Ultraviolet‐curable electrolyte medium for an electrochromic device and method of manufacturing the electrochromic device with the ultraviolet‐curable electrolyte medium

Abstract

An ultraviolet‐curable (UV‐curable) electrolyte medium for an electrochromic device, the UV‐ curable electrolyte medium including: a low‐volatility solvent; an ionic salt at least partially dissolved in the low‐volatility solvent; a UV‐curable monomer or oligomer at least partially dissolved in the low‐ volatility solvent; and a photoinitiator. A method of manufacturing an electrochromic device, the method including: a depositing step including depositing a UV‐curable electrolyte medium onto a first electrode of a first workpiece; a wet‐laminating step including bringing together the first workpiece and a second workpiece with a second electrode layer such that the UV‐curable electrolyte medium is sandwiched between the first electrode layer and the second electrode layer thus forming a laminated workpiece; and a curing step including irradiating the UV‐curable electrolyte medium with ultraviolet electromagnetic radiation while translating the laminated workpiece.

Description

ULTRAVIOLET-CURABLE ELECTROLYTE MEDIUM FOR AN ELECTROCHROMIC DEVICE AND METHOD OF MANUFACTURING THE ELECTROCHROMIC DEVICE WITH THE ULTRAVIOLET-CURABLE ELECTROLYTE MEDIUMFIELD OF THE DISCLOSURE

[0001] The present disclosure generally relates to an ultraviolet-curable electrolyte medium for an electrochromic device, and more particularly to a method of making the electrochromic device with the ultraviolet-curable electrolyte medium in an ambient environment by performing a wetlamination step soon after a depositing step that deposits the ultraviolet-curable electrolyte medium and before a curing step that cures the ultraviolet- curable electrolyte medium.BACKGROUND

[0002] Electrochromic devices are utilized to alter optical properties as a function of changing electrical input. Such electrochromic devices sometimes include an electrochromic material disposed between a pair of substrates. At least one of the pair of substrates exhibits a degree of optical transparency. The electrochromic medium likewise exhibits a degree of transparency (e.g., transmittance, or some other optical property) that can change as a function of the changing electrical input. Thus, electrical manipulation of the electrochromic material alters an overall optical transparency or reflectivity of the electrochromic device perceived by a viewer. Applications for electrochromic devices include windows, display covers, rearview mirrors, among other things.

[0003] In some instances, the electrochromic medium is an electrolyte medium. The electrochromic device can then include a cathodic electro-optic film disposed on one substrate and an anodic electro- optic film disposed on the other substrate also facing the electrolyte medium. The electrolyte medium is sandwiched between the cathodic electro-optic film and the anodic electro-optic film.SUMMARY

[0004] It can be desirable to manufacture such film-containing electrochromic devices with roll-to- roll equipment in an open environment (e.g., exposed to air, standard temperature and pressure). The cathodic electro-optic film can be applied onto one of the substrates, the anodic electro-optic film can be applied onto the other of the substrates, the electrolyte medium can be applied over at least one of the cathodic electro-optic film and the anodic electro-optic film, and the two substrates can be laminated together.

[0005] In the development of that roll-to-roll process, solution-based formulations for the electrolyte medium have been used. The solution-based formulations include a salt, a low-volatility solvent, a polymer binder, and a carrier solvent. The carrier solvent dilutes the polymer sufficiently to renderthe formulation suitable for coating onto the selected film as the substrate is moving. The electrolyte medium, on the film over the substrate, is then dried by removing the carrier solvent. The two substrates can then be laminated together as mentioned.

[0006] However, there is a problem in that the electrolyte medium can be hygroscopic (e.g., absorbs water from the air). The hygroscopic nature of the electrolyte medium is problematic because the addition of water changes the formulation of the electrolyte medium, which negatively impacts the performance thereof. A significant amount of time can elapse between application of the electrolyte medium and lamination (e.g., the sealing of the electrolyte medium from the atmosphere) to accommodate the removal of the carrier solvent. The greater the amount of time, the greater the amount of water that can enter the formulation of the electrolyte medium.

