當(dāng)前位置：淺析中空玻璃丁基膠內(nèi)溢及改善方法
時(shí)間：2025-10-07 來(lái)源：http://www.lingmaicnc.com/ 發(fā)布人：昌盛機(jī)械
中空玻璃丁基膠中空玻璃丁基膠即中空玻璃用丁基熱熔密封膠，是以丁基橡膠、聚異丁烯為基料，配以少量的輔料，經(jīng)過(guò)高溫、捏合、真空攪拌而制成。它屬于熱塑性中空玻璃密封膠，是中空玻璃的第一道密封，其主要作用有二：一是預(yù)固定間隔框和玻璃，起粘結(jié)作用；二是保持中空玻璃的密封性（水汽的滲透或惰性氣體的泄露），延長(zhǎng)中空玻璃的使用壽命。1
Hollow glass butyl rubber, also known as butyl hot melt sealant for insulating glass, is made from butyl rubber and polyisobutene as base materials, with a small amount of auxiliary materials, and is processed through high temperature, kneading, and vacuum stirring. It belongs to thermoplastic insulating glass sealant and is the first seal of insulating glass. Its main functions are twofold: first, to pre fix the spacer frame and glass, and to provide bonding; The second is to maintain the sealing of the insulating glass (due to the penetration of water vapor or leakage of inert gases), and extend the service life of the insulating glass. one
丁基密封膠的主要特性（1）具有永久塑性中空玻璃上墻后會(huì)因?yàn)闇囟群惋L(fēng)荷載影響發(fā)生泵吸效應(yīng)。因丁基膠具備永久的塑性，故丁基膠隨著腔體內(nèi)氣體的膨脹而拉伸，隨著腔體內(nèi)氣體的收縮而回彈，確保中空玻璃腔體的不間斷密封。（2）與其它密封膠對(duì)比，丁基密封膠水蒸氣滲透率極低，密封性能優(yōu)異。（3）剪切強(qiáng)度較高丁基膠對(duì)基材（玻璃、鋁及不銹鋼等）的黏合性較強(qiáng)，抵抗剪切滑動(dòng)的能力較高，中空玻璃預(yù)壓以后可承載一定重量的大片玻璃的下片，一定時(shí)間內(nèi)不易滑片或墜片。2丁基密封膠典型內(nèi)溢案例丁基膠內(nèi)溢不僅僅是外觀質(zhì)量問(wèn)題，在中空玻璃長(zhǎng)期使用過(guò)程中，內(nèi)溢處往往也是密封薄弱處。丁基膠內(nèi)溢后無(wú)法完全復(fù)位，密封性能無(wú)法保證，從而導(dǎo)致水汽從玻璃邊部進(jìn)入腔體內(nèi)，造成中空玻璃失效，Low-E膜層出現(xiàn)氧化（圖1）。圖1 某項(xiàng)目中空玻璃丁基膠內(nèi)溢處膜層氧化3丁基膠內(nèi)溢原因分析及改善建議（1）生產(chǎn)因素為保證產(chǎn)品出廠初始外觀質(zhì)量，中空玻璃生產(chǎn)時(shí)一般要求丁基膠壓滿(mǎn)鋁條不留白，不留伸縮移變空間，故丁基膠往往用量偏大和涂布偏上限，后期經(jīng)過(guò)儲(chǔ)存、運(yùn)輸、安裝，極易造成丁基膠內(nèi)溢。改善建議：①常規(guī)鋁間隔條側(cè)面寬度一般為5 mm，建議生產(chǎn)時(shí)丁基膠涂布寬度4 mm，鋁條邊部?jī)蛇吀黝A(yù)留0.5 mm左右鋁條露白，確保經(jīng)過(guò)中空預(yù)壓后丁基膠能完全覆蓋鋁條，不產(chǎn)生內(nèi)溢現(xiàn)象。②丁基膠涂布寬度與丁基膠涂布機(jī)的溫度、氣壓、打膠速度相關(guān)。建議丁基膠涂布機(jī)擠出溫度控制在110～130 ℃，氣壓20 MPa左右，打膠速度35 m/min左右，不同的設(shè)備參數(shù)會(huì)有差異，所有的參數(shù)設(shè)置目的是為了保證合適的丁基膠用量及與基材的粘接性能。③丁基膠涂布應(yīng)均勻、連續(xù)，單邊重量應(yīng)為3～4 g/m為宜。④鋁間隔條角部位置是丁基膠涂布交匯處，也是最容易出現(xiàn)內(nèi)溢的地方，需要進(jìn)行適當(dāng)?shù)哪蠛咸幚?，避免膠量過(guò)大。（2）儲(chǔ)存、運(yùn)輸因素外道膠未固化即打包、玻璃堆放不合理、打包帶過(guò)緊等因素也易造成丁基膠內(nèi)溢。改善建議：①玻璃生產(chǎn)完成后宜靜止?fàn)顟B(tài)存放在玻璃架上48 h以上，待外道密封膠徹底固化后，發(fā)貨裝車(chē)前再進(jìn)行包裝或打包。②木箱包裝，玻璃擺放順序應(yīng)從大到小碼放，玻璃與玻璃之間應(yīng)墊軟木墊隔離，軟木墊位置均勻間隔，以免局部集中受力而導(dǎo)致丁基膠內(nèi)溢。③打包帶應(yīng)固定在木箱上，不宜直接固定在玻璃上，避免打包帶單點(diǎn)受力將玻璃擠壓變形，造成局部丁基膠內(nèi)溢。④包裝好的玻璃在運(yùn)輸過(guò)程中應(yīng)將玻璃架或木箱固定牢固，避免道路顛簸或剎車(chē)造成玻璃碰撞或移動(dòng)。玻璃架或木箱固定時(shí)，固定繩不應(yīng)壓到玻璃，以免玻璃運(yùn)輸過(guò)程中局部受力，造成中空玻璃丁基膠內(nèi)溢甚至間隔條變形，影響密封性能。（3）安裝因素幕墻安裝時(shí)，壓塊過(guò)緊，易造成中空玻璃在使用過(guò)程中丁基膠局部?jī)?nèi)溢。門(mén)窗玻璃安裝時(shí)，不能為了防止玻璃顫動(dòng)，一味地強(qiáng)力夾緊玻璃，不預(yù)留物體熱脹空間，導(dǎo)致后期因受熱膨脹，丁基膠被擠壓變形而內(nèi)溢。改善建議：①安裝時(shí)，注意玻璃壓塊、窗框扣條、密封膠條的松緊度適中。②玻璃的板面大小、厚度要通過(guò)強(qiáng)度、撓度進(jìn)行專(zhuān)業(yè)計(jì)算，按照安全玻璃的設(shè)計(jì)規(guī)范設(shè)計(jì)和生產(chǎn)，避免因玻璃板面過(guò)大、厚度偏薄而引起的中空影像變形或玻璃顫動(dòng)。（4）氣候因素①溫度因素中空玻璃在日常使用過(guò)程中，由于受環(huán)境溫度變化影響，會(huì)出現(xiàn)泵吸效應(yīng)，中空腔內(nèi)氣體會(huì)產(chǎn)生膨脹或收縮，在氣體膨脹或收縮時(shí)，玻璃會(huì)產(chǎn)生向外或向內(nèi)的撓曲變形。用于內(nèi)道密封的丁基膠屬于柔性材料，而鋁條屬于剛性材料，在中空玻璃不斷撓曲變形的擠壓作用下，丁基膠在腔體內(nèi)側(cè)蠕動(dòng)并產(chǎn)生剝離或內(nèi)溢（圖2、圖3）。圖2 腔體膨脹圖3 腔體收縮②風(fēng)荷載因素以尺寸為1.5 m×2.4 m，厚度為8 mm＋12A＋8 mm的鋼化中空玻璃為例，在50 m標(biāo)高成都地區(qū)風(fēng)荷載作用下，玻璃撓度計(jì)算值為7.47 mm，玻璃的形變明顯，對(duì)丁基膠產(chǎn)生擠壓作用，變形越大作用力越大，丁基膠內(nèi)溢越明顯。③氣壓因素中空玻璃的生產(chǎn)地與使用地存在海拔差異，大氣壓力產(chǎn)生變化，中空腔內(nèi)外氣壓差造成中空玻璃腔體膨脹或收縮，亦會(huì)導(dǎo)致丁基膠內(nèi)溢。綜上，造成丁基膠內(nèi)溢原因較多，生產(chǎn)、儲(chǔ)存、運(yùn)輸、安裝中均要特別注意。除可控因素外，中空玻璃丁基膠由于固有的永久塑性，在高溫、高壓作用下，均會(huì)隨著玻璃的運(yùn)動(dòng)產(chǎn)生蠕動(dòng)，導(dǎo)致在正常使用過(guò)程中緩慢發(fā)生內(nèi)溢現(xiàn)象，是可避免的。
