This thesis addresses the limited durability and poor recyclability of conventional insulated glass units (IGUs). Standard edge seals typically fail after 20–30 years, leading to premature replacement and low-quality recycling of the glass. Existing innovations mainly focus on improving thermal performance and do not address circularity and service life.

The aim of this research is to redesign the IGU edge seal through material innovation and research-informed design to improve durability, enable disassembly and maintain required façade performance. The methodology consisted of a literature review, analysis of standards and design requirements, material screening using Granta EduPack, and proof-of-concept experiments.

The novelty lies in combining a heat-bonded fused glass spacer connection with a flexible, thermally debondable polymer sealant, creating a hybrid edge seal that supports both long-term performance and future material recovery. Results demonstrate that the proposed concept can improve thermal performance, reduce contamination, enable reuse and high-quality glass recycling.