[0007] The present disclosure addresses that problem in several ways. The electrolyte medium is made to be ultraviolet (UV) curable (e.g., curable due to impingement from electromagnetic radiation of one or more ultraviolet wavelengths). The UV-curable electrolyte medium is deposited upon an electrode layer of a workpiece, such as part of a rol l-to-roll process. Soon after, the workpiece and another workpiece, which includes another electrode layer, are brought together and laminated to form a laminated workpiece. The laminated workpiece is then subjected to a curing step where the UV-curable electrolyte medium is irradiated with ultraviolet electromagnetic radiation to at least partially cure the UV-curable electrolyte medium. The UV-curable electrolyte medium is closed off from the water in the ambient atmosphere via the lamination step. The two electrode layers isolate the UV-curable electrolyte medium from the ambient atmosphere. The curing step occurs later, after lamination, and takes advantage of the ultraviolet electromagnetic radiation being transmissible through the electrode layers of the laminated workpiece to irradiate the UV-curable electrolyte medium laminated therebetween.

[0008] According to a first aspect of the present disclosure, an ultraviolet-curable (UV-curable) electrolyte medium for an electrochromic device, the UV-curable electrolyte medium comprises: a low-volatility solvent; an ionic salt at least partially dissolved in the low-volatility solvent; a UV- curable monomer or oligomer at least partially dissolved in the low-volatility solvent; and a photoinitiator.

[0009] According to another aspect of the present disclosure, a method of manufacturing an electrochromic device, the method comprises: (A) a translating step comprising translating (i) a first workpiece comprising a first substrate, a first conductive layer disposed on the first substrate, and afirst electrode layer disposed on the first conductive layer and (ii) a second workpiece comprising a second substrate, a second conductive layer disposed on the second substrate, and a second electrode layer disposed on the second conductive layer; (B) a depositing step comprising depositing a UV-curable electrolyte medium onto either the first electrode of the first workpiece or the second electrode of the second workpiece; (C) a wet-laminating step comprising bringing together the first workpiece and the second workpiece such that the UV-curable electrolyte medium is sandwiched between the first electrode layer and the second electrode layer thus forming a laminated workpiece; and (D) a curing step comprising irradiating the UV-curable electrolyte medium with ultraviolet electromagnetic radiation while translating the laminated workpiece.

[0010] These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] In the Drawings:

[0012] FIG. 1 is an elevation view of a cross-section of an electrochromic device, illustrating an electrolyte medium sandwiched between a first substrate and a second substrate;

[0013] FIG. 2 is a flow-chart of a method of manufacturing the electrochromic device, illustrating a translating step, a depositing step, a wet-laminating step, and a curing step; and

[0014] FIG. 3 is schematic diagram of the method as a roll-to-rol I process.DETAILED DESCRIPTION

[0015] The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to an electrochromic device. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

[0016] For purposes of description herein, the terms "upper," "lower," "right," "left," "rear," "front," "vertical," "horizontal," and derivatives thereof, shall relate to the disclosure as oriented in FIG. 1. Unless stated otherwise, the term "front" shall refer to a surface of the device closest to an intendedviewer, and the term "rear" shall refer to a surface of the device furthest from the intended viewer. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

[0017] The terms "including," "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by "comprises a . . . " does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

[0018] Referring to FIG. 1, an electrochromic device 10 with an electrolyte medium 12 of the present disclosure is herein disclosed.

[0019] In addition to the electrolyte medium 12, the electrochromic device 10 can include a first substrate 14 and a second substrate 16. The electrolyte medium 12 is sandwiched between the first substrate 14 and the second substrate 16. The first substrate 14 includes an inward facing surface 18 and an outward facing surface 20. The second substrate 16 likewise includes an inward facing surface 22 and an outward facing surface 24. The inward facing surface 18 of the first substrate 14 and the inward facing surface 22 of the second substrate 16 face each other. The electrolyte medium 12 is sandwiched between the inward facing surface 18 of the first substrate 14 and the inward facing surface 22 of the second substrate 16. The outward facing surface 20 of the first substrate 14 and the outward facing surface 24 of the second substrate 16 face away from each other. The outward facing surface 20 and inward facing surface 18 of the first substrate 14, and the outward facing surface 24 and inward facing surface 22 of the second substrate 16, can all be planar and parallel to each other.

