Colour changing electrochromic device and method of manufacturing thereof
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- TRUSSCORE INC
- Filing Date
- 2024-08-01
- Publication Date
- 2026-06-10
Smart Images
Figure CA2024051017_06022025_PF_FP_ABST
Abstract
Description
COLOUR CHANGING ELECTROCHROMIC DEVICE AND METHOD OF MANUFACTURING THEREOFCROSS-REFERENCE
[0001] The present application claims priority to United States Provisional Patent Application No. 63 / 517,441 entitled COLOUR CHANGING ELECTROCHROMIC DEVICE AND METHOD OF MANUFACTURING THEREOF” filed on August 3, 2023, the entire contents of which are incorporated by reference herein for all purposes.FIELD
[0002] The various embodiments described herein generally relate to electrochromic devices, and, more specifically, to electrochromic devices and methods of manufacturing thereof.BACKGROUND
[0003] Currently there exist only a few methods of changing the colour of walls, ceilings, floors, furniture pieces, automobiles or any other surface to achieve a reflective colour change. Some of the ways in which the colour can be changed include painting the surface, applying a film to the surface, such as wallpaper or vinyl wrap, or physically changing the surface material.
[0004] Current methods of changing the colour of a surface generally require a large amount of physical labour and time to complete. Moreover, once a surface colour is changed, the treatment may be semi-permanent and difficult to remove or change once again.
[0005] Other methods which may be more temporary include applying light to the surface using projecting or backlighting. However, these methods can require a large amount of power, as well as the need to replace the bulbs once the bulbs reach their end-of-life.
[0006] An electrochromic material is a material that, when a voltage is applied to it, either oxidizes or reduces changing its electronic state enough to cause a change in the spectrum of light that is reflected or absorbed by the material.
[0007] One example of an electrochromic material is electrochromic glass, also known as “smart glass”. Smart glass is optically transparent material that either tints to a colour or becomes opaque when a voltage is applied to the smart glass device. The materials used in smart glass typically have high optically transparency to allow users to see through the material. Smart glass typically has a direct transmittance (DT) greater than or equal to 85%, resulting in high clarity and low haze to achieve the function of glass. Haze is the scattering of light by a film that results in a cloudy appearance or poorer clarity of objects that are viewed through the film, and is characterized by the percentage of transmitted light passing through a specimen that deviates from the incident beam by more than 2.5° from the normal incident beam. As a result, all materials in a typical smart glass device stack are typically optically transparent with low haze.
[0008] DT and Haze can be calculated using the following equations:Direct Transmittancewhere It is the direct transmittance flux, and l0is the incident flux; andHazewhere ( )2° is the scattered flux that is deviated from the incident beam between 2.5° and 90°, It is the direct transmitted flux, (ls)f is the forward scattered flux (scattered intensity between 0° and 90°).
[0009] In another example, large-scale display screens comprise an array of pixels in which each pixel is individually addressed to form a picture that is recognizable to viewers. However, display technologies can be difficult to scale because as the surface area increases, the number of individually addressedpixels increases as well. As such, electrochromic display technologies typically cannot be used for large surfaces.
[0010] Improved systems, device and methods of changing the colour of a surface are needed.SUMMARY
[0011] In one aspect, an electrochromic device for producing colour change is taught herein. The electrochromic device can comprise: a panel layer; a first conductor layer coupled to the panel layer; an electrolyte layer coupled to the first conductor layer; an electrochromic layer applied to the electrolyte layer; and a second conductor layer coupled to the electrochromic layer; such that when a voltage is applied between the first conductor layer and the second conductor layer, the electrochromic layer produces a colour change.
[0012] In one embodiment, the second conductor layer and the overcoat layer can be optically transparent. In one embodiment, the device can be connected to a processing device allowing the processing device to control when the voltage is applied. In one embodiment, the colour change can comprise a range of unique electrochromic colours that are capable of subtractive colour mixing to form a range of observed colours. For example, the combination of cyan, yellow, magenta, and black can be used to form a range of observed colours.
[0013] In one embodiment, the device can further comprise: an adhesive layer coated on the panel layer. In one embodiment the device can further comprise: a substrate layer coated on the adhesive layer. In one embodiment the device can further comprise: an ion storage layer applied to the first conductor layer. In one embodiment the device can further comprise: an overcoat layer applied to the second conductor layer.
[0014] In one embodiment, the electrochromic layer can comprise a polymeric material. In one embodiment, the polymeric material can be a poly(3,4-ethylenedioxythiophene) (EDOT) based polymer. In one embodiment, the polymeric material can be a poly(3,4-propylenedioxythiophene) (ProDOT)based polymer. Other polymeric electrochromic materials include Poly(3,4- propylenedioxypyrrole) (ProDOP), Poly(3,4-ethylenedioxypyrrole) (EDOP), Poly(pyrrole) (Pyr), Poly(thiophene) (Th), Poly(thieno(3,2-b)thiophene), poly(dithieno(3,2-b:2',3'-d)thiophene), poly(diketopyrrolopyrrole) (DPP), Poly(cyclopenta[2,1-b:3,4-b']-dithiophene) (CPDT), Poly(2-benzofuran), Poly(2,1 ,3-benzoxadiazole), Poly(2,1 ,3-benzothiadiazole), Poly(1 ,2,3- benzotriazole), Poly(quinoxaline), Poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOTPSS), Poly(isoindigo), Poly(1 ,4-dioxylbenzene), Poly(alicyclic nonliner dianhydride), Poly(phthalimide), Poly(2,3-bis-phenyl- quinoxaline), Poly(anthracene), Poly(carbazole) (Cbz), Poly(benzodithiophene), Poly(1 ,7-dihydro-s-indacene), Poly(benzo[1 ,2-c:4,5- c']bis([1 ,2,5]thiadiazole)), Poly(triphenylamine) (TAA). In another embodiment, the electrochromic layer can comprise a small molecule electrochromic materials such as viologens, phthalates, triphenylamines, benzonitriles, azobenenzenes, benzodipyrrolidones. In yet another embodiment, the electrochromic layer can comprise metal oxides such as WOx, NiOx, TiOx, MoOx, NbOx, VOx, TaOx. In yet another embodiment, the electrochromic layer can comprise of Fe (II, III) hexacyanoferrate (II, III) also knows as Prussian blue. In yet another embodiment, the electrochromic layer can comprise of coordination complexes consisting of a metal such as Fe, Ni, Ru, Os, Co, Pt, Ir, Pd and a ligand or combination of ligands such as Polypyridyl ligands e.g. 2’-bipyridine (bpy) and 2,2’:6’,2”-terpyridine (tpy) and their derivatives. In yet another embodiment, the electrochromic layer can comprise of metallo- polymers such as Ru-tethered poly(2,5-dithienylpyrrole) and transition metal complexes of polyazomethines. In another embodiment, the electrochromic layer can also comprise a combination of these materials, such as, an alternating polymer, cross-linked polymer, or any other suitable combination.
[0015] In another aspect, a method of fabricating an electrochromic device is taught herein. The method can comprise: providing a panel layer; coating a first conductor layer to the panel layer; coating an electrolyte layer to the first conductor layer; coating an electrochromic layer to the electrolyte layer; coating a second conductor layer to the electrochromic layer; and applying a voltagebetween the first conductor layer and the second conductor layer to produce a colour change by the electrochromic layer.
[0016] In one embodiment, the second conductor layer and the overcoat layer are optically transparent.
[0017] In one embodiment, the method can further comprise: coating an adhesive layer on the panel layer. In one embodiment, the method can further comprise: coating a substrate layer on the adhesive layer. In one embodiment, the method can further comprise: coating an ion storage layer to the first conductor layer. In one embodiment, the method can further comprise: coating an overcoat layer to the second conductor layer.