The main characteristic of butyl sealant is that (1) it has permanent plastic properties, and after being installed on the wall, it will experience pumping effect due to temperature and wind load. Due to the permanent plasticity of butyl rubber, it stretches with the expansion of gas inside the cavity and rebounds with the contraction of gas inside the cavity, ensuring uninterrupted sealing of the hollow glass cavity. (2) Compared with other sealants, butyl sealant has extremely low vapor permeability and excellent sealing performance. (3) Butyl adhesive has high shear strength and strong adhesion to substrates such as glass, aluminum, and stainless steel. It has a high ability to resist shear sliding. After preloading, insulating glass can bear a certain weight of large pieces of glass, and it is not easy to slide or fall off for a certain period of time. A typical case of internal overflow of 2-butyl sealant: Internal overflow of butyl sealant is not only a problem of appearance quality, but also a weak sealing point in the long-term use of insulated glass. After the butyl rubber overflows, it cannot be completely reset, and the sealing performance cannot be guaranteed, resulting in water vapor entering the cavity from the edge of the glass, causing the hollow glass to fail and the Low-E film layer to oxidize (Figure 1). Figure 1 Analysis and improvement suggestions for the oxidation of the film layer at the overflow of butyl rubber in a certain project's insulated glass. (1) Production factors: In order to ensure the initial appearance quality of the product before leaving the factory, it is generally required that the butyl rubber be fully pressed onto the aluminum strip during the production of insulated glass without leaving any space for expansion or contraction. Therefore, the amount of butyl rubber used is often too large and the coating limit is too high. After storage, transportation, and installation in the later stage, it is easy to cause internal overflow of butyl rubber. Improvement suggestion: ① The width of the side of the conventional aluminum spacer strip is generally 5 mm. It is recommended to apply butyl rubber with a width of 4 mm during production, and reserve about 0.5 mm on each side of the aluminum strip edge to ensure that the butyl rubber can completely cover the aluminum strip after hollow preloading without internal overflow. ② The width of butyl rubber coating is related to the temperature, air pressure, and gluing speed of the butyl rubber coating machine. It is recommended to control the extrusion temperature of the butyl rubber coating machine at 110-130 ℃, the air pressure at around 20 MPa, and the gluing speed at around 35 m/min. Different