profile comprising a foam rubber spacer body extending in a longitudinal direction (Z), and having: an inner surface facing towards the intervening space between glazing panes an outer surface facing away from the intervening space between glazing panes two side surfaces extending between the inner surface and the outer surface, said side surfaces being adapted to be connected to glazing planes so as to form the intervening space optionally two connecting surfaces for connecting the side surfaces with the outer surfaces characterized in that at least the outer surface is covered with a foil having as its outermost layer an acid-treated polymeric material. In a preferred embodiment, the acid-treated polymeric material is a TCA-treated PET foil.

In a preferred embodiment, the acid-treated polymeric material is a PET foil with a minimum consistent surface tension of 45 dyne/cm, preferably a PET foil with a minimum consistent surface tension of 50 dyne/cm or more preferable a PET foil with a minimum consistent surface tension of 58 dyne/cm

In another preferred embodiment, the acid-treated polymeric material is a TCA-treated Polyester foil.

In a preferred embodiment, the acid-treated polymeric material is a Polyester foil with a minimum consistent surface tension of 45 dyne/cm, preferably a Polyester foil with a minimum consistent surface tension of 50 dyne/cm, more preferable a Polyester foil with a minimum consistent surface tension of 60 dyne/cm even more preferable a Polyester foil with a minimum consistent surface tension of 70 dyne/cm and most preferable a Polyester foil with a minimum consistent surface tension of 80 dyne/cm

Foils, which are suitable for the invention, are commercially available under tradenames such as Kemafoil® and Optimont®.

In a preferred embodiment, the foil having as its outermost layer an acid-treated polymeric material and also comprises diffusion barrier layers.

In a preferred embodiment, the foil is a multilayer diffusion barrier foil as described in the embodiments of the multilayer diffusion barrier foil.

In a preferred embodiment, the spacer body is made of a foamed silicone rubber or EPDM rubber.

According to the invention, there is also provided a spacer profile for use as part of a spacer profile frame, which is suitable for being mounted in and/or along an edged area of an insulating glazing unit so as to surround an intervening space between glazing panes, the spacer profile comprising a foam rubber spacer body extending in a longitudinal direction (Z), and having: an inner surface facing towards the intervening space between glazing panes an outer surface facing away from the intervening space between glazing panes two side surfaces extending between the inner surface and the outer surface, said side surfaces being adapted to be connected to glazing planes so as to form the intervening space optionally two connecting surfaces for connecting the side surfaces with the outer surfaces characterized in that at least the outer surface is covered with a foil having as its outermost layer a polymeric material having a roughness Ra of at least 0.25 pm.

Preferably, both the outer wall outer surface and at least part of the side surfaces is covered with a foil having as its outermost layer a polymeric material having a roughness Ra of at least 0.25 pm more preferably at least 0.35 pm and even more preferred at least 0.40 pm and most preferred at least 0.7 pm

Suited R_a of the polymeric material can be selected from R_a of at least 0.25 pm, at least 0.30 pm, at least 0.35 pm, at least 0.40 pm, at least 0.45 pm, at least 0.50 pm, at least 0.55 pm, at least 0.60 pm, at least 0.65 pm, at least 0.70 pm, at least 0.75 pm, at least 0.80 pm, at least 0.85 pm, at least 0.90 pm, at least 0.95 pm, at least 1.0 pm, at least 1.1 pm, at least 1 .2 pm, at least 1.3 pm, at least 1.4 pm, at least 1.5 pm, at least 1 .6 pm, at least 1.7 pm and at least 2.0 pm.

In a preferred embodiment, the polymeric material is a polar polymeric material.

In a preferred embodiment, the polar polymeric material is selected from the group consisting of polyethylene terephthalate (PET), Polyurethane, Polycarbonate (PC), Polymethyl methacrylate (PMMA), Polyvinyl acetate, acrylate elastomers, polyvinyl butyral, Poly styrene, polyvinyl alcohol and polychloroprene. The person skilled in the art would understand that each of the above-mentioned polar polymers has multiple variations within each polymer.

In a preferred embodiment, the foil has embedded silica flakes extending from the outer surface. This has the advantages as describer earlier.