[0018] In one embodiment, the electrochromic layer comprises a polymeric material. In one embodiment, the polymeric material can be a poly(3,4- ethylenedioxythiophene) (EDOT) based polymer. In one embodiment, the polymeric material can be a poly(3,4-propylenedioxythiophene) (ProDOT) based polymer. Other polymeric electrochromic materials include: Poly(3,4- propylenedioxypyrrole) (ProDOP), Poly(3,4-ethylenedioxypyrrole) (EDOP), Poly(pyrrole) (Pyr), Poly(thiophene) (Th), Poly(thieno(3,2-b)thiophene), poly(dithieno(3,2-b:2',3'-d)thiophene), poly(diketopyrrolopyrrole) (DPP), Poly(cyclopenta[2,1-b:3,4-b']-dithiophene) (CPDT), Poly(2-benzofuran), Poly(2,1 ,3-benzoxadiazole), Poly(2,1 ,3-benzothiadiazole), Poly(1 ,2,3- benzotriazole), Poly(quinoxaline), Poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOTPSS), Poly(isoindigo), Poly(1 ,4-dioxylbenzene), Poly(alicyclic nonliner dianhydride), Poly(phthalimide), Poly(2,3-bis-phenyl- quinoxaline), Poly(anthracene), Poly(carbazole) (Cbz), Poly(benzodithiophene), Poly(1 ,7-dihydro-s-indacene), Poly(benzo[1 ,2-c:4,5- c']bis([1 ,2,5]thiadiazole)), Poly(triphenylamine) (TAA). In another embodiment, the electrochromic layer can comprise a small molecule electrochromic materials such as viologens, phthalates, triphenylamines, benzonitriles, azobenenzenes, benzodipyrrolidones. In yet another embodiment, the electrochromic layer can comprise metal oxides such as WOx, NiOx, TiOx, MoOx, NbOx, VOx, TaOx. In yet another embodiment, the electrochromic layercan comprise of Fe (II, III) hexacyanoferrate (II, III) also knows as Prussian blue. In yet another embodiment, the electrochromic layer can comprise of coordination complexes consisting of a metal such as Fe, Ni, Ru, Os, Co, Pt, Ir, Pd and a ligand or combination of ligands such as Polypyridyl ligands e.g. 2’-bipyridine (bpy) and 2,2’:6’,2”-terpyridine (tpy) and their derivatives. In yet another embodiment, the electrochromic layer can comprise of metallo- polymers such as Ru-tethered poly(2,5-dithienylpyrrole) and transition metal complexes of polyazomethines. In another embodiment, the electrochromic layer can also comprise a combination of these materials, such as, an alternating polymer, cross-linked polymer, or any other suitable combination.
[0019] These and other features and advantages of the present application will become apparent from the following detailed description taken together with the accompanying drawings. It should be understood, however, that the detailed description and the specific examples, while indicating preferred embodiments of the application, are given by way of illustration only, since various changes and modifications within the spirit and scope of the application will become apparent to those skilled in the art from this detailed description.BRIEF DESCRIPTION OF THE DRAWINGS
[0020] For a better understanding of the various embodiments described herein, and to show more clearly how these various embodiments may be carried into effect, reference will be made, by way of example, to the accompanying drawings which show at least one example embodiment, and in which:
[0021] FIG. 1 is a schematic view of an electrochromic film;
[0022] FIG. 2 is a schematic view of an electrochromic film in its coloured (left) and bleached state (right);
[0023] FIG. 3 is a diagram of two exemplary polymeric materials that may be used as an electrochromic material in at least one embodiment of an electrochromic device as described herein; and
[0024] FIG. 4A is a schematic view of an electrochromic device according to an embodiment;
[0025] FIG. 4B is a schematic view of an electrochromic device according to an embodiment;
[0026] FIG. 5A is a schematic view of an electrochromic device according to an embodiment;
[0027] FIG. 5B is a schematic view of an electrochromic device according to an embodiment;
[0028] FIG. 5C is a schematic view of an electrochromic device according to an embodiment;
[0029] FIG. 6A is a schematic view of an electrochromic device according to an embodiment;
[0030] FIG. 6B is a schematic view of an electrochromic device according to an embodiment;
[0031] FIG. 6C is a schematic view of an electrochromic device according to an embodiment;
[0032] FIG. 7 is a schematic view of an electrochromic device according to an embodiment;
[0033] FIG. 8 is a schematic view of an example of a colour mixing pallet;
[0034] FIG. 9 is a schematic view of an electrochromic device according to an embodiment;
[0035] FIG. 10A is a schematic view of an electrochromic device according to an embodiment;
[0036] FIG. 10B is a schematic view of an electrochromic device according to an embodiment;
[0037] FIG. 10C is a schematic view of an electrochromic device according to an embodiment;
[0038] FIG. 10D is a schematic view of an electrochromic device according to an embodiment;
[0039] FIG. 10E is a schematic view of an electrochromic device according to an embodiment;
[0040] FIG. 10F is a schematic view of an electrochromic device according to an embodiment;
[0041] FIG. 10G is a schematic view of an electrochromic device according to an embodiment;
[0042] FIG. 10H is a schematic view of an electrochromic device according to an embodiment;
[0043] FIG. 101 is a schematic view of an electrochromic device according to an embodiment;
[0044] FIG. 11 is a flowchart representing an embodiment of a method of creating an electrochromic device.
[0045] FIG. 12A is an expanded view of an electrochromic device according to an embodiment; and
[0046] FIG. 12B is an expanded view of an electrochromic device according to an embodiment.DETAILED DESCRIPTION OF THE EMBODIMENTS
[0047] Various apparatuses, methods and systems will be described below to provide an example of one or more embodiments. No embodiment described below limits any claims and any claims may cover apparatuses that differ from those described below. The claims are not limited to apparatuses, methods or systems having all of the features of any one apparatus, method, or system described below or to features common to multiple or all of the apparatuses, methods and systems described below.
[0048] It is possible that an apparatus, system or method described herein is not an embodiment of any claim. Any embodiment disclosed herein that is not claimed in this document may be the subject matter of another protectiveinstrument, for example, a continuing patent application, and the applicants, inventors or owners do not intend to abandon, disclaim or dedicate to the public any such embodiment merely by its disclosure in this document.
[0049] The terms "including", "comprising", and variations thereof mean "including but not limited to", unless expressly specified otherwise. A listing of items does not imply that any or all of the items are mutually exclusive, unless expressly specified otherwise. The terms "a", "an", and "the" mean "one or more", unless expressly specified otherwise.
[0050] As used herein and in the claims, two or more parts are said to be "coupled", "connected", "attached", “mounted” or "fastened" where the parts are joined or operate together either directly or indirectly (i.e. , through one or more intermediate parts), so long as a link occurs. As used herein and in the claims, two or more parts are said to be "directly coupled", "directly connected", "directly attached", or "directly fastened" where the parts are connected in physical contact with each other. As used herein, two or more parts are said to be "rigidly coupled", "rigidly connected", "rigidly attached", or "rigidly fastened" where the parts are coupled so as to move as one while maintaining a constant orientation relative to each other. None of the terms "coupled", "connected", "attached", “mounted”, and "fastened" distinguish the manner in which two or more parts are joined together.
[0051] It should be noted that the term “coupled” used herein indicates that two elements can be directly coupled to one another or coupled to one another through one or more intermediate elements.
[0052] Some elements herein may be identified by a part number, which is composed of a base numberfollowed by an alphabetical or subscript-numerical suffix (e.g., 112a, or 1121 ). Multiple elements herein may be identified by part numbers that share a base number in common and that differ by their suffixes (e.g., 1121 , 1122, and 1123). Elements with a common base number may in some cases be referred to collectively or generically using the base number without a suffix (e.g., 112).