equipment parameters may vary, and the purpose of setting all parameters is to ensure the appropriate amount of butyl rubber and the adhesion performance with the substrate. ③ The application of butyl rubber should be uniform and continuous, and the weight on one side should be 3-4 g/m. ④ The corner position of the aluminum spacer strip is the intersection of butyl rubber coating, which is also the most prone to internal overflow. It needs to be properly kneaded to avoid excessive rubber volume. (2) Storage and transportation factors such as uncured outer layer glue before packaging, unreasonable stacking of glass, and tight packaging tape can also easily cause internal overflow of butyl rubber. Improvement suggestion: After the completion of glass production, it is advisable to store it in a static state on a glass rack for more than 48 hours. After the outer sealant is completely cured, it should be packaged or packed before shipment and loading. ② Wooden box packaging, glass should be placed in order from large to small, and cork pads should be placed between glass to isolate them. The cork pads should be evenly spaced to prevent local concentrated stress from causing internal overflow of butyl rubber. ③ The packing tape should be fixed on the wooden box and should not be directly fixed on the glass to avoid deformation of the glass caused by single point force on the packing tape, resulting in local overflow of butyl rubber. ④ The packaged glass should be securely fastened to the glass frame or wooden box during transportation to avoid collision or movement caused by road bumps or braking. When fixing the glass frame or wooden box, the fixing rope should not be pressed against the glass to avoid local stress during glass transportation, which may cause the butyl rubber of the insulated glass to overflow or even deform the spacer strip, affecting the sealing performance. (3) During the installation of curtain walls, if the pressure blocks are too tight, it is easy for the butyl rubber to overflow locally during the use of the insulated glass. When installing door and window glass, it is not advisable to forcefully clamp the glass without reserving space for thermal expansion in order to prevent glass vibration. This may cause the butyl rubber to be squeezed and deformed due to thermal expansion in the later stage, resulting in internal overflow. Improvement suggestion: ① During installation, pay attention to the moderate tightness of glass pressure blocks, window frame fasteners, and sealing strips. ② The size and thickness of the glass surface should be professionally calculated based on strength and deflection, and designed and produced according to the design specifications of safety glass to avoid hollow image deformation or glass vibration caused by the glass surface being too large or too thin. (4) Climate factor ① Temperature factor: During daily use, insulated glass may experience a pumping effect due to changes in environmental temperature. The gas inside the cavity will expand or contract, causing the glass to undergo outward or inward bending deformation during gas expansion or contraction. The