Classifications

• • E—FIXED CONSTRUCTIONS
  • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
  • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
  • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
  • E06B3/66—Units comprising two or more parallel glass or like panes permanently secured together
  • E06B3/663—Elements for spacing panes
  • E06B3/66309—Section members positioned at the edges of the glazing unit
  • E06B3/66314—Section members positioned at the edges of the glazing unit of tubular shape
  • E06B3/66319—Section members positioned at the edges of the glazing unit of tubular shape of rubber, plastics or similar materials
• • E—FIXED CONSTRUCTIONS
  • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
  • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
  • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
  • E06B3/66—Units comprising two or more parallel glass or like panes permanently secured together
  • E06B3/663—Elements for spacing panes
  • E06B3/66309—Section members positioned at the edges of the glazing unit
  • E06B2003/6638—Section members positioned at the edges of the glazing unit with coatings

Definitions

• the invention relates to a spacer profile with a particularly good diffusion barrier, the improved diffusion barrier itself and the use of the improved diffusion barrier for spacer profiles.
• spacer profiles are used to separate the panes.
• the intervening space between the panes is 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 reduces the resistance to heat conduction.
• One of the ways to prevent the gas from leaking and/or undesired external gasser to enter the intervening space is to provide the spacer profile with a diffusion barrier.
• barrier foils of thin metal layer was used as a diffusion barrier.
• barrier foils of metal have one important draw back. They are by nature very heat-conducting and thereby reduce the insulating properties of the IGU. Therefore, it has been proposed to replace barrier foils made of a thin metal layer with synthetic materials instead, because the heat conductivity of such synthetic materials is significantly lower than it is for metal layers.
• the synthetic material EVOH is used as a barrier material.
• barrier foils made of synthetic materials are often only function as a barrier against a couple of gasses and/or are prone to cracks when the spacer profile is bent into a window frame.
• multilayers barrier foils where multiple layers of the same or different barrier materials are put on top of each other.
• EP2802726 B1 is an example of such a synthetic spacer profile, where a multilayer foil has been proposed as a replacement for metal foils.
• the multiple layers with barrier properties are arranged intermittently with a synthetic material such as PET.
• the inventor has found that by arranging the layers with barrier properties in a certain order, a multilayer barrier foil with improved properties can be obtained.
• 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:
• the spacer body further comprises two connection walls extending between the side walls and the outer wall.
• the multilayer diffusion barrier foil extends at least partially on the sidewalls outer surface.
• the multilayer diffusion barrier foil extends over the two connection walls and at least partially on the sidewalls outer surface.
• the usual way to provide a very thin ceramic layer in a multilayer diffusion barrier foil is to provide the thin ceramic layer on a polymeric support layer.
• This polymeric support layer carriers and supports the integrity of the ceramic layer.
• the ceramic layer can be glued on the support layer, it can be crosslinked with the support layer so as to form a chemical bonding to the polymeric support layer, and it can be sputtered/sprayed upon the support layer.
• the person skilled in the art is aware of such methods.
• top coatings can be applied on top of each ceramic layer so as to protect the ceramic layer from interaction with the glue usually used to connect the multiple layers.
• the multilayer barrier foil will function without the top coating, and variants without coating exist, but it is preferred to have a top coating on top.
• the at least two polymeric support layers have a thickness between 5 ⁇ m and 120 ⁇ m, more preferably between 7 ⁇ m and 100 ⁇ m and most preferably between 10 ⁇ m and 80 ⁇ m.
• the at least two ceramic layers have a thickness between 8 nm and 1000 nm, more preferably between 10 nm and 200 nm and most preferably between 20 nm and 100 nm.
• the coating has a thickness between 2 nm and 200 nm, more preferably between 3 nm and 100 nm and most preferably between 5 nm and 80 nm
• the at least two polymeric support layers are made of a polymeric material selected from the group of polyethylene (PE), polypropylene (PP), polyethyleneterephthalate (PET), polyamide, PVC, acrylonitrile, polyacrylate, silicone and mixtures thereof.
• the at least two polymeric support layers are made of a polymeric material selected from the group polyethylene (PE), polypropylene (PP), polyethyleneterephthalate (PET), polyacrylate and mixtures thereof.
• the at least two polymeric support layers are made of polyethylene terephthalate (PET).
• the ceramic material is selected from the group consisting of aluminium oxides, SiOx layers, where 1 ⁇ x ⁇ 2, silicium nitrides and mixtures thereof.
• the two polymeric support layers can be made of different materials and that the ceramic layers of the at least two ceramic layers can be made of different ceramic materials.
• the at least two polymeric support layers are made of the same polymeric material and that the at least two ceramic layers are made of the same ceramic material.
• a preferred combination of polymeric support layers and ceramic layers is that the at least two polymeric support layers are made of PET and that the at least two ceramic layers are made of SiOx, where 1 ⁇ x ⁇ 2.
• the multilayer diffusion barrier foil has as its outer layer a polymeric layer which has a roughness Ra of at least 0.25 ⁇ m, preferably at least 0.30 ⁇ m, more preferably at least 0.35 ⁇ m and even more preferred at least 0.40 ⁇ m and most preferred at least 0.7 ⁇ m.
• the advantage of providing the multibarrier foil with an outer layer being a polymeric layer with the above specified roughness is that the spacer profile becomes compatible with almost all primary and/or secondary sealants used in the industry.
• 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.
• Some synthetic materials usually work best when the multi barrier foil can be improved if the outermost synthetic layer is compatible with all of the traditional sealant i.e. such sealants or adhesives as poly-isobutyl, polysulfides, hot melt secondary sealants, silicones, polyurethanes etc.
• Polymeric layers with the above specified roughness are compatible with all traditional sealants.
• the invention in another aspect, relates to a multilayer barrier foil comprising at least two ceramic layers and at least two polymeric support layers, wherein two of the at least two ceramic layers do not have a polymeric support layer between them.
• the materials and thicknesses can be as described above.
• the multilayer barrier film further comprises an outer layer being a polymeric layer which has a roughness Ra of at least 0.25 ⁇ m, preferably at least 0.30 ⁇ m, more preferably at least 0.35 ⁇ m and even more preferred at least 0.40 ⁇ m and most preferred at least 0.7 ⁇ m.
• the invention relates to the use of multibarrier films comprising at least two ceramic layers and at least two polymeric support layers, wherein two of the at least two ceramic layers do not have a polymeric support layer between them, in the spacer profiles and/or insulating glazing units.
• the multilayer diffusion barrier foil with at least two ceramic layers and at least two polymeric support layers, wherein two of the at least two ceramic layers do not have a polymeric support layer between them, can be constructed in various ways.
• One possibility is to first deposit a ceramic layer on a polymeric support layer, then provide a top coating on the ceramic layer and then again deposit another ceramic layer before applying a second polymeric support layer.
• Another possibility is to provide two polymeric support layers, each having a ceramic layer and then gluing them together with the two ceramic layers facing each other. The result is two polymeric support layers and two ceramic layers where there is no polymeric support layers between the two ceramic layers.
• one of the above described multilayer diffusion barrier foils is provided with an outer layer being a polymeric layer which has a roughness Ra of at least 0.25 ⁇ m, preferably at least 0.30 ⁇ m, more preferably at least 0.35 ⁇ m and even more preferred at least 0.40 ⁇ m and most preferred at least 0.70 ⁇ m
• This outer layer with the above specified roughness can be glued on top of the at least two polymeric support layers and the at least two ceramic layers.
• the preferred way of providing a polymeric layer, which has a roughness Ra of at least 0.25 ⁇ m, is by treating a polymeric material with certain acids. 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.
• the outer layer is an acid-treated polymeric foil. It is particularly preferred that the acid-treated polymeric foil is an acid - silica flakes treated PET foil.
• the outer layer is a TCA-treated PET foil. More preferred is a TCA-treated PET foil with silica flakes extending from the surface.
• 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.
• 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.
• 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.
• silicon oxide is deposited on a TCA-treated PET foil, and it is particularly preferred that the silica flakes are extending from the surface.
• 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 is improved.
• Suited R a of the polymeric material can be selected from R a of at least 0.25 ⁇ m, at least 0.30 ⁇ m, at least 0.35 ⁇ m, at least 0.40 ⁇ m, at least 0.45 ⁇ m, at least 0.50 ⁇ m, at least 0.55 ⁇ m, at least 0.60 ⁇ m, at least 0.65 ⁇ m, at least 0.70 ⁇ m, at least 0.75 ⁇ m, at least 0.80 ⁇ m, at least 0.85 ⁇ m, at least 0.90 ⁇ m, at least 0.95 ⁇ m, at least 1.0 ⁇ m, at least 1.1 ⁇ m, at least 1.2 ⁇ m, at least 1.3 ⁇ m, at least 1.4 ⁇ m, at least 1.5 ⁇ m, at least 1.6 ⁇ m, at least 1.7 ⁇ m and at least 2.0 ⁇ m.
• An alternative to manufacturing the above described outer layer is to purchase commercially available foils with the above described properties.
• Some of the commercially available foils are sold under tradenames such as Kemafoil ® and Optimont ® .
• a particularly preferred multilayer barrier foil according to the invention can be made by gluing two ceramis ® foils (marketed by Celplast), or similar foils provided by other companies, which are a PET foil with a SiOx layer and a coating, together with the SiOx layers facing each other. On top of those two foils, a Kemafoil ® or Optimont ® foil is glued with the rough side facing outwards.
• 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.
• 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 ⁇ 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.
• 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-b illustrate a cross section of two different spacer profiles, where the invention can also be applied.
• 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.
• 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.
• 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 .
• Figure 3 shows the spacer profile of figure 2b additionally having a multilayer diffusion barrier foil 100.
• FIG 4 shows the multilayer barrier foil 100 in its simplest form.
• the multilayer diffusion barrier foil 100 comprises a first polymeric support layer 101 and a first ceramic layer 102.
• the first ceramic layer 102 is a SiOx layer, where 1 ⁇ x ⁇ 2.
• the multilayer barrier foil 100 has a second polymeric support layer 104 and a second ceramic layer 103.
• the second ceramic layer 103 is a SiOx layer, where 1 ⁇ x ⁇ 2.
• the first 101 and second polymeric support layers 104 in this embodiment constitute the at least two support layers, and they can be of the same material, or they can be of different materials.
• the first ceramic layer 102 and the second ceramic layer 103 in this embodiment constitute the at least two ceramic layers.
• the at least to ceramic layers can be separated by and adhesive, by a coating or the like.
• each of the first ceramic layer 102 and the second ceramic layer 103 is between 8 nm and 1000 nm, more preferably between 10 nm and 200 nm and most preferably between 20 nm and 100 nm
• each of the first polymeric support layer 101 and the second polymeric support layer 104 is 5 ⁇ m and 120 ⁇ m, more preferably between 7 ⁇ m and 100 ⁇ m and most preferably between 10 ⁇ m and 80 ⁇ m.
• 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 shows the multilayer diffusion barrier foil 100 of figure 4 further comprising an outer layer of a polymeric material 105 which has a roughness Ra of at least 0.25 ⁇ m.
• 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.
• the polar polymeric material further comprises embedded silica flakes extending from the outer surface 115 thereby increasing the roughness and surface area.
• the roughness R a is at least 0.25 ⁇ m on the outer side, preferably the roughness R a is at least 0.30 ⁇ m, more preferably at least 0.35 ⁇ m and even more preferred at least 0.40 ⁇ m.
• 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.
• FIG. 6 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 polymeric 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 terephthalate (PET) etc. Particularly preferred is polyehtylen or PET. Then follows a first ceramic layer 102.
• suitable ceramic layers are a metal layer or an aluminium oxide layer or a SiOx layer, where 1 ⁇ x ⁇ 2.
• 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.
• the multilayer diffusion barrier foil 100 further comprises a second polymeric support layer 104 that can be of a polymeric material.
• Suitable polymeric materials for the second polymeric support layer 104 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.
• PET polyethylene terephthalate
• a second ceramic layer 134 examples of suitable ceramic layers are an aluminium oxide layer or a SiOx layer, where 1 ⁇ x ⁇ 2.
• there is a second coating layer 107 which is optional.
• Figure 6 further illustrates a second adhesive layer 109. As illustrated, there is no support layers between the first ceramic layer 102 and the second ceramic layer 103. There is only coatings and an adhesive.
• 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.
• 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.
• the roughness R a is at least 0.25 ⁇ m on the outer side, preferably the roughness R a is at least 0.30 ⁇ m, more preferably at least 0.35 ⁇ m and even more preferred at least 0.40 ⁇ m.
• 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.
• One possible way of constructing the multilayer diffusion barrier foil illustrated in figure 6 is to glue together two ceramis ® foils (marketed by Celplast) or similar foils provided by other companies, which is a PET foil with a SiOx layer and a coating on top.
• the two ceramis ® foils are glued together with he SiOx layers facing each other and by use of an adhesive.
• a Kemafoil ® or Optimont ® foil is provided with the aid on an adhesive with the rough side facing outwards, i.e. on the side facing away from the at least two ceramic layers.
• 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 are stated.
• test equipment complying with the one illustrated in figure 7 is needed.

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Citations (4)

• 2024
  • 2024-02-01 EP EP24155189.4A patent/EP4596824A1/fr active Pending

Patent Citations (4)

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