[0053] It should be noted that terms of degree such as "substantially", "about", and "approximately" as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree may also be construed as including a deviation of the modified term, such as by 1 %, 2%, 5% or 10%, for example, if this deviation does not negate the meaning of the term it modifies.
[0054] It should also be noted that, as used herein, the wording “and / or” is intended to represent an inclusive-or. That is, “X and / or Y” is intended to mean X or Y or both X and Y, for example. As a further example, “X, Y, and / or Z” is intended to mean X or Y or Z or any combination thereof of X, Y, and Z.
[0055] Furthermore, the recitation of numerical ranges by endpoints herein includes all numbers and fractions subsumed within that range (e.g., 1 to 5 includes 1 , 1.5, 2, 2.75, 3, 3.90, 4, and 5). It is also to be understood that all numbers and fractions thereof are presumed to be modified by the term "about" which means a variation of up to a certain amount of the number to which reference is being made if the end result is not significantly changed, such as 1 %, 2%, 5%, or 10%, for example.
[0056] In some examples, similar references may be used in different figures to denote similar components. In some examples, like features may only be labeled in one instance for simplicity and clarity of the drawings.
[0057] The various embodiments described herein generally relate to using electrochromic material to achieve the colour change of a surface such as a wall, ceiling, floor, automobile, furniture or other surface. An electrochromic material is a material that when a voltage is applied to it, either oxidizes or reduces changing its electronic state enough to cause a change in the spectrum of light that is reflected or absorbed by the material. Examples of suitable electrochromic materials include but are not limited to: polymeric materials and combinations thereof such as but not limited to Poly(3,4-ethylene dioxythiophene) (EDOT), Poly(3,4-propylenedioxythiophene) (ProDOT) Poly(3,4-propylenedioxypyrrole) (ProDOP), Poly(3,4-ethylenedioxypyrrole) (EDOP), Poly(pyrrole) (Pyr), Poly(thiophene) (Th), Poly(thieno(3,2-b)thiophene), poly(dithieno(3,2-b:2',3'-d)thiophene), poly(diketopyrrolopyrrole) (DPP), Poly(cyclopenta[2,1-b:3,4-b']-dithiophene) (CPDT), Poly(2-benzofuran), Poly(2,1 ,3-benzoxadiazole), Poly(2,1 ,3-benzothiadiazole), Poly(1 ,2,3- benzotriazole), Poly(quinoxaline), Poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOTPSS), Poly(isoindigo), Poly(1 ,4-dioxylbenzene), Poly(alicyclic nonliner dianhydride), Poly(phthalimide), Poly(2,3-bis-phenyl- quinoxaline), Poly(anthracene), Poly(carbazole) (Cbz), Poly(benzodithiophene), Poly(1 ,7-dihydro-s-indacene), Poly(benzo[1 ,2-c:4,5- c']bis([1 ,2,5]thiadiazole)), Poly(triphenylamine) (TAA), small molecule electrochromic materials such as viologens, phthalates, triphenylamines, benzonitriles, azobenenzenes, .benzodipyrrolidones, metal oxides such as; WOx, NiOx, TiOx, MoOx, NbOx, VOx, TaOx, Fe (II, III) hexacyanoferrate (II, III) also knows as Prussian blue, coordination complexes consisting of a metal such as; Fe, Ni, Ru, Os, Co, Pt, Ir, Pd and a ligand or combination of ligands such as polypyridyl ligands e.g. 2’-bipyridine (bpy) and 2,2’:6’,2”-terpyridine (tpy) and their derivatives, metallo-polymers such as Ru-tethered poly(2,5- dithienylpyrrole), and transition metal complexes of polyazomethines. electrochromic materials.
[0058] An electrochromic device and method of manufacturing an electrochromic device is taught herein. The electrochromic device can be used to change the colour of surfaces such as walls instantly and digitally using electrochromic technology. Electrochromic technology can be applied to a surface such as a panel or cladding material used for walls, ceilings and floors. When a voltage is applied to the electrochromic material, it can change colour; and a different voltage can be used to change the wall to a different colour or back to its original colour. This colour change can be uniform across the entire panel and can be used to create a colour change on the surface that is observable by the viewer.
[0059] FIG. 1 is a general diagram of an electrochromic device 100. An electrochromic device 100 can include a first conductor layer 104, an ion storage layer 105, an electrolyte layer 106, an electrochromic layer 107, and asecond conductor layer 108. The second conductor layer is ideally transparent. When an appropriate voltage is applied between the first conductor layer 104 and the second conductor layer 108, the electrochromic layer 107 undergoes a redox reaction, causing a change in the spectrum of light that is reflected or absorbed by the electrochromic material 107. The transition from a coloured state to colourless is herein referred to as bleaching. The transition from a first state to a second state is also herein referred to as bleaching. The term bleaching is used for simplicity and clarity, however it should be noted that electrochromic materials can have multiple coloured states with colourless not being a required state. The bleached electrochromic layer is referred to as 107b. The electrochromic device in its unbleached state is referred to as 100a, and the electrochromic device in its bleached state is referred to as 100b.
[0060] The various layers of the electrochromic device, such as, for example, the first conductor layer 104, the ion storage layer 105, the electrolyte layer 106, the electrochromic layer 107, and the second conductor layer 108 may have varying thickness. The layers may be formed separately forming discontinuous layers or, may be formed continuously having virtually no separation or very little separation between consecutive layers.
[0061] The layers above the electrochromic layer should ideally be transparent such that the change in colour or state is visible to an observer. For instance, in one embodiment, the second conductor layer 108 is transparent such that any changes in the spectrum of light that is reflected or absorbed by the electrochromic material can be seen. If the second conductor layer 108 were to have a reduced direct transmittance, typically less than 85%, the colour changes occurring to the electrochromic layer 107 may be obscured or not visible to an observer.
[0062] Referring now to FIG. 2, shown therein is an example of an electrochromic device 111 , according to one embodiment. In a first embodiment, the electrochromic device 111 includes: a panel layer 101 , an adhesive layer 102, a substrate layer 103, a first conductor layer 104, an ion storage layer 105, an electrolyte layer 106, an electrochromic layer 107, asecond conductor layer 108, and a protective overcoat layer 109. The aforementioned plurality of layers can collectively be referred to herein as a stack 113. It should be understood that the term stack and reference number 113 used herein can refer to any arrangement of a plurality of electrochromic layers and should not be limited to the arrangement shown in FIG. 2.
[0063] When a voltage is applied between the first conductor layer 104 and the second conductor layer 108, the electrochromic layer 107 becomes bleached, causing a change in the spectrum of light that is reflected or absorbed by the electrochromic material 107. The bleached electrochromic layer is referred to herein as 107b. The electrochromic device in its unbleached state is referred to as 111a, and the electrochromic device in its bleached state is referred to as 111 b.
[0064] The panel layer 101 can comprise a panel such as wall panel, ceiling panel, or other surface panel. In one embodiment, the panel layer 101 can be constructed from a rigid thermoplastic, such as polyvinyl chloride (PVC), acrylonitrile butadiene styrene (ABS), or any other suitable thermoplastic. In another embodiment, the panel layer can be constructed from any other suitable material, such as glass, fiberglass, polymer materials, etc. In an alternative embodiment, the panel layer 101 can be flexible in order to conform to curved surfaces. The panel layer 101 can further comprise an attachment mechanism that allows the panel to be attached to, or coupled to, framing structures (such as 2” x 4” framing) or a surface (such as but not limited to a drywall panel or a ceiling panel).
[0065] The attachment mechanism can comprise an adhesive layer 102 can be applied to, and in direct contact with the panel layer. The adhesive layer 102 can be used for laminating, connecting, gluing, bonding or adhering the panel layer 101 to the substrate layer 103. The adhesive layer 102 can comprise any suitable adhesive or adhesion mechanism. Examples of suitable adhesives include, but are not limited to, resins, thermoplastic glues, monomer glues, thermosetting polymers, and the like.
[0066] The substrate layer 103 can comprise a substrate. The substrate can be a flexible polymer material such as polyethylene terephthalate (PET) or polyvinyl chloride (PVC). The substrate layer 103 can be stacked above, and coupled to the panel layer 101 , via the adhesive layer 102. The substrate layer 103 is preferably a thin layer less than 10 mil (254um) with an ideal thickness less than 3mil (76.2 urn) to allow for wrapping around the edges of panel layer 101 during lamination.
[0067] The substrate layer 103 can be coupled to a first conductor layer 104. The first conductor layer 104 can comprise a layer of a conductive material. For example, the conductive materials that can be used for the first conductor layer 104 may comprise, but are not limited to, metallic micro and nano-materials, metallic nanostructures, nickel, allotropes of carbon (e.g., graphite, graphene, nanotubes), gold, copper, silver, aluminum, conductive polymers and combinations thereof, or the like. The first conductor layer 104 can preferably by flexible. In one embodiment, a nickel and carbon ink blend can be used to form the first conductor layer 104. In one embodiment, the first conductor layer 104 can have a sheet resistance of (e.g. 1-10 Q / sq) to ensure the overall resistance of the device is low with an upper sheet resistance bound of 1000 Q / sq). The first conductor layer 104 can be in electrical communication with the remaining layers. The thickness of the conductor layer can be in the range of 1 nm to 100 urn with an ideal thickness of 1-10um.
[0068] In at least one embodiment, an ion storage layer 105 can be coupled to the conductor layer 104. The ion storage layer 105 can comprise a material that will hold the transferred ions to maintain charge separation of the device between the ion storage layer 105 and electrochromic layer 107. In one embodiment, poly(3,4-ethylenedioxythiophene (PEDOT) and / or polystyrene sulfonate (PSS) may be used as the ion storage layer 105. Other materials that can be used to maintain charge separation include, but are not limited to: Metal oxides such as NiO, CeO2, lrO2, TiO2, Nb20s, Vox, TaOx, mesoporous / nanoparticle ITO, and polymeric materials such as Poly[(3,4-propylenedioxy)pyrrole] (PProDOP), Poly(2,2,6,6-tetramethyl-4-piperidinyloxy methacrylate)-co-(4-benzoylphenyl methacrylate) (PRMA-co-BP).
[0069] The electrolyte layer 106 can be coupled to, or stacked above the ion storage layer 105. In one embodiment, lithium salt (Li+) in a polymer matrix can be used to form the electrolyte layer. Other salts or ions can also be used, as well as ionic liquids and polymer electrolytes. Salts include materials such as Lithium perchlorate (UCIO4), Lithium hexafluorophosphate (LiPFe), Lithium tetrafluoroborate (LiBF4), Lithium bis(trifluoromethanesulfonyl)imide (LiTFSI), Lithium bis (oxalato)borate (LiBOB), Lithium trifluoromethanesulfonate (LiOTf), Sodium perchlorate (NaCIO4), Sodium hexafluorophosphate (NaPF6), Sodium tetrafluoroborate (NaBF4), Sodium bis(trifluoromethanesulfonyl)imide (NaTFSI), Sodium bis (oxalato)borate (NaBOB), Sodium trifluoromethanesulfonate (NaOTf), Tetrabutylammonium perchlorate (TBACIO4), Tetrabutylammonium hexafluorophosphate (TBAPF6), Tetrabutylammonium tetrafluoroborate (TBABF4), Tetrabutylammonium bis(trifluoromethanesulfonyl)imide (TBATFSI), Tetrabutylammonium bis (oxalato)borate (TBABOB), Tetrabutylammonium trifluoromethanesulfonate (TBAOTf) and Iodine. Ionic liquids include materials such as ethylammonium nitrate (EAN), 1-Butyl-3-methylimidazolium chloride ([BMIM][CI]), 1-Butyl-3- methylimidazolium tetrafluoroborate ([BMIM][BF4]), 1-Butyl-3- methylimidazolium hexafluorophosphate ([BMIM][PF6]), 1 -ethyl-3 methylimidazolium bis(trifluoromethylsulfonyl)imide [EMIM][TFSI] and 1-ethyl- 3-methylimidazolium trifluoromethanesulfonate [EMIM][OTf], The polymer matrix includes polymers such as Polymethyl methacrylate (PMMA), Polyethylene glycol (PEO), Polyvinylidene fluoride (PVDF), Nation, and nanocellulose. Polymer electrolytes include polymers such as poly(sodium styrene sulfonate) (PSS), polyacrylic acid (PAA). In another embodiment, the electrolyte layer can also comprise a combination of these materials.
[0070] In one embodiment, liquid electrolytes may be used in the electrolyte layer 106, however, it should be noted that any puncture may cause the liquid to leak out. In another embodiment, gel electrolytes may be used in theelectrolyte layer 106. Gel electrolytes can have a range of viscosities. A two- solvent system may be used in the electrolyte layer 106 such that one solvent evaporates after printing and the other solvent remains to keep the material in a gel state. A polymer can be used as a binder to form the gel and a salt, ionic liquid or combination can be added as an electrolyte. In one example, the electrolyte material can consist of propylene carbonate (remaining solvent), acetonitrile (evaporating solvent), polymethyl methacrylate (PMMA) (polymer binder), LiOTf (electrolyte salt). In one embodiment, a colourant can be added to the electrolyte material formulation to make the electrolyte layer a colour such that the layers behind the electrolyte layer 106 can be hidden.
[0071] In an embodiment, a polymer electrolyte (polyelectrolyte) can be used in the electrolyte layer 106. In one embodiment, a block copolymer with a polystyrene block, a charged polymer electrolyte with TFSI counterion, and an acrylate or PEG block can be used as the polyelectrolyte. The proposed electrolyte formulations may provide for a solid state electrolyte, or very minimal solvent required to allow ion transport. Because the electrolyte is bound to the polymer, there is no worry about phase separation.
[0072] The electrochromic layer 107 can be coupled to, or stacked above, and in direct contact with the ion storage layer 106. In one embodiment, the electrochromic layer 107 and the ion storage layer 106 can be combined to form a single layer. The electrochromic layer 107 can change colour when a voltage is applied. The electrochromic layer 107 can comprise an electrochromic material such as, but not limited to, the materials provided in FIG. 3, a polymeric material (e.g., polypyrrole, PEDOT, polyaniline, orthe like.), small molecules (such as but not limited to phthalates and / or viologens), or a metal oxide (such as but not limited to tungsten, molybdenum, titanium and / or niobium oxides, and / or the like.).
[0073] It should be noted that metal oxides may include heavy metals, and therefore may not be compatible for some applications. Small molecules such as phthalates and viologens typically have low stability and can be harmful to humans. Organic materials such as viologens can be used in theelectrochromic layer 107. Viologens comprise 4,4'-bi pyrid ine compounds which can display a range of reversible colour changes. In one embodiment, the range of colour can be between a colourless and a deep blue colour. Furthermore, viologens can be "tuned" to a deep blue or intense green colour; however, it can be appreciated that any colour on the visible colour spectrum can be created using viologens. The colour changes occur due to redox reactions.
[0074] As organic materials, viologens can be seen as promising alternatives for electronic applications, compared to metal-based systems which tend to be expensive, toxic and a problem to recycle. Possible advantages of viologens include their optical contrast, colouration efficiency, redox stability, ease of design and potential to scale up for large-area preparation. In one embodiment, Viologens can be used in conjunction with phenylenediamine. Viologens can also be used in conjunction with titanium dioxide.