[0020] The first substrate 14 and the second substrate 16 can each be made of, or include, glass, plastic, or other optically transparent or translucent material(s), non-limiting examples of which include borosilicate glass, soda lime glass, or polymeric materials, such as natural and synthetic polymeric resins, plastics, and / or composites. Non-limiting examples of such include polyesters (e.g.,PET), polyimides (PI), polycarbonates, polysulfones, polyethylene naphthalate (PEN), ethylene vinyl acetate (EVA), acrylate polymers, as well as cyclic olefin copolymers (COC) (such as those commercially available from TOPAS® Advanced Polymers). In some aspects, both the first substrate 14 and the second substrate 16 are made of an optically transparent or translucent material, while, in other aspects, only one the first substrate 14 and the second substrate 16, is made of an optically transparent or translucent material. The first substrate 14 and the second substrate 16 can be made from the same or different materials and may have the same or different dimensions.

[0021] The electrochromic device 10 can further include a first conductive layer 26 and a second conductive layer 28. The first conductive layer 26 can be disposed on the inward facing surface 18 of the first substrate 14, either directly or with an interlayer (not illustrated) therebetween. The second conductive layer 28 can be disposed on the inward facing surface 22 of the second substrate 16, either directly or with an interlayer (not illustrated) therebetween. The electrolyte medium 12 is sandwiched between the first conductive layer 26 and the second conductive layer 28.

[0022] The first conductive layer 26 and the second conductive layer 28 may serve to inject and / or accept electrons to facilitate oxidation and / or reduction reactions for the electrochromic device 10. The first conductive layer 26 and the second conductive layer 28 are electrically conductive. The first conductive layer 26 and the second conductive layer 28 can be made of, or include, any material that includes one or more of the following features: (a) substantially transparent to electromagnetic radiation in the visible and / or infrared wavelength ranges; (b) bonds reasonably well to the first substrate 14 and the second substrate 16, as the case may be; (c) generally resistant to corrosion from materials contained within the electrochromic device 10 or the atmosphere; and / or (d) exhibits minimal diffuse or specular reflectance as well as sufficient electrical conductance. Depending on the application, only one of the first conductive layer 26 and the second conductive layer 28 may be required to be transparent while the other of the first conductive layer 26 and the second conductive layer 28 may be opaque. In some applications, both the first conductive layer 26 and the second conductive layer 28 are transparent (e.g., to desired wavelengths of electromagnetic radiation). According to some aspects, one of the first conductive layer 26 and the second conductive layer 28, such as the second conductive layer 28, may include a metal reflector or one or more coatings configured as a partially reflective, partially transmissive ("transflective") coating. Inclusion of a metal reflector or a transflective coating may render the electrochromic device 10 at least partially reflective. Accordingly, the material(s) forming the first conductive layer 26 and the secondconductive layer 28 may be the same or different. Non-limiting examples of material that may be used to form one or both of the first conductive layer 26 and the second conductive layer 28 can include transparent conductive oxides (TCOs), such as fluorine doped tin oxide (FTO), for example TEC™ glass, indium tin oxide (ITO), doped zinc oxide, indium zinc oxide (IZO), aluminum doped zinc oxide (AZO), and metal oxide / metal / metal oxide (where the metal oxide can be substituted with metal carbide, metal nitride, metal sulfide, etc.).

[0023] The electrochromic device 10 can further include a first electrode layer 30 and a second electrode layer 32. The first electrode layer 30 is disposed on the first conductive layer 26, with the first conductive layer 26 sandwiched between the inward facing surface 18 of the first substrate 14 and the first electrode layer 30. The second electrode layer 32 is disposed on the second conductive layer 28, with the second conductive layer 28 sandwiched between the inward facing surface 22 of the second substrate 16 and the second electrode layer 32. The electrolyte medium 12 is sandwiched between the first electrode layer 30 and the second electrode layer 32.

[0024] The first electrode layer 30 and the second electrode layer 32 may serve to undergo redox reactions based on the gaining or losing of electrons from or to the first conductive layer 26 or the second conductive layer 28, as the case may be, and the insertion or extraction of ions from or to the electrolyte medium 12. One of the first electrode layer 30 and the second electrode layer 32 is, or includes, a cathodic material, such as a material that changes transparency and / or color upon reduction. The other of the first electrode layer 30 and the second electrode layer 32 is, or includes, an anodic material. In some instances, one of the first electrode layer 30 and the second electrode layer 32 is a thin film of the cathodic material or the anodic material, while the other of the first electrode layer 30 and the second electrode layer 32 is a thin film of the other of the cathodic material and the anodic material. In other instances, one of the first electrode layer 30 and the second electrode layer 32 includes the cathodic material dispersed in a polymeric gel matrix, while the other of the first electrode layer 30 and the second electrode layer 32 includes the anodic component dispersed in a polymeric gel matrix. In such instances, the cathodic material and the anodic material can be mobile with the polymeric gel matrix.