In a most preferred embodiment, the polar polymeric material is a PET.

In another aspect of the invention, the invention relates to a method of making spacer profiles compatible with multiple sealants, said method comprising the steps of: providing a spacer profile for use as part of a spacer profile frame, which is suitable for being mounted in and/or along an edged area of an insulating glazing unit so as to surround an intervening space between glazing panes, the spacer profile comprising a spacer body extending in a longitudinal direction (Z), said spacer profile comprising a spacer body having: o an inner surface facing towards the intervening space between glazing panes o an outer surface facing away from the intervening space between glazing panes o two side surfaces extending between the inner surface and the outer surface, said side surfaces being adapted to be connected to glazing planes so as to form the intervening space o optionally two connecting surfaces for connecting the side surfaces with the outer surfaces adding a foil having as its outermost layer an acid-treated polymeric material to the spacer body or adding a foil having as its outermost layer a polymeric material having a roughness Ra of at least 0.25 pm

In a preferred embodiment of the method, the acid-treated polymeric material is a TCA- treated PET foil. In a preferred embodiment of the method, the acid-treated polymeric material is PET foil with a minimum surface tension of 45 dyne/cm, preferably a PET foil with a minimum surface tension of 50 dyne/cm or more preferable a PET foil with a minimum surface tension of 58 dyne/cm.

In a preferred embodiment of the method, the acid-treated polymeric material is a TCA- treated Polyester foil.

In a preferred embodiment of the method, the acid-treated polymeric material is a Polyester foil with a minimum consistent surface tension of 45 dyne/cm, preferably a Polyester foil with a minimum consistent surface tension of 50 dyne/cm, more preferable a Polyester foil with a minimum consistent surface tension of 60 dyne/cm even more preferable a Polyester foil with a minimum consistent surface tension of 70 dyne/cm and most preferable a Polyester foil with a minimum consistent surface tension of 80 dyne/cm.

In another aspect, the invention relates to a multilayer diffusion barrier foil for use in spacer profiles for insulating glass units, the multilayer diffusion barrier foil comprises: at least one support layer at least one organic or inorganic diffusion barrier layer an outer layer characterized in that the outer layer is an acid-treated polymeric material.

In yet another aspect, the invention relates to a multilayer diffusion barrier foil for use in spacer profiles for insulating glass units, the multilayer diffusion barrier foil comprises: at least one support layer at least one organic or inorganic diffusion barrier layer an outer layer characterized in that the outer layer has a roughness Ra of at least 0.25 pm, preferably at least 0.30 pm, more preferably at least 0.35 pm and even more preferred at least 0.40 pm and most preferred at least 0.7 pm.

A preferred organic diffusion barrier layer is polyvinyl alcohols and ethylene vinyl alcohols (EVOH). Preferred inorganic diffusion barrier layers are metal layers or aluminium oxide layers or SiOx layers, where 1 < x < 2.

Among the advantages of multilayer barrier foils are that multiple properties can be incorporated in one foil or enhanced diffusion impermeability can be achieved. The invention can be used together with traditional multilayer barrier foils by applying an outer layer of an acid-treated polymeric material or an outer layer of a polymeric material having a roughness R_a of at least 0.25 pm on the outer side. Preferably, the roughness R_a is at least 0.30 pm, more preferably at least 0.35 pm and even more preferred at least 0.40 pm and most preferred at least 0.7 pm.

Suited R_a of the acid-treated polymeric material can be selected from R_a of at least 0.25 pm, at least 0.30 pm, at least 0.35 pm, at least 0.40 pm, at least 0.45 pm, at least 0.50 pm, at least 0.55 pm, at least 0.60 pm, at least 0.65 pm, at least 0.70 pm, at least 0.75 pm, at least 0.80 pm, at least 0.85 pm, at least 0.90 pm, at least 0.95 pm, at least 1.0 pm, at least 1.1 pm, at least 1.2 pm, at least 1.3 pm, at least 1.4 pm, at least 1.5 pm, at least 1.6 pm, at least 1.7 pm and at least 2.0 pm.

For instance, by using different layers in the multilayer diffusion barrier foil, inert gasses such as argon can be contained in the intervening space between the glass panes by one of the layers while another layer keeps moisture out of the intervening space.

A particularly suited multilayer diffusion barrier foil for use in spacer profiles for insulating glass units comprises: a first support layer a first organic or inorganic diffusion barrier layer provided on the first support layer optionally a first coating provided on the first inorganic diffusion barrier layer a first adhesive layer provided on the first inorganic layer or on the optionally first coating a second support layer provided on the first adhesive layer a second organic or inorganic diffusion barrier layer provided on the second support layer optionally a second coating provided on the second inorganic diffusion barrier layer characterized in that the multilayer diffusion barrier foil further comprises an outer layer of a polymeric material having a roughness R_a of at least 0.25 pm on the outer side.

Alternatively, but also preferred is that the above described multilayer diffusion barrier foil has and acid-treated polymeric material as the outer layer.

Preferably, the roughness R_a is at least 0.30 pm, more preferably at least 0.35 pm and even more preferred at least 0.40 pm.

Preferably, at least one of the first or second diffusion barrier layers is a SiOx layer, where 1 < x < 2.

Preferably, the polymeric material of the outer layer is a polar polymeric material.

In a preferred embodiment, the polar polymeric material is selected from the group consisting of polyethylene terephthalate (PET), Polyurethane, Polycarbonate (PC), Polymethyl methacrylate (PMMA), Polyvinyl acetate, acrylate elastomers, polyvinyl butyral, Poly styrene, polyvinyl alcohol and polychloroprene.

Preferably, the polymeric material of the outer layer has embedded silica flakes extending outwards from the surface.

Alternatively, the outer layer of the multilayer diffusion barrier foil is an acid-treated polymeric material.

In a preferred embodiment, the acid-treated polymeric material is a TCA-treated PET layer.

In a preferred embodiment, the acid-treated polymeric material is an acid - silica flakes treated PET layer. In a preferred embodiment, the acid-treated polymeric material is a TCA silica flakes treated PET layer.

Another advantage of silica flakes extending from the surface is an improved wettability and a consistent wettability. The effect of the improved wettability is that the sealants have a better adherence to the surface.

In a preferred embodiment, the acid-treated polymeric material is a PET foil with a minimum surface tension of 45 dyne/cm, preferably a PET foil with a minimum surface tension of 50 dyne/cm or more preferable a PET foil with a minimum surface tension of 58 dyne/cm.

In another embodiment, the multilayer diffusion barrier foil for use in spacer profiles for insulating glass units further comprises: a second adhesive layer provided on the second inorganic layer or on the optionally second coating a third support layer provided on the second adhesive layer a third inorganic diffusion barrier layer provided on the third support layer optionally a third coating provided on the third inorganic diffusion barrier layer.

The first, second and third inorganic layers can independent of each other be selected from the group consisting of metals, aluminium oxides and silicium oxides.

Preferably, the silicium oxides have the formula SiOx, where 1<x<2

Preferably, the aluminim oxides have the formula AlOy, where 0.5<y<1.5

In another aspect, the invention relates to the use of TCA-treated foils in the manufacturing of spacer profiles.

In another aspect, the invention relates to the use of TCA-treated PET foil as an outer layer on spacer bodies or spacer profiles.

The outer layer of a polymeric material of the multilayer barrier foil can be attached to the foil using known techniques such as welding or by use of an adhesive layer. A layer that is suitable for all embodiments of the invention as the outermost layer is commercially available TCA-treated foils.

The surface tension can be measured by various methods. The values referred to in this application is measured by a Force Tensionmeter

Roughness may be quantified using various measures e.g. by following ISO4288 (1996) procedure. Historically, the roughness average R_a has often been used. R_a is the arithmetic average of the absolute deviations measured from a common reference. Another measure is the root mean square of the roughness average RRMS. RRMS is the root mean square or standard deviation of the roughness average. From the calculation of RRMS, e.g. a single large deviation within the non-smooth surface will affect RRMS more than R_a, since it weighs such deviations more heavily. In the present application, R_a is used to characterise the surface roughness.

Without being bound by theory, it is believed that there is a synergy between a polar polymer and embedded silica flakes extending from the surface of the polar polymer, when it comes to the secondary sealants adherence to the outer surface of the foil on the spacer or the spacer itself. The rougher surface and the polarity of the polymer provides good connection points to the secondary sealant, and the silicium in the silica flakes chemical bonds to the silanes in the secondary sealants. The result is a structure, where the secondary sealant adheres tightly to the surface during the entire lifespan of more than 20 years.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a schematic illustration of a spacer profile.

Figs. 2a-d are illustrations of the spacer profiles with various cross sections.

Figs. 3a-3c are illustrations of super spacer profiles with various cross sections.

Fig. 4 is an illustration of a multilayer diffusion barrier foil.

Fig 5 is an illustration of a particularly suited multilayer diffusion barrier foil.

Fig 6 is an illustration of a spacer profile according to the invention. Fig 7 is an illustration of the equipment used for testing adhesion.

DESCRIPTION OF DRAWINGS

In figure 1 , a spacer profile 1 suitable for the invention is illustrated. The spacer profile 1 comprises a profile body 10, where the profile body comprises an inner wall 11 and an outer wall 12 being separated from the inner wall 11 by a first distance d1. When mounted between the panes in an IG unit, the inner wall is facing towards the interior of the IG unit, i.e. the intervening space formed between the panes and the spacer. The profile body in figure 1 further comprises two side walls 13, 14. The side walls 13, 14 can be parallel to each other, or they can be slightly slanted. The angle 0 between the side walls 13, 14 and the inner wall 11 can be between 60° and 120°, preferably between 60° and 105°, or even more preferably between 75° and 105°. The two side walls 13, 14 are separated by a second distance d2, and they have a height h. In figure 1 , the inner wall and the outer wall are illustrated as being parallel, but that does not have to be the case. Solutions exist, where the inner wall and the outer wall are separated by a first distance d1 , and where they are slanted, curved etc. relative to each other. The inner wall 11 , the outer wall 12 and the two side walls 13, 14 define a chamber 50, the chamber being suitable for containing a desiccant.

Figures 2 a-d illustrate a cross section of four different spacer profiles, where the invention can also be applied. In figure 2a, the spacer comprises a profile body 10 which comprises an inner wall 11 and an outer wall 12 being separated from the inner wall 11 by a first distance d1. The profile body 10 further comprises two sidewalls 13, 14 of a height h. Their orientation relative to the inner wall can be as described for figure 1. The two side walls 13, 14 are separated by a second distance d2. Together the inner wall 11 , the outer wall 12 and the two side walls 13, 14 define a chamber 50 suitable for containing a desiccant. The side walls 13, 14 have an inner surface 31 and an outer surface 32, where the inner surface is the surface towards the chamber 50, and the outer surface 32 is the opposite side. Usually, the outer surface 32 is the place where a primary sealant is applied, when the spacer profile is mounted in an IG unit.

The spacer profile in figure 2b differs from the spacer profile in figure 2a in that the spacer body 10 further comprises two outer connection walls 15, 16. The outer connection walls 15, 16 connect the sidewalls 13, 14 with the outer wall 12. Together the inner wall 11 , the outer wall 12, the two side walls 13, 14 and the two outer connection walls 15, 16 define a chamber 50 suitable for containing a desiccant. The outer connection walls can be straight as illustrated, but other shapes such as curved, concave, convex etc. can also be useable. As can be seen from figure 2b, the height h of the side walls are decreased, when the outer connection walls 13, 14 are present compared to the height of the side walls, when the profile body does not comprise outer connection walls as illustrated in figure 2a.

The spacer in figure 2c differs from the spacer in figure 2a in that the spacer body 10 further comprises two inner connection walls 17, 18. The inner connection walls 17, 18 connect the sidewalls 13, 14 with the inner wall 11. Together, the inner wall 11 , the outer wall 12, the two side walls 13, 14 and the two inner connection walls 17, 18 define a chamber 50 suitable for containing a desiccant.

The spacer in figure 2d differs from the spacer in figure 2a in that the spacer body 10 further comprises two outer connection walls 15, 16 and two inner connection walls 17, 18. The outer connection walls 15, 16 connect the side walls 13, 14 with the outer wall 12. The inner connection walls 17, 18 connect the side walls 13, 14 with the inner wall 11. Together the inner wall 11 , the outer wall 12, the two side walls 13, 14, the two inner connection walls 17, 18 and the two outer connection walls 15, 16 define a chamber 50 suitable for containing a desiccant. The side walls 13, 14 have a height h.

Figures 3 a-c illustrate a cross section of three different coilable soft spacer profiles made of a rubber compound such as a foamed silicone rubber or EPDM rubber, where the invention can also be applied. In figure 3a, the spacer profile comprises a foam rubber spacer body 60 extending in a longitudinal direction (Z). Preferably, the foam rubber is a silicone foam rubber. The foam rubber spacer body 60 further comprises an inner surface 21 facing toward the intervening space between glazing panes, when the spacer profile is mounted in an IGU. The foam rubber spacer body 60 further comprises an outer surface 22 facing away from the intervening space between glazing panes and two side surfaces 23, 24. Preferable the side surfaces 23, 24 connect the inner surface 21 and the outer surface 22, but variants with smaller connection surfaces are also within the scope of this spacer profile. The foam rubber spacer body 60 can comprise desiccants distributed within the rubber foam.

In figure 3b, the spacer profile comprises a foam rubber spacer body 60 extending in a longitudinal direction (Z). Preferably, the foam rubber is a foamed silicone rubber. The foam rubber spacer body 60 further comprises an inner surface 21 facing toward the intervening space between glazing panes, when the spacer profile is mounted in an IGU. The foam rubber spacer body 60 further comprises an outer surface 22 facing away from intervening space between glazing panes and two side surfaces 23, 24. The side faces connect with the inner surface 21 and to the outer surface 22 via two connecting surfaces 25, 26. The foam rubber spacer body 60 can comprise desiccants distributed within the rubber foam.

In figure 3c, a particularly suited super spacer profile is illustrated. This super spacer differs from the super spacer in figure 3b in that the connection surfaces 25, 26 are divided into three subsections, a first curved section 26A, 25A, which is illustrated as curving outwards, but it can equally well be curving inwardly, a substantially straight section 25B, 26B and a second curved section 25C, 26C. The second curved section 25C, 26C is also illustrated as curving outwardly but can equally well be curving inwardly. The advantage with the structure illustrated in figure 3A is that more room is given to the primary and/or secondary sealant, thus creating a more diffusion-tight solution when mounted in an IGU. The foam rubber spacer body 60 can comprise desiccants distributed within the rubber foam.

Figure 4 illustrates a multilayer diffusion barrier foil 100 having a first support layer 101 and a first barrier layer 103. The first barrier layer 103 can be an inorganic layer. Preferably, the first barrier layer 103 is a SiOX layer, where 1 < X < 2. Further, the composite barrier foil 100 has a second support layer 102 and a second barrier layer 104. The second barrier layer 104 can be an inorganic layer. Preferably, the second barrier layer 104 is a SiOX layer, where 1 < X < 2. The first and second support layers can be of the same material, or they can be of different materials. Preferably, the support layers are of a polymeric material. The multilayer diffusion barrier foil of the embodiment illustrated in figure 4 can be used on all of the spacer bodies illustrated in figures 1-3 and also on variants thereof.

Figure 5 illustrates a multilayer diffusion barrier foil 100 having particularly good diffusion barrier properties while at the same time provides good binding to the primary and secondary sealants. The illustrated multilayer diffusion barrier foil 100 comprises a first support layer 101. The first support layer 101 can be of a polymeric material. Suitable polymeric materials are known by the person skilled in the art and are usually but not limited to polyethylene, polypropylene, polyethylene teraphtalate (PET) etc. Particularly preferred is polyehtylen or PET. Then follows a first barrier layer 103. The first barrier layer can be a polymeric layer such as polyvinyl alcohols or polycarbonates, or the first barrier layer can be an inorganic layer. Examples of suitable inorganic layers are a metal layer or an aluminioxide layer or a SiOx layer, where 1 < x < 2. In the illustration in figure 5, there is a first coating layer 106. The coating can be a PVA (polyvinyl alcohol) based coating.

The multilayer diffusion barrier foil 100 will work without the coating layer and thus, it is optional, but the performance is better, when a coating is used.

On the first coating layer 106 or on the first barrier layer 103 there is provided a first adhesive layer 107. The multilayer diffusion barrier foil 100 further comprises a second support layer 102 that can be of a polymeric material. Suitable polymeric materials for the second support layer 102 are known by the person skilled in the art and are usually but not limited to polyethylene, polypropylene, polyethylene teraphtalate (PET) etc. Particularly preferred is polyethylene or PET. Then follows a second barrier layer 104. The second barrier layer can be a polymeric layers such as polyvinyl alcohols or polycarbonates or the second barrier layer can be an inorganic layer. Examples of suitable inorganic layers are a metal layer or an aluminioxide layer or a SiOx layer, where 1 < x < 2. In the illustration in figure 5 there is a second coating layer 108 which is optional. Figure 5 further illustrates a second adhesive layer 109. Then follows a third support layer 110 which again can be of a polymeric material. Suitable polymeric materials for the third support layer 102 are known by the person skilled in the art and are usually but not limited to polyethylene, polypropylene, polyethylene terephthalate (PET) etc. Particularly preferred is polyethylene or PET. Then follows a third barrier layer 111. The third barrier layer can be a polymeric layers such as polyvinyl alcohols or polycarbonates, or the first barrier layer can be an inorganic layer. Examples of suitable inorganic layers are a metal layer or an aluminioxide layer or a SiOx layer, where 1 < x < 2. In figure 5, there is further illustrated an option third coating layer 112 and a third adhesive layer 113. The outer layer 105 is a polymeric material. The polymeric material can be a polar polymeric material, preferably selected from the group consisting of polyethylene terephthalate (PET), Polyurethane, Polycarbonate (PC), Polymethyl methacrylate (PMMA), Polyvinyl acetate, acrylate elastomers, polyvinyl butyral, Poly styrene, polyvinyl alcohol and polychloroprene. Preferably, the polar polymeric material further comprises embedded silica flakes extending from the outer surface 115 in the direction opposite the inner surface facing the intervening space - thereby increasing the roughness and surface area. Preferably, the roughness R_a is at least 0.25 pm on the outer side, preferably the roughness R_a is at least 0.30 pm, more preferably at least 0.35 pm and even more preferred at least 0.40 pm.

Further, it is preferred that the surface has a minimum surface tension of 45 dyne/cm, preferably a minimum surface tension of 50 dyne/cm or more preferable a minimum surface tension of 58 dyne/cm.

Suitable outer layers 105 are TCA-treated PET layers with embedded silica flakes which are commercially available.

The person skilled in the art would understand that the invention illustrated in figure 5 can be used together with the spacer bodies illustrated in figures 1-3, and it is also suitable for variations of the designs in figures 1-3 and also for other types of spacer profiles.

Figure 6 shows the spacer profile of figure 2b additionally having a multilayer diffusion barrier foil 100. The multilayer diffusion barrier foil 100 has as its outer layer a polymeric material. The polymeric material can be a polar polymeric material, preferably selected from the group consisting of polyethylene terephthalate (PET), Polyurethane, Polycarbonate (PC), Polymethyl methacrylate (PMMA), Polyvinyl acetate, acrylate elastomers, polyvinyl butyral, Poly styrene, polyvinyl alcohol and polychloroprene. Preferably, the polar polymeric material further comprises embedded silica flakes extending from the outer surface 115 thereby increasing the roughness and surface area. Preferably, the roughness R_a is at least 0.25 pm on the outer side, preferably the roughness R_a is at least 0.30 pm, more preferably at least 0.35 pm and even more preferred at least 0.40 pm.

Figure 7 illustrates the principle of the adhesion test performed according to the norm EN 1279-6. The samples must fulfil the criteria described in the norm, where both load and time is stated. Min. 0.30 MPa load for 10 minutes. For the achievement of a defined tensile tension, test equipment complying with the one illustrated in figure 7 is needed. This allows the application of different forces by a suitable set of weights. A tensile test machine may be used.

In the test, various sealant types were tested for adhesion to different foil surfaces, and the results are shown in the table below, where OK is a satisfactory adhesion, NOK is a non-satisfactory adhesion, and OK&NOK is an unstable result, where adhesion might be lost during aging.

Laboratory test results

* Condition is 95%RH for a period of 4 weeks at stable temperature. OK & NOK are expressing quite unstable results.

It must be considered that the result will vary slightly when tested with products from different manufactures of sealants!

LIST OF REFERENCE SIGNS

1 spacer profile

2 spacer frame

3 glazing panes

4 intervening spacer

10 spacer body

11 Inner wall

12 outer wall

13,14 side walls

15,16 outer connection walls

17,18 inner connection walls

21 inner surface

22 outer surface

23, 24 side surfaces

25,26 connection surfaces

25A, 26A first curved section

25B, 26B substantially straight section

25C, 26C second curved section

50 chamber

60 foam rubber spacer body

100 multilayer diffusion barrier foil

101 first support layer

102 second support layer

103 first barrier layer

104 second barrier layer

105 outer layer

106 first coating layer

107 first adhesive layer

108 second coating layer

109 second adhesive layer

110 third support layer

111 third barrier layer

112 third coating layer

113 third adhesive layer

114 inner surface towards intervening space 115 from the outer surface d1 first distance d2 second distance

Claims

1. A spacer profile (1) for use as part of a spacer profile frame, which is suitable for being mounted in and/or along an edged area of an insulating glazing unit so as to surround an intervening space between glazing panes, the spacer profile comprising a spacer body extending in a longitudinal direction (Z), said spacer body (10) comprising: an inner wall (11) facing the intervening space between and extending in a transverse direction (X) an outer wall (12) separated from the inner wall by a first distance (d1) two side walls extending in a hight direction (Y) and separated by a second distance (d2) where the inner wall, the two side walls and the outer wall define a chamber suitable for desiccants; optionally the two outer connection walls and/or the two inner connection walls are part of the defining of the chamber (50) where the outer wall (12) has an outer wall outer surface facing away from the chamber where the side walls have side walls (13, 14) outer surfaces facing away from the chamber characterized in that the spacer body at least on the outer wall as an outer most outer layer has a layer of polymeric material having a roughness Ra of at least 0.25 pm, preferably at least 0.30 pm, more preferably at least 0.35 pm and even more preferred at least 0.40 pm and most preferred at least 0.7 pm.

2. A spacer profile according to claim 1 , wherein the spacer body further comprises two outer connection walls (15, 16) extending between the side walls and the outer wall.

3. A spacer profile according to claim 1 or 2, wherein the spacer body further comprises two inner connection walls (17,18) extending between the side walls and the inner wall.

4. A spacer profile according to claim 2 or 3, wherein the two outer connection walls (15 16) and/or the two inner connection walls (17, 18) are part of defining the chamber (50) suitable for desiccants.

5. A spacer profile (1) for use as part of a spacer profile frame, which is suitable for being mounted in and/or along an edged area of an insulating glazing unit so as to surround an intervening space between glazing panes, the spacer profile comprising a foam rubber spacer body (60) extending in a longitudinal direction (Z), and having: an inner surface (21) facing towards the intervening space between glazing panes an outer surface facing (22) away from the intervening space between glazing panes two side surfaces (23, 24) extending between the inner surface and the outer surface, said side surfaces being adapted to be connected to glazing planes so as to form the intervening space characterized in that at least the outer surface is covered with a foil having as its outermost layer an acid-treated polymeric material.

6. A spacer profile (1) according to claim 5, wherein the foam rubber spacer body further has two connecting surfaces ( 25, 26) for connecting the side surfaces with the outer surface.

7. A spacer profile (1) according to claim 5 or 6, wherein the foil having as its outermost layer an acid-treated polymeric material has a roughness Ra of at least 0.25 pm, preferably at least 0.30 pm, more preferably at least 0.35 pm and even more preferred at least 0.40 pm and most preferred at least 0.7 pm.

8. A spacer profile (1) according to any one of claims 1 - 4, wherein the outermost layer is a foil having a roughness Ra of at least 0.25 pm, preferably at least 0.30 pm, more preferably at least 0.35 pm and even more preferred at least 0.40 pm and most preferred at least 0.7 pm.

9. A spacer profile (1) according to any one of claims 5 - 8, where the foil having as its outermost layer an acid-treated polymeric material and further comprises layers having diffusion barrier properties.

10. A spacer profile (1) according to any one of claims 5 - 9, wherein the foil having as its outermost layer an acid-treated polymeric material has TCA-treated PET foil as its outermost layer.

11. A spacer profile (1) according to any one of claims 5-10, wherein the foil having as its outermost layer an acid-treated polymeric material has silica flakes extending from the outer surface.

12. A spacer profile (1) according to any one of claims 5-11 , wherein the foil having as its outermost layer the acid-treated polymeric material and is a PET foil with a minimum surface tension of 45 dyne/cm, preferably a PET foil with a consistent surface tension of 50 dyne/cm or more preferable a PET foil with a minimum surface tension of 58 dyne/cm

13. A spacer profile according (1) to claim 9, wherein the layers having diffusion barrier properties are a composite diffusion barrier having a TCA-treated PET foil as its outermost layer.

14. A spacer profile according to claim 9, wherein the layers having diffusion barrier properties are a composite diffusion barrier having a PET foil with silica flakes extending from the outer surface as its outermost layer.

15. A multilayer diffusion barrier foil (100) for use in spacer profiles for insulating glass units, the multilayer diffusion barrier foil comprises: at least one support layer (101 , 102) at least one metallic and/or inorganic layer an outer layer (105) characterized in that the outer layer is an acid-treated polymeric material

16. A multilayer diffusion barrier foil (100) for use in spacer profiles for insulating glass units, the multilayer diffusion barrier foil comprises: at least one support layer (101 , 102) at least one metallic and/or inorganic layer an outer layer (105) characterized in that the outer layer has a roughness Ra of at least 0.25 pm, preferably at least 0.30 pm, more preferably at least 0.35 pm and even more preferred at least 0.40 pm and most preferred at least 0.7 pm.

17. A multilayer diffusion barrier foil according to claim 15 or 16, wherein the outer layer is a TCA-treated PET layer

18. A multilayer diffusion barrier foil according to any one of claims 15 - 17, wherein the outer layer is a PET layer having embedded silica flakes extending from the surface and having a Roughness R_a of at least 0.25 pm

19. A method of making spacer profiles (1) compatible with multiple sealants, said method comprising the steps of: providing a spacer profile for use as part of a spacer profile frame, which is suitable for being mounted in and/or along an edged area of an insulating glazing unit so as to surround an intervening space between glazing panes, the spacer profile comprising a spacer body extending in a longitudinal direction (Z), said spacer profile comprising a spacer body having: o an inner surface (21) facing towards the intervening space between glazing panes o an outer surface (22) facing away from the intervening space between glazing panes o two side surfaces (23, 24) extending between the inner surface (21) and the outer surface (22), said side surfaces being adapted to be connected to glazing planes so as to form the intervening space adding a foil having as its outermost layer an acid-treated polymeric material to the spacer body or adding a foil having as its outermost layer a polymeric material having a roughness Ra of at least 0.25 pm.

20. A method according to claim 19, where the spacer body further has two connecting surfaces (25, 26) for connecting the side surfaces with the outer surface.

21. A method according to claim 19 or 20, where the foil having as its outermost layer an acid-treated polymeric material and is a TCA-treated PET foil.

22. A method according to claim 19 or 20, where the foil having as its outermost layer an acid-treated polymeric material and is an acid-treated polymeric material with silica flakes extending from the surface.

23. A method according to claim 21 , wherein the foil having as its outermost layer a TCA- treated PET foil is a multilayer diffusion barrier foil (100).

24. Use of TCA-treated foils having embedded silica flakes extending from the surface in the manufacturing of spacer profiles.

25. Use of PET foil having embedded silica flakes extending from the surface as an outer layer on spacer bodies or spacer profiles.