[0075] In one embodiment, the electrochromic layer can comprise a polymeric material. FIG. 3 shows an example of polymeric materials such as Poly(3,4-ethylene dioxythiophene) (EDOT) and Poly(3,4- ropylenedioxythiophene) (ProDOT)-based polymers that can be used as materials for the electrochromic layer 107. Other polymeric electrochromic materials include Poly(3,4-propylenedioxypyrrole) (ProDOP), Poly(3,4- ethylenedioxypyrrole) (EDOP), Poly(pyrrole) (Pyr), Poly(thiophene) (Th), Poly(thieno(3,2-b)thiophene), poly(dithieno(3,2-b:2',3'-d)thiophene), poly(diketopyrrolopyrrole) (DPP), Poly(cyclopenta[2, 1 -b : 3 ,4-b']-d ith iop hene) (CPDT), Poly(2-benzofuran), Poly(2,1 ,3-benzoxadiazole), Poly(2,1 ,3- benzothiadiazole), Poly(1 ,2,3-benzotriazole), Poly(quinoxaline), Poly(3,4- ethylenedioxythiophene) polystyrene sulfonate (PEDOTPSS), Poly(isoindigo), Poly(1 ,4-dioxylbenzene), Poly(alicyclic nonliner dianhydride), Poly(phthalimide), Poly(2,3-bis-phenyl-quinoxaline), Poly(anthracene), Poly(carbazole) (Cbz), Poly(benzodithiophene), Poly(1 ,7-dihydro-s-indacene), Poly(benzo[1 ,2-c:4,5-c']bis([1 ,2,5]thiadiazole)), Poly(triphenylamine) (TAA). In another embodiment, the electrochromic layer can comprise a small moleculeelectrochromic materials such as viologens, phthalates, triphenylamines, benzonitriles, azobenenzenes, benzodipyrrolidones. In yet another embodiment, the electrochromic layer can comprise metal oxides such as WOx, NiOx, TiOx, MoOx, NbOx, VOx, TaOx. In yet another embodiment, the electrochromic layer can comprise of Fe (II, III) hexacyanoferrate (II, III) also knows as Prussian blue. In yet another embodiment, the electrochromic layer can comprise of coordination complexes consisting of a metal such as Fe, Ni, Ru, Os, Co, Pt, Ir, Pd and a ligand or combination of ligands such as Polypyridyl ligands e.g. 2’-bipyridine (bpy) and 2,2’:6’,2”-terpyridine (tpy) and their derivatives. In yet another embodiment, the electrochromic layer can comprise of metallo-polymers such as Ru-tethered poly(2,5-dithienylpyrrole) and transition metal complexes of polyazomethines. In another embodiment, the electrochromic layer can also comprise a combination of these materials, such as, an alternating polymer, cross-linked polymer, or any other suitable combination.
[0076] Polymeric materials are typically stable, flexible, environmentally safe, easily form films and are solution processable. In one embodiment, the electrochromic polymers can be soluble in solvents with a reduced environmental impact than halogenated solvents. Some examples solvents categories are water, alcohols, esters, amines and aromatics.
[0077] In another embodiment, the electrochromic layer can comprise small molecule electrochromic materials, which typically are single colour transitions, and a full range of colours are available dependent on molecular structure, with their neutral state typically being transparent. In yet another embodiment, the electrochromic layer can comprise metal oxide electrochromic materials, which typically have very high contrast between the coloured and transparent states. In yet another embodiment, the electrochromic layer can comprise of metal ligand coordination complexes which often can reach multiple oxidation states resulting in multiple colour states. In yet another embodiment, the electrochromic layer can comprise of a metallo-polymer which can offercharacteristics of electrochromic polymers and metal coordination complexes in the same material.
[0078] A second, or transparent, conductor layer 108 can be coupled to or stacked above the electrochromic layer 107. The transparent conductor layer 108 should preferably have high optical transparency, such as, but not limited to greater than about 85% optical transparency. A transparent material may be used to construct the transparent conductor layer. In one embodiment, the transparent material can be a transparent polymer material such as PET, Acrylic, PMMA, or another transparent polymer. In another embodiment, glass may be used as the transparent material for constructing the transparent conductor layer. In at least one embodiment, the transparent conductor layer can further comprise a conductive coating, coated on the transparent material. The conductive coating may be an indium tin oxide (ITO) coating, a fluorinedoped tin oxide (FTO) coating, a transparent conductive oxide (TOO) coating, a metal nanowire coating, a transparent conductive ink coating, a coating composed of allotropes of carbon (e.g., nanotubes, graphene, and / or the like), a conductive polymer coating, or combinations thereof.
[0079] A protective overcoat layer 109 can be coupled to and stacked above the transparent conductor layer 108. The protective overcoat layer 109 should preferably have high optical transparency and transmittance, such as, but not limited to greater than about 85% optical transparency. The protective overcoat layer 109 can preferably offer a physical barrier / protection of the device 111 from external elements or forces. A protective overcoat layer 109 can be constructed from polymeric materials such as PMMA and polyvinylidene fluoride (PVDF), however other suitable materials can be used.
[0080] I n at least one embodiment, only the transparent conductor layer 108 and the protective overcoat layer 109 may provide optical transparency, such that the electrochromic layer(s) of the device can be visible. In one embodiment, the panel layer 101 can be opaque.
[0081] In one embodiment, the panel layer 101 can be used for interior walls and ceilings and floors. In this embodiment, the electrochromic device can betransparent as well as the transparent conductor layer 108, and the protective overcoat layer 109. In another embodiment, the electrochromic device can be transparent for all the layers above the electrochromic layer 107. Furthermore, the remaining layers do not have the requirement of high direct transmittance, high clarity or low haze properties. As such, the subsequent layers can utilize materials with any level of transmittance and haze including opaque materials. For example, the conductor layer 104 could utilize an opaque conductive metal ink, which will be much cheaper than any transparent conductive material. Easing the limitation of transparency, clarity, and low haze allows for a dramatically larger range of material choices.
[0082] In another embodiment, the panel layer 101 can be used as windows for applications such as smart glass. In this embodiment, the materials for the layers can be selected materials with high level of transmittance and low level of haze.
[0083] In one embodiment, the electrochromic device 111 can be constructed as a flexible electrochromic film 110 comprising the substrate layer 103, the conductor layer 104, the ion storage layer 105, the electrolyte layer 106, the electrochromic layer 107, the transparent conductor layer 108, and the protective overcoat layer 109. The flexible electrochromic film layers 110 can then be laminated to the panel layer 101 via the adhesive layer 102, to form the electrochromic device 111. The electrochromic film layers 110 can have a total thickness less than <1 OOmil (2.54 mm), with a more preferred embodiment between 1-15mil (25.4 - 381 pm). The electrochromic film layers 110 can be laminated using an adhesive layer 102 to the panel layer 101 such that the colour change of the electrochromic is visible. The electrochromic device 111 can also be referred to as the electrochromic panel 111 or digital paint panel 111. The electrochromic device 111 can comprise the electrochromic film layers 110 coupled to a panel layer 101 using an adhesion mechanism 102. The electrochromic film layers 110 can also be referred to as the electrochromic film 110 or digital paint 110. The electrochromic film layers 110 can comprise the stack of layers 103 to 109. The electrochromic film layers 110 can comprisethe substrate layer 103, the conductor layer 104, the ion storage layer 105, the electrolyte layer 106, the electrochromic layer 107, the transparent conductor layer 108, and the protective overcoat layer 109.