[0025] The cathodic material can be, or include, a viologen or a metal oxide, such as tungsten, among other options. Exemplary viologens include, but are not limited to, methyl viologen, octyl viologen, benzyl viologen, and polymeric viologens. In one aspect, the cathodic material is, or includes, an octyl viologen. In some aspects, the cathodic component may include crystalline or nanocrystallinetungsten oxide (WOX, where x is 2.6 < x <3.4), vanadium oxide (V2O5), nickel oxide (NiO), ferrocenium, perovskite materials, such as samarium nickelate (SmNiC ), or other metal oxides of the formula AyBzOx, where A and B are metals. The relative amounts of components A and B may vary such that y and z may individually be any value from about 1 to about 20. For example, y and z may individually be any value from about 1 to about 20, about 1 to about 15, about 1 to about 10, about 1 to about 5, or about 1 to about 3. The amount of oxygen present in metal oxides of the formula AyBzOxmay vary at least in part based on the oxidation states of the metals A and B and their relative amount in the film. According to one aspect, the value of x will nominally be at a level sufficient to attain stoichiometry. For example, the value of x may be from about 80% to about 120% of the stoichiometric value. In some examples, the value of x may be from about 80% to about 120%, about 80% to about 110%, about 80% to about 100%, about 90% to about 120%, about 90% to about 110%, about 90% to about 100%, about 95% to about 120%, about 95% to about 110%, about 95% to about 105%, or about 90% to about 100% of stoichiometry. The concentration of the cathodic material when disposed within a polymeric gel matrix can be about 10 millimolar (mM) to about 200 mM.

[0026] The anodic material can be one or more of a metallocene, a 5,10-dihydrophenazine, a phenothiazine, a phenoxazine, a carbazole, a triphendioxazine, a triphenodithiazine, a ferrocene, a substituted ferrocene, a substituted ferrocenyl salt, a phenazine, a substituted phenazine, and a substituted phenothiazine, including a substituted dithiazine, thianthrene, and a substituted thianthrene, di-tert-butyl-diethylferrocene, 5,10-dimethyl-5,10-dihydrophenazine (DMP), bis(triethylaminopropyl)dihydrophenazine bis(tetrafluoroborate), 3,7,10-trimethylphenothiazine, 2,3,7,8-tetramethoxy-thianthrene, 10-methylphenothiazine, tetramethylphenazine (TMP), 5,10- triethylammoniumpropylphenazine, and bis(butyltriethylammonium)-para- methoxytriphenodithiazine (TPDT). In one aspect, the anodic component includes 5,10-dihydro- 5,10-dimethylphenazine. In another aspect, the anodic component includes a combination of 5,10- dihydro-5,10-dimethylphenazine and 5,10-dineopentyl-5,10-dihydro-2,7-di-isobutylphenazine, 5,10- triethylammoniumpropylphenazine. The total concentration of anodic components can be about 10 mM to about 130 mM, when disposed in a polymeric matrix.

[0027] In other instances, the anodic material can be, or include, nickel oxide (NiO), nickel tungsten oxide (NiWO), nickel vanadium oxide, nickel chromium oxide, nickel aluminum oxide, nickel manganese oxide, nickel magnesium oxide, chromium oxide (CrzOs), manganese oxide (MnO?),Prussian blue, cerium titanium oxide (CeO2— TiO2), cerium zirconium oxide (CeO2— ZrO2), nickel oxide (NiO), nickel-tungsten oxide (NiWO), or vanadium oxide (V2O5).