butyl rubber used for internal sealing is a flexible material, while the aluminum strip is a rigid material. Under the continuous bending and deformation of the hollow glass, the butyl rubber crawls inside the cavity and produces peeling or overflow (Figure 2, Figure 3). Figure 2 Chamber Expansion Figure 3 Chamber Shrinkage ② Wind Load Factor Taking a tempered insulating glass with a size of 1.5 m × 2.4 m and a thickness of 8 mm+12A+8 mm as an example, under the wind load in the Chengdu area at an elevation of 50 m, the calculated deflection of the glass is 7.47 mm. The deformation of the glass is significant, and it exerts a squeezing effect on the butyl rubber. The larger the deformation, the greater the force, and the more obvious the overflow of the butyl rubber. ③ There is an altitude difference between the production and use areas of insulated glass due to air pressure factors, which causes changes in atmospheric pressure. The pressure difference between the inside and outside of the hollow cavity causes the hollow glass cavity to expand or contract, and can also lead to overflow of butyl rubber. In summary, there are many reasons for the overflow of butyl rubber, and special attention should be paid to production, storage, transportation, and installation. In addition to controllable factors, due to its inherent permanent plasticity, butyl rubber for insulating glass will undergo creep with the movement of the glass under high temperature and high pressure, resulting in slow internal overflow during normal use, which can be avoided.
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如何從源頭解決丁基膠內(nèi)溢丁基膠內(nèi)溢問(wèn)題，雖屬于正?，F(xiàn)象，但是也成為了行業(yè)痛點(diǎn)及投訴焦點(diǎn)。各原材料廠家和科研機(jī)構(gòu)，為了滿(mǎn)足客戶(hù)不斷對(duì)高質(zhì)量產(chǎn)品的要求，一直致力于研發(fā)新的防內(nèi)溢結(jié)構(gòu)丁基膠和復(fù)合材料產(chǎn)品。丁基膠內(nèi)溢與丁基膠永久塑性相關(guān)，所以只有改變傳統(tǒng)丁基膠＋剛性間隔條的密封方式，才能從源頭解決丁基膠內(nèi)溢的問(wèn)題。熱塑性間隔密封膠（Thermo Plastic Spacer Sealant），簡(jiǎn)稱(chēng)TPSS，是以聚異丁烯、丁基橡膠和具有干燥氣體功能的材料等制成，需熱涂敷擠出成型，具有間隔支撐及干燥等功能的中空玻璃用密封材料，是一種一體化中空玻璃密封工藝，它代替了普通中空玻璃的丁基膠、剛性間隔條和分子篩（圖4）。
How to solve the problem of internal overflow of butyl rubber from the source, although it is a normal phenomenon, has also become a pain point and complaint focus in the industry. Various raw material manufacturers and research institutions have been committed to developing new anti overflow structural butyl rubber and composite material products to meet customers' continuous demands for high-quality products. The overflow of butyl rubber is related to the permanent plasticity of butyl rubber, so only by changing the traditional sealing method of butyl rubber+rigid spacer strip can the problem of butyl rubber overflow be solved from the source. Thermo Plastic Spacer Sealant, abbreviated as TPSS, is a sealing material for insulating glass made of polyisobutene, butyl rubber, and materials with drying gas function. It requires hot coating and extrusion molding, and has functions such as spacing support and drying. It is an integrated insulating glass sealing process that replaces the butyl rubber, rigid spacer strips, and molecular sieves of ordinary insulating glass (Figure 4).
間隔條結(jié)構(gòu)對(duì)比熱塑性間隔密封膠按照膠體是否具有交聯(lián)特征分為非反應(yīng)型間隔密封膠（TPSS-NR）和反應(yīng)型間隔密封膠（TPSS-R）。非反應(yīng)型間隔密封膠，膠體線(xiàn)性分子鏈段無(wú)交聯(lián)固化特征，與玻璃和第二道密封膠無(wú)化學(xué)粘接特性，只能與聚硫類(lèi)密封膠配套使用，適用于有框中空玻璃的生產(chǎn)。反應(yīng)型間隔密封膠，膠體分子鏈段有交聯(lián)固化特征，與玻璃和第二道密封膠有化學(xué)粘接特性，密封性更好，強(qiáng)度更高，彈性可恢復(fù)，適用于門(mén)窗和幕墻中空玻璃。反應(yīng)型間隔密封膠（TPSS-R）與玻璃和外道密封膠形成鉸鏈反應(yīng)，化學(xué)粘接，邊部形成了一個(gè)彈性整體（圖5），會(huì)隨腔體內(nèi)氣體膨脹而膨脹，隨腔體內(nèi)氣體收縮而收縮，從源頭避免了因泵吸效應(yīng)產(chǎn)生的丁基膠內(nèi)溢現(xiàn)象。圖5 彈性整體反應(yīng)型間隔密封膠（TPSS-R），不存在內(nèi)溢及撕裂等情況，在化學(xué)粘接的作用下，本體以及粘接面不存在漏氣通道，中空玻璃的密封性能更強(qiáng)、更持久，產(chǎn)品使用壽命為25年以上，高于中空玻璃國(guó)家標(biāo)準(zhǔn)規(guī)定的至少15年，滿(mǎn)足現(xiàn)今對(duì)于材料與建筑物同周期的追求，也是目前行業(yè)內(nèi)丁基膠防內(nèi)溢的有效方法之一。
Comparison of spacer structures: Thermoplastic spacer sealants are divided into non reactive spacer sealants (TPSS-NR) and reactive spacer sealants (TPSS-R) based on whether the gel has cross-linking characteristics. Non reactive interval sealant, colloidal linear molecular chain segments without cross-linking and curing characteristics, no chemical bonding properties with glass and second sealant, can only be used in conjunction with polysulfide sealant, suitable for the production of framed insulating glass. Reactive interval sealant, with cross-linking and curing characteristics of colloidal molecular chain segments, has chemical bonding properties with glass and second sealant, better sealing performance, higher strength, and recoverable elasticity, suitable for hollow glass in doors, windows, and curtain walls. The reactive spacer sealant (TPSS-R) forms a hinge reaction with the glass and outer sealant, chemically bonding and forming an elastic whole at the edges (Figure 5). It expands with the gas inside the cavity and contracts with the gas inside the cavity, avoiding the phenomenon of butyl rubber overflow caused by pumping effect from the source. Figure 5 Elastic integral reactive spacer sealant (TPSS-R) has no internal overflow or tearing. Under the action of chemical bonding, there is no air leakage channel on the body and bonding surface. The sealing performance of insulated glass is stronger and more durable. The product has a service life of more than 25 years, which is at least 15 years higher than the national standard for insulated glass. It meets the current pursuit of materials and buildings with the same cycle and is also one of the effective methods for preventing internal overflow of butyl rubber in the industry.
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