[0084] The electrochromic film 110 that is applied to the panel 101 can contain at least one electrochromic material 107. The electrochromic film 110 may be reasonably transparent (i.e., greater than about 85% light transmittance) from the outward facing side through all material layers up to the electrochromic material (layers 108 and 109) The electrochromic film 110 can also have a protective coating on its surface and a transparent conductor layer 108. The electrochromic film 110 and have a way to apply a voltage / current to the device.
[0085] The electrochromic device 111 preferably has high transmittance (i.e. in the order of greater than about 85%) to the electrochromic layer, allowing the light to escape the film. The values of haze and clarity may be varied since the colour change is ideally homogenous across the full electrochromic film (10), so colour clarity / haze levels can vary.
[0086] Typically, the electrochromic material 107 can be sandwiched between two electrodes, with interconnection points at the conductor layer 104 and transparent conductor layer 108. However, other device architectures are possible such as both electrical leads being in the same plane as the electrochromic material 107. These alternative architectures are not shown in the present application.
[0087] Electrical interconnection points can be used to couple the electrochromic film 110 to a control module 112 (V) to energize and control the electrochromic film 110. The control module can either manually or wirelessly apply an excitation voltage to the electrochromic device film 110 to activate the colour state.
[0088] FIG. 2 shows a schematic of an electrochromic device 111 in its coloured state 111a and bleached state 111 b is shown. An applied voltage can be used to switch the device between states. The voltage can range to anysuitable voltage required to drive the redox reaction, but can usually range between + / - about 3 V.
[0089] It can be noted that when the device 111 is coloured, it can be referred to as the coloured state 111a, when it is colourless, it can be referred to as the bleached state 111 b. However, it can also be noted that some materials transition from one colour to another so this definition may be ambiguous. Additionally, some materials can achieve multiple coloured states at different voltages. In an example device with only one colour transition, a colour change may occur at a specific, specified voltage, such as but not limited to -0.8 V, and can return to its original state when a different voltage is applied, such as but not limited to 1 V. In another embodiment, at a more positive or negative voltage, an activation voltage can be applied to drive the colour change faster.
[0090] In at least one embodiment, the colour change is homogeneous across the full panel or panels; however, the colour change can be patterned or alternated for appearance. The colour change may occur over a timeframe in a range of about microseconds to about 5 minutes (e.g., forthe colour change to completely occur). In at least one embodiment, the colour change may occur within a timeframe of about 1 second to about 20 seconds.
[0091] Overtime, the electrochromic layer 107 may discharge ions, causing the colour of the electrochromic layer to change back automatically, or without the need to change voltage. This discharge can be dependent upon the materials used for the electrochromic, the electrolyte and the ion storage material.
[0092] In at least one embodiment, a periodic voltage pulse may be applied to the walls to maintain the desired colour for an extended period of time. Between pulses, the walls remain in an electrically open state (no voltage applied, this includes 0 V as some electrochromic materials will change state at 0 V). The frequency of the electrical pulse may vary based on the materials used to create the electrochromic device. Some electrolytes and ion storagematerial can maintain charge separation for a very long periods of time such as days to weeks, and therefore will require pulses less frequently.
[0093] FIG. 4 provides an embodiment or method of achieving multiple colours using the electrochromic film 110. In this embodiment, the ion storage material layer 105 also serves as an electrochromic material. In FIG. 4A, a voltage can be applied which can change the colour of the electrochromic layer 107 to a bleached state 107b. If the electrochromic layer 107 is in a bleached state 107b, and the electrolyte is transparent, it can be possible to see through to the ion storage layer 105. In FIG. 4B, a suitable voltage (such as 1.2 V) can be applied to the ion storage material layer 105 to cause the ion storage layer to change colour, such that the colour change can be observed. Therefore, the colour change of the electrochromic layer 107 by applying a first voltage can be seen in FIG. 4A and the colour change of or ion storage material layer 105b by applying a second voltage can be seen in FIG.3B.
[0094] FIG. 5 provides a schematic view of an electrochromic device according to at least one embodiment described herein. In this embodiment, a plurality of electrochromic materials in the electrochromic layer 107 are provided and subsequently mixed. If the electrochromic materials have different electrical potential windows that cause them to reduce or oxidize at varying voltages, a variety of different colours may be observed as each electrochromic material oxidizes or reduces.
[0095] At device 411a, the electrochromic layer 107 is set showing a base colour. When a voltage is applied to device 411a, the first material in the electrochromic mix forms device 411c, having a unique colour formed by the electrochromic layer 107c, showing only the colour of the remaining material in the electrochromic mix. When a voltage is applied to device 411c, the at least two materials in the electrochromic mix are bleached to form device 411 b, showing none of the colour of the electrochromic layer 107.
[0096] FIG. 6 is a schematic view of an electrochromic device according to an embodiment. In this embodiment, an electrochromic material that can achieve multiple colour states is used within the electrochromic later 107. Whena voltage is applied to device 511 a, the first material in the electrochromic mix forms device 511b, having a unique colour formed by the electrochromic layer 107c. A further voltage can be applied to the device 511 b , to form device 511 c, having a bleached state 107b. Metal oxides often can achieve this, but the difference between colours is often 0.1 -0.2V. It may be difficult to maintain the desired voltage across the large area of a wall panel to a tight tolerance such as 0.1V.
[0097] FIG. 7 is a schematic view of an electrochromic device according to another embodiment to achieve multiple colours using electrochromic layer 107. When a voltage is applied to device 611 a, the first material in the electrochromic mix forms device 611 b, having a unique colour formed by the electrochromic layer 107c. A further voltage can be applied to the device 511 b, to form device 511c, having a bleached state 107b. A further voltage can be applied to the device 511c, to form device 511 d, having a bleached state 107b and state 105b of the ion storage layer 105. In this embodiment, an electrochromic ion storage material 105 which is observable is used such that when layer 105 is bleached to form layer 105b, the colour change of layer 105 can be observed in device 611d.
[0098] In one embodiment, an electrochromic layer 107 that can achieve multiple coloured states is used. Once the electrochromic is bleached, if the electrolyte is transparent, an Ion Storage Material 105 that is also an electrochromic can be observed. The observer can see the ion storage layer which can then change to a coloured state when a voltage is applied.
[0099] FIG. 8 is a schematic view of an example of a colour mixing pallet applied to a panel 101. CMY colour palettes typically comprise cyan, magenta and yellow colours which are mixed at different intensities to produce a broad range of colours. Though the CMY pallet is shown in FIG.8, it can be understood that other mixing pallets may be used, including but not limited to primary colours RYB, RGB colours, CMYK, and other colour mixing pallets.
[0100] In this embodiment, small areas of colour (pixels) are used such that the pixel are small enough to be indistinguishable by the human eye at areasonable viewing distance. The same voltage can then be applied to all the pixels of a colour (e.g. all yellow pixels) to colour or bleach the yellow. In a similar manner, apply voltage to all the cyan and magenta pixels to achieve appropriate colour mixing to achieve the desired colour. Channels may be provided for each colour, for example a first channel for Cyan, a second channel for Magenta, a third channel for Yellow, and optionally a fourth channel for Black (CMYK). For example, when a voltage is applied, it is applied to all the cyan pixel channels at the same time, allowing the colour to change uniformly.
[0101] In one embodiment, the panel may be pixelated with colour mixing pallets CMY, RYB, RGB, CMYK, etc. Using colour mixing theory, it can be possible to access the full colour spectrum by colouring or bleaching colours. More colours may be needed to achieve depth of colour. In one embodiment, the channels or pixels may be patterned to form varying patterns and shapes of colour.
[0102] FIG. 9 is a schematic view of an electrochromic device 800 according to an embodiment. In this embodiment, the electrochromic device 800 includes a plurality of electrochromic stacks 813 such that one or more electrochromic stacks 813 is positioned on top of another electrochromic stack 813 to form a multi-stack electrochromic device 800. The multi-layered electrochromic device 800 may optionally comprise an insulator 802 and / or insulator 818 between stacks 813. Each stack 813 comprises transparent conductor layers, such as transparent conductor layers 828, 820, 816, 804, and 108 shown in FIG. 9, such that an observer can look through the entire stack 813 to visually see a bottom layer (e.g., of lowermost stack 813) of the device 800. In this embodiment, each colour change produced within each stack 813 can be controlled (turned on or off) as required for visualizing a plurality of desired colours.
[0103] In this embodiment, a voltage V can be applied across any one or more of the plurality of electrochromic stacks 813, for example, if a voltage is applied between the conductor layer 104 and transparent conductor layer 108, the colour of electrochromic layer 107 can change. If a voltage is appliedbetween the transparent conductor layer 804 and transparent conductor layer 816, the colour of electrochromic layer 810 can change. If a voltage is applied between the transparent conductor layer 820 and transparent conductor layer 828, the colour of electrochromic layer 826 can change. This can enable colour mixing of any colours (e.g., CMY, RYB, RGB, CMYK, or the like) to achieve the desired colour. The stack 113 may further comprise ion storage layers 105, 806, and 822. The stack may further comprise electrolyte layers 106, 808, and 824.
[0104] FIGS. 10A to 101 provide schematic views of additional electrochromic devices, according to various embodiments. Electrochromic device 911 A provides an electrochromic device according to one embodiment. In this embodiment, the electrochromic device 911 A includes: a panel layer 101 , an adhesive layer 102, a substrate layer 103, a conductor layer 104, an ion storage layer 105, an electrolyte layer 106, an electrochromic layer 107, a transparent conductor layer 108, and a protective overcoat layer 109.
[0105] Device 911 B provides an electrochromic device according to another embodiment. In this embodiment, the ion storage layer 105 is formed above the electrochromic layer 107 and the electrolyte layer 106. As such, the electrochromic device 911 B provides the following configuration: a panel layer 101 , an adhesive layer 102, a substrate layer 103, a conductor layer 104, an electrochromic layer 107, an electrolyte layer 106, ion storage layer 105, a transparent conductor layer 108, and a protective overcoat layer 109.
[0106] Device 911C provides an electrochromic device according to another embodiment. In this embodiment, the ion storage layer 105 is omitted. As such, the electrochromic device 911 C provides the following configuration: a panel layer 101 , an adhesive layer 102, a substrate layer 103, a conductor layer 104, an electrolyte layer 106, an electrochromic layer 107, a transparent conductor layer 108, and a protective overcoat layer 109.
[0107] Device 911 D provides an electrochromic device according to another embodiment. In this embodiment, the ion storage layer 105 is omitted, and the electrolyte layer 106 is above the electrochromic layer 107. As such,the electrochromic device 911 D provides the following configuration: a panel layer 101 , an adhesive layer 102, a substrate layer 103, a conductor layer 104, an electrochromic layer 107, an electrolyte layer 106, a transparent conductor layer 108, and a protective overcoat layer 109.
[0108] Device 911 E provides an electrochromic device according to another embodiment. In this embodiment, the electrochromic layer 107 is mixed with the electrolyte layer 106. As such, the electrochromic device 911 E provides the following configuration: a panel layer 101 , an adhesive layer 102, a substrate layer 103, a conductor layer 104, ion storage layer 105, a combined electrolyte and electrochromic layer 910, a transparent conductor layer 108, and a protective overcoat layer 109.
[0109] Device 911 F provides an electrochromic device according to another embodiment. In this embodiment, the electrochromic layer 107 is mixed with the electrolyte layer 106; and the ion storage layer 105 is above the electrochromic and electrolyte mixed layer. As such, the electrochromic device 911 F provides the following configuration: a panel layer 101 , an adhesive layer 102, a substrate layer 103, a conductor layer 104, a combined electrolyte and electrochromic layer 910, ion storage layer 105, a transparent conductor layer 108, and a protective overcoat layer 109.
[0110] Device 911G provides an electrochromic device according to another embodiment. In this embodiment, the electrolyte layer 106 and the ion storage layer 105 are omitted. As such, the electrochromic device 911G provides the following configuration: a panel layer 101 , an adhesive layer 102, a substrate layer 103, a conductor layer 104, an electrochromic layer 107, a transparent conductor layer 108, and a protective overcoat layer 109.
[0111] Device 911 H provides an electrochromic device according to another embodiment. In this embodiment, the electrochromic layer 107 is mixed with the electrolyte layer 106; and the ion storage layer 105 is omitted. As such, the electrochromic device 911 H provides the following configuration: a panel layer 101 , an adhesive layer 102, a substrate layer 103, a conductorlayer 104, a combined electrolyte and electrochromic layer 910, a transparent conductor layer 108, and a protective overcoat layer 109.
[0112] Device 9111 provides an electrochromic device according to another embodiment. In this embodiment, the electrochromic layer 107 is mixed with the electrolyte layer 106 and the ion storage layer 105 to form combined layer 912. As such, the electrochromic device 9111 provides the following configuration: a panel layer 101 , an adhesive layer 102, a substrate layer 103, a conductor layer 104, a combined electrolyte, electrochromic layer and ion storage layer 912, a transparent conductor layer 108, and a protective overcoat layer 109.
[0113] A method 1300 of fabricating an electrochromic device is also described herein and shown in FIG. 11 . An electrochromic device according to at least one embodiment described herein can be made on a thin film (e.g., less than about 5 mm) substrate layer 103.
[0114] At a first step 1310 of the method 1300, a stack of electrochromic layers is prepared. In a first embodiment, layers 104 to 109 can be printed onto layer 103. In another embodiment, a plurality of films may be produced and then laminated together. This can be accomplished by making a first film component of layers 103 to 105, and another film component of layers 107 to 109. The film components can then be laminated together using the electrolyte layer 106 as the interfacial bonding layer.
[0115] In one embodiment, a first material layer can be used as a lamination layer. The first material layer can comprise any of the material layers including, but not limited to, the electrolyte layer 106, the electrochromic layer 107, etc. The following method steps are explained using the embodiment shown in device 911 Afor illustrative purposes, it can be understood that the method may be applied to form other embodiments of electrochromic stack layers. Using the embodiment shown in device 911 A, substrate layer 103 to 105 comprise a first partial stack constructed by suitable print methods. The electrochromic layer 107, the conductor layer 108 and the protective overcoat layer 109 cancomprise a second partial stack constructed by suitable print methods. The electrolyte layer 106 can then be printed onto at least one of the first or second partial stack. The first partial stack and the second partial stack can then be laminated together. In this embodiment, the electrolyte layer 106 acts as both the electrolyte and a lamination glue. The lamination glue can be activated via heat, UV, chemical bonding or other method. In another embodiment, a lamination glue can be applied to at least one of the first or second partial stacks prior to lamination. The step 1310 can also be completed by starting from the substrate layer 103 and printing each subsequent layer to the previous layer.
[0116] In another embodiment, a film with the transparent conductor layer 108 may be provided and the subsequent layers in reverse order 107 to 102 can be printed thereupon. In another embodiment, a film with the conductor layer 104 may be provided and layers 105 to 109 can be printed thereupon. In another embodiment, a protective overcoat film 109 may be provided and the subsequent layers in reverse order 108 to 103 can be printed thereupon. As such, the protective overcoat film 109 may act as the substrate layer in some embodiments.
[0117] In one embodiment, slot die coating can be used as a print method to prepare the electrochromic film because it can generate large area films to very high tolerance levels (nm thickness). In another embodiment, a combination of print techniques may be used. Other large area capable solution print methods include, but are not limited to, offset printing, flexography, rotogravure, inkjet, doctor blading, bar coating and spray coating.
[0118] At step 1320, electrical connections 1322 can be formed to the panel. In one embodiment, the electrical connections are coupled to at least one of the conductor layers 104, 108. In one embodiment, conductive strips can be used to form electrical connections with the conductor layers. The electrical connections can have a connection to transition to traditional wired electronics for ease of connectivity. In one embodiment, the electrical connections can be formed at step 1310 when the electrochromic stack is being prepared.
[0119] At step 1330, the electrochromic film 110 of the stack of electrochromic layers can then be adhered (e.g., laminated) to a panel layer 101 using an adhesive layer 102. Adhesive layer 102 can be applied during lamination. The adhesive layer 102 can be formed as a part of the electrochromic film with a release layer that can be removed during lamination.
[0120] In one embodiment, the electrochromic stack laminated to the panel layer can be cut to a desired size. In one example, the length of the panels can be 8 ft, 10 ft, 12 ft, 16 ft, or 20 ft panels, but it can be understood that any suitable panel size is acceptable.
[0121] At step 1340, the panels can be installed to a wall or other structure. In one example, wiring can be installed to the walls or structures. The wiring may be formed inside wall trim, baseboards, crown mouldings, or through wall outlets. The wiring may include connection points through or behind the studs of walls. The connection points can include snap connectors to electrically connect the electrochromic panel to a power source. The completed electrochromic panel, including the panel layer 101 can be installed and electrically connected to the connection points 1322 applied to the panel in step 1320. A connection wire can be attached to a controller which regulates power and takes user inputs.
[0122] The above methods may be combined in any way to develop another method of fabricating the electrochromic device.
[0123] FIG. 12A and 12B show magnified schematic views of an electrochromic device, according to at least embodiment described herein. In one example embodiment, a user may purchase a digital paint panel 1 11 with an electrochromic film 1 10 applied. In another example embodiment, a user may purchase a kit comprising the digital paint panel 11 1 , an electrochromic film 110 and an adhesive mechanism 102. In another example embodiment, the user may purchase the electrochromic film 110 separately to install the electrochromic film 110 on an existing panel 11 1. The digital paint panels 111 can be installed in a built environment as a wall, ceiling and or floor finish. The required electrical connections can be made between the digital paint panel111 and a control module (not shown) during installation. The control module and electrical connections can be compatible with standard residential and commercial building power specifications and electrical outlets, respectively. The control module can provide for a user to apply a specific voltage to the digital paint panel 111 that serves as the electrical excitation or stimuli to activate the colour state.
[0124] While the applicant's teachings described herein are in conjunction with various embodiments for illustrative purposes, it is not intended that the applicant's teachings be limited to such embodiments. On the contrary, the applicant's teachings described and illustrated herein encompass various alternatives, modifications, and equivalents, without departing from the embodiments, the general scope of which is defined in the appended claims.
Claims
CLAIMSWhat is claimed is:
1. An electrochromic device for producing a colour change, the device comprising: a first power source; a panel layer configured to support a stack of electrochromic layers; and the stack of electrochromic layers comprising: a first conductor layer disposed on the panel layer; an electrolyte layer disposed on the first conductor layer; an electrochromic layer disposed on the electrolyte layer, the electrochromic layer comprising an electrochromic material; and a second conductor layer coupled to the electrochromic layer, the second conductor layer being transparent; wherein, when the first power source applies a voltage between the first conductor layer and the second conductor layer, the electrochromic material undergoes a transition between a bleached state and an unbleached state, the bleached state and the unbleached state being different colours, to produce the colour change.
2. The electrochromic device of claim 1 , wherein the stack of electrochromic layers further comprises an overcoat layer disposed on the second conductor layer, the second conductor layer and the overcoat layer both being optically transparent.
3. The device of claim 1 or claim 2, wherein the stack of electrochromic film layers further comprises an adhesive layer coated on the panel layer.
4. The device of 3, wherein the stack of electrochromic layers further comprises a substrate layer coated on the adhesive layer.
5. The device of claim 3 or claim 4, wherein the stack of electrochromic layers further comprises an ion storage layer applied to the first conductor layer.
6. The device of any one of claims 3 to 5, wherein the stack of electrochromic layers further comprises an overcoat layer applied to the second conductor layer.
7. The device of any one of claims 1 to 6, wherein the electrochromic layer comprises a polymeric material.
8. The device of claim 7, wherein the polymeric material comprises at least one of: Poly(3,4-ethylene dioxythiophene) (EDOT), Poly(3,4- ropylenedioxythiophene) (ProDOT), Poly(3,4-propylenedioxypyrrole) (ProDOP), Poly(3,4-ethylenedioxypyrrole) (EDOP), Poly(pyrrole) (Pyr), Poly(thiophene) (Th), Poly(thieno(3,2-b)thiophene), poly(dithieno(3,2-b:2',3'- d)thiophene), poly(diketopyrrolopyrrole) (DPP), Poly(cyclopenta[2,1-b:3,4-b']- dithiophene) (CPDT), Poly(2-benzofuran), Poly(2,1 ,3-benzoxadiazole), Poly(2,1 ,3-benzothiadiazole), Poly(1 ,2,3-benzotriazole), Poly(quinoxaline), Poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOTPSS), Poly(isoindigo), Poly(1 ,4-dioxylbenzene), Poly(alicyclic nonliner dianhydride), Poly(phthalimide), Poly(2,3-bis-phenyl-quinoxaline), Poly(anthracene), Poly(carbazole) (Cbz), Poly(benzodithiophene), Poly(1 ,7-dihydro-s-indacene), Poly(benzo[1 ,2-c:4,5-c']bis([1 , 2, 5]thiadiazole)), and Poly(triphenylamine) (TAA).
9. The device of any one of claims 1 to 8, wherein the colour of the unbleached state comprises a combination of cyan, magenta, yellow, and / or black.
10. A system for producing a colour change, the system comprising: the electrochromic device of any one of claims 1 to 10; anda processing device coupled to the first power source and configured to control when the voltage is applied to the electrochromic device.11 . A method of producing a colour change with an electrochromic device, the method comprising: providing a panel layer of an electrochromic device; providing a stack of electrochromic layers on the panel layer, the stack of electrochromic film layers comprising: a first conductor layer disposed on the panel layer; an electrolyte layer disposed on the first conductor layer; an electrochromic layer disposed on the electrolyte layer, the electrochromic layer comprising an electrochromic material; and a second conductor layer coupled to the electrochromic layer, the second conductor layer being transparent; and applying a voltage between the first conductor layer and the second conductor layer to produce the colour change.
12. The method of claim 11 , wherein the stack of electrochromic layers further comprises an overcoat layer disposed on the second conductor layer, the second conductor layer and the overcoat layer both being optically transparent.
13. The method of claim 11 or claim 12, wherein the stack of electrochromic film layers further comprises an adhesive layer coated on the panel layer.
14. The method of claim 13, wherein the stack of electrochromic layers further comprises a substrate layer coated on the adhesive layer.
15. The method of claim 13 or claim 14, wherein the stack of electrochromic layers further comprises an ion storage layer applied to the first conductor layer.
16. The method of any one of claims 13 to 15, wherein the stack of electrochromic layers further comprises an overcoat layer applied to the second conductor layer.
17. The method of any one of claims 11 to 16, wherein the electrochromic layer comprises a polymeric material.
18. The method of claim 17, wherein the polymeric material is a EDOT based polymer.
19. The method of claim 17, wherein the polymeric material is a ProDOT based polymer.
20. The method of any one of claims 11 to 19, wherein the colour of the unbleached state comprises a combination of cyan, magenta, yellow, and / or black