[0028] The electrolyte medium 12 can facilitate movement of ions (e.g., alkali metal ions) between the first electrode layer 30 and the second electrode layer 32. The electrolyte medium 12 includes an ionic salt dispersed within a polymeric matrix (e.g., the result of at least partially curing a monomer / oligomer composition). The ionic salt can be a metal salt or an ammonium salt, among other options. The ionic salt includes cations and anions. The electrolyte medium 12 can include one or more of the following cations: H+, alkali metal cations, such as Li+, Na+, and K+, alkaline metal cations, such as Ca2+, Ba2+, and Sr2+, Mg+, NR'4+(where each R' is individually H, alkyl, or cycloalkyl), among other options. The cation can be a cation of tetramethylammonium, tetraethylammonium, or tetrabutylammonium, or combinations thereof. The electrolyte medium 12 can include one or more of the following anions: F“, Cl-, Br“, I", BFT, PFe“, SbFe“, AsFe“, CIO4-, SO3CF3“, N(CF3SO2)2“, C(CF3SO2)3“, N(SO2C2F5)2, AI(OC(CF3)3)4", BAr4 ", or mixtures of anions thereof, where Ar is an aryl or fluorinated aryl group. It can be noted however that fluorine-containing ions can lead to corrosion of the first conductive layer 26 and the second conductive layer 28.

[0029] The polymeric matrix of the electrolyte medium 12 can be the result of at least partially curing one or more curable monomers or oligomers. Such one or more curable monomers and oligomers include poly(ethylene glycol) methyl ether methacrylate, a difunctional aliphatic urethane acrylate, 1,4-butanediol diacrylate, tris[2-(acryloyloxy)ethyl] isocyanurate, polypropylene glycol) diacrylate, polypropylene glycol) dimethacrylate, poly(ethylene glycol) diacrylate, trimethylolpropane propoxylate triacrylate, 1,4-butanediol divinyl ether, methyl methacrylate, methyl acrylate, isocyanatoethyl methacrylate, 2-isocyanatoethyl acrylate, 2-hydroxyethyl methacrylate, 2- hydroxyethyl acrylate, 3-hydroxypropyl methacrylate, glycidyl methacrylate, 4-vinylphenol, acetoacetoxy methacrylate, and acetoacetoxy acrylate.

[0030] The electrochromic device 10 can include a sealing member 34. The sealing member 34 can be any suitable structure for sealing a perimeter of the electrochromic device 10 to isolate the first conductive layer 26, the second conductive layer 28, the first electrode layer 30, the second electrode layer 32, and the electrolyte medium 12 from ambient oxygen and / or moisture. In one aspect, the sealing member 34 may be a heat seal film which attaches to the first substrate 14 and the second substrate 16 around a perimeter of the electrochromic device 10. In one aspect, the sealing member34 contacts, and is sandwiched between, the inward facing surface 18 of the first substrate 14 and the inward facing surface 22 of the second substrate 16.

[0031] The electrolyte medium of the electrochromic device 10 can be a product of at least partially curing an ultraviolet -curable electrolyte medium 36 (see FIG. 3) of the present disclosure. The UV- curable electrolyte medium 36 includes a low-volatility solvent, an ionic salt, a UV-curable monomer or oligomer, and a photoinitiator. The ionic salt is at least partially dissolved in the low-volatility solvent, as is the UV-curable monomer or oligomer. The photoinitiator may be dissolved in the low- volatility solvent as well.

[0032] The low-volatility solvent is "low-volatility" in the sense that it exhibits a boiling point that is greater than or equal to 150 °F ("'65.56 °C). The low-volatility solvent can be, or include, one or more of 3-methylsulfolane, dimethyl sulfoxide, dimethyl formamide, tetraglyme, ethoxyethanol, acetonitrile, glutaronitrile, 3-hydroxypropionitrile, 2-methylglutaronitrile, 2-acetylbutyrolactone, beta-propiolactone, y-butyrolactone, y-valerolactone, propylene carbonate, and ethylene carbonate. In embodiments, the low-volatility solvent is propylene carbonate. In embodiments, the electrolyte medium is substantially free of a non-low-volatility solvent (e.g., exhibits a boiling point of less than 150 °F).

[0033] As mentioned, the ionic salt can be, or include, a metal salt or an ammonium salt. In some aspects, the metal salt is, or includes, one or more of lithium triflate, lithium perchlorate, sodium triflate, and sodium perchlorate. In some aspects, the ammonium salt is, or includes, a cation of one or more of tetramethylammonium, tetraethylammonium, and tetrabutylammonium. The ionic salt can include one or more of the following cations: H+, alkali metal cations, such as Li+, Na+, and K+, alkaline metal cations, such as Ca2+, Ba2+, and Sr2+, Mg+, NR'4+(where each R' is individually H, alkyl, or cycloalkyl), among other options. The ionic salt can include one or more of the following anions: F“, cr, Br, r, BF4", PF6", SbF6“, ASF6“, CIO4", SO3CF3“, N(CF3SO2)2“, C(CF3SO2)3“, N(SO2C2F5)2, AI(OC(CF3)3)4~, and BAr4 ", where Ar is an aryl or fluorinated aryl group. It should be understood that that the ionic salt is at least partially in a dissociated state while at least partially dissolved within the low-volatility solvent.

[0034] The UV-curable monomer or oligomer can be any monomer and / or oligomer that is capable of being at least partially cured, with the assistance of the photoinitiator, when irradiated with ultraviolet electromagnetic radiation. The UV-curable monomer or oligomer can be, or include, one or more of an acrylate, a methacrylate, and a vinyl ether. More particular examples for the UV-curable monomer or oligomer include one or more of poly(ethylene glycol) methyl ether methacrylate, a difunctional aliphatic urethane acrylate, 1,4-butanediol diacrylate, tris[2- (acryloyloxy)ethyl] isocyanurate, polypropylene glycol) diacrylate, polypropylene glycol) dimethacrylate, polypthylene glycol) diacrylate, trimethylolpropane propoxylate triacrylate, 1,4- butanediol divinyl ether, methyl methacrylate, methyl acrylate, isocyanatoethyl methacrylate, 2- isocyanatoethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxyethyl acrylate, 3-hydroxypropyl methacrylate, glycidyl methacrylate, 4-vinylphenol, acetoacetoxy methacrylate, and acetoacetoxy acrylate. In embodiments, the UV-curable monomer or oligomer is a combination of polypthylene glycol) methyl ether methacrylate and a difunctional aliphatic urethane acrylate. A commercially available difunctional aliphatic urethane acrylate is BRC-843D (Bomar, Torrington, Connecticut, USA).

[0035] The photoinitiator can be any photoinitiator capable of initiating polymerization of the UV- curable monomer or oligomer when irradiated with ultraviolet electromagnetic radiation. Suitable examples of the photoinitiator include one or more of 1-Hydroxy-cyclohexyl-phenyl-ketone (Irgacure® 184), 2-Hydroxy-2-methylpropiophenone, 2,2-dimethoxy-2-phenylacetophenone (Irgacure® 651), 2,2-diethoxyacetophenone, (diphenyl(2,4,6-trimethylbenzoyl)-phosphine oxide) (TPO), and phenyl bis(2,4,6-trimethylbenzoyl)phosphine oxide (Irgacure® 819). In embodiments, the photoinitiator is a combination of (diphenyl(2,4,6-trimethylbenzoyl)-phosphine oxide) (TPO) and phenyl bis(2,4,6-trimethylbenzoyl)phosphine oxide (Irgacure® 819).

[0036] Referring now to FIGS. 2 and 3, a method 100 of manufacturing the electrochromic device 10 is herein disclosed. The method 100 includes at least a translating step 102, a depositing step 104, a wet-laminating step 106, and a curing step 108.

[0037] The translating step 102 includes translating both a first workpiece 110 and a second workpiece 112. The first workpiece 110 and the second workpiece 112 are initially separated from each other. The first workpiece 110 includes the first substrate 14, the first conductive layer 26 disposed on the first substrate 14 (e.g., on what would subsequently be the inward facing surface 18 of the first substrate 14), and the first electrode layer 30 disposed on the first conductive layer 26. The second workpiece 112 includes the second substrate 16, the second conductive layer 28 disposed on the second substrate 16 (e.g., on what would subsequently be the inward facing surface 22 of the second substrate 16), and the second electrode layer 32 disposed on the second conductive layer 28. The translating step 102, and the method 100 generally, can be configured as a roll-to-rol I process. The first workpiece 110 can be formed and wound as a first roll 114, and the second workpiece 112can be formed and wound as a second roll 116. During the translating step 102, the first workpiece 110 and the second workpiece 112 are unwound from the first roll 114 and the second roll 116, respectively.

[0038] The depositing step 104 includes depositing the UV-curable electrolyte medium 36 onto either the first electrode layer 30 of the first workpiece 110 or the second electrode layer 32 of the second workpiece 112. A coating station 118 can be utilized to deposit the UV-curable electrolyte medium 36. The coating station 118 can be any suitable type of equipment for depositing the UV- curable electrolyte medium 36, such as a slot die for extrusion, a lamination system, a screen printing system, drawdown bars, Mayer rods (rod coating), gravure printing, a sol-gel process, spin coating, die casting, dip coating, or inkjet printing, for example. In embodiments, the depositing step 104 includes flowing the UV-curable electrolyte medium 36 through an outlet of a slot die onto either the first electrode layer 30 of the first workpiece 110 or the second electrode layer 32 of the second workpiece 112.

[0039] In any event, after the depositing step 104, the UV-curable electrolyte medium 36 is disposed on either the first electrode layer 30 or the second electrode layer 32. The illustration in the Drawings shows the first workpiece 110 being brought into or adjacent to the coating station 118 with the first electrode layer 30 thereof positioned to accept the deposition of the UV-curable electrolyte medium 36, while the second workpiece 112 is translated to bypass the coating station 118. The scenario could be reversed. The depositing step 104 and the translating step 102 can occur simultaneously but need not. During the depositing step 104, the UV-curable electrolyte medium 36 can have a gellike or film-like consistency.

[0040] The wet-laminating step 106 includes bringing together the first workpiece 110 and the second workpiece 112 such that the UV-curable electrolyte medium 36 is sandwiched between the first electrode layer 30 and the second electrode layer 32 thus forming a laminated workpiece 120. After the UV-curable electrolyte medium 36 is deposited, for example, onto the first electrode layer 30 of the first workpiece 110, the first workpiece 110 and the second workpiece 112 are translated to be adjacent to each other, such as between a pair of laminating rollers 122. The laminating rollers 122 can force the second electrode layer 32 of the second workpiece 112 and the UV-curable electrolyte medium 36 upon the first workpiece 110 to contact each other. The laminating rollers 122 may simultaneously heat treat the sealing member 34 upon either or both of the first workpiece 110 and the second workpiece 112 to fuse the sealing member 34 to either or both of the firstworkpiece 110 and the second workpiece 112. As a result of the wet-laminating step 106, the laminated workpiece 120 is formed. The laminated workpiece 120 is similar to the electrochromic device 10 described above but the UV-curable electrolyte medium 36 remains yet uncured (or uncured to a desired degree) so as to form the electrolyte medium 12.

[0041] In embodiments, a period of time of less than 10 seconds elapses between (i) when the UV- curable electrolyte medium 36 is deposited during the depositing step 104 and (ii) when the deposited UV-curable electrolyte medium 36 is sandwiched between the first electrode layer 30 and the second electrode layer 32 during the wet-laminating step 106. The period of time being less than 10 seconds limits the amount of water that the UV-curable electrolyte medium 36 absorbs from the ambient environment 124 before the wet-laminating step 106 largely prevents interaction between the UV-curable electrolyte medium 36 and the ambient environment 124. The period of time may be less than 1 second, 1 second, 2 seconds, 3 seconds, 4 seconds, 5 seconds, 6 seconds, 7 seconds, 8 seconds, 9 seconds, less than 10 seconds, or within any range bound by any two of those values (e.g., from 3 seconds to 6 seconds, from 1 second to 7 seconds, and so on).

[0042] The curing step 108 includes irradiating the UV-curable electrolyte medium 36 with ultraviolet electromagnetic radiation while translating the laminated workpiece 120. For example, the laminated workpiece 120 can be translated to a curing station 126. At the curing station 126, the laminated workpiece 120 is exposed to ultraviolet electromagnetic radiation. The irradiation of the UV-curable electrolyte medium 36 with ultraviolet electromagnetic radiation at least partially polymerizes (e.g., cures) the UV-curable monomer or oligomer. Parameters of the curing station 126, such as time, temperature, and intensity of ultraviolet electromagnetic radiation, can be set based on characteristics of the UV-curable electrolyte medium 36, non-limiting examples of which include the UV-curable monomer or oligomers, the low-volatility solvent, additives, thickness of the UV- curable electrolyte medium 36, desired degree of gelling, and desired thickness of the electrolyte medium 12 as cured.

[0043] The curing step 108 forms a cured workpiece 128. The cured workpiece 128 can then be wound into a third roll 130. The third roll 130 can be further processed to separate numerous of the electrochromic devices 10 therefrom. It should be understood that in a roll-to-roll process, the first substrate 14, the first conductive layer 26, and the first electrode layer extend contiguously from the first roll 114 of the first workpiece 110 to the cured workpiece 128 wound as the third roll 130. Likewise, the second substrate 16, the second conductive layer 28, and the second electrode layer32 extend contiguously from the second roll 116 of the second workpiece 112 to the cured workpiece128 wound as the third roll 130.

[0044] The UV-curable electrolyte medium 36 and the method 100 address the problems set forth in the Summary, among other problems, in a variety of ways. The ambient environment 124 (e.g., open air) can surround the first workpiece 110 and the second workpiece 112 during all of the translating step 102, the depositing step 104, and the wet-laminating step 106, as well as the laminated workpiece 120 during the curing step 108, without UV-curable electrolyte medium 36 absorbing a significant amount of water from the ambient environment 124. The UV-curable electrolyte medium 36 can be separated from the ambient environment 124 after formulation and until deposition onto the first electrode layer 30 or the second electrode layer 32 during the depositing step 104. That limits the level of water absorption from the ambient environment 124 that occurs before the depositing step 104. The UV-curable electrolyte medium 36 is exposed to the ambient environment 124 after the depositing step 104 but only for the period of time of less than 10 seconds before the wet-laminating step 106 occurs and the UV-curable electrolyte medium 36 is sandwiched between the first substrate 14 and the second substrate 16 and thus separated from the ambient environment 124. The period of time, as such, avoids a need and associated cost to conduct the curing step 108 in a controlled atmosphere of low or no water (e.g., a nitrogen atmosphere).

[0045] It will be understood by one having ordinary skill in the art that construction of the described disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

[0046] Examples

[0047] Examples 1A-1D - For these examples, fixed weights of polyethylene glycol) methyl ether methacrylate and a difunctional aliphatic urethane acrylate (Bomar BRC-843D) were combined. Both monomers are liquid at room temperature. A photoinitiator of fixed weight was then dissolved in the combined monomers using a FlackTek Speedmixer. The photoinitiator was a combination of 50 wt% Irgacure® IR184 (1-Hydroxy-cyclohexyl-phenyl-ketone) and 50% TPO (diphenyl(2,4,6- trimethylbenzoyl)-phosphine oxide). Variable weight percentages of an ionic salt, specifically lithium perchlorate (LiCIC ), for each example were dissolved in a low-volatility solvent, specifically propylene carbonate, of a fixed weight percentage using a Speedmixer. The two solutions were then combined and mixed in a Speedmixer. The weight ratio of PEGMA / Bomar-843D controls Li+mobilityand gel rigidity. Table 1 below summarizes the four examples. "Mon" means combined monomers."PI" means photoinitiator. "IS" means ionic salt.

[0048] Each of the examples were then evaluated. Example 1A was determined to form a soft film that was easily torn and conductive. Example IB was determined to form a soft somewhat sticky gel that was conductive. Example 1C was determined to form a soft sticky gel that was barely conductive. Example ID was determined to form a very soft and sticky gel that was not conductive.

[0049] Examples 2A-2D - For these examples, fixed weights of polyethylene glycol) methyl ether methacrylate and a difunctional aliphatic urethane acrylate (Bomar BRC-843D) were combined. A photoinitiator of fixed weight was then dissolved in the combined monomers using a Speedmixer. The photoinitiator was a combination of 50 wt% Irgacure® IR184 (1-Hydroxy-cyclohexyl-phenyl- ketone) and 50% TPO (diphenyl(2,4,6-trimethylbenzoyl)-phosphine oxide). An ionic salt, specifically lithium perchlorate (LiCIC ), of fixed weight was dissolved in a low-volatility solvent, specifically propylene carbonate, of a variable weight percentage for each example using a Speedmixer. The two solutions were then combined and mixed in a Speedmixer. Table 2 below summarizes the four examples. "Mon" means combined monomers. "PI" means photoinitiator. "IS" means ionic salt.

[0050] Each of the examples were then evaluated. Example 2A was determined to form a soft and somewhat sticky gel and was conductive. Examples 2B and 2C were determined to form a soft film that was easily torn and conductive. Example 2D was determined to form a somewhat firmer film that was not conductive.

[0051] Examples 3A-3D - For these examples, fixed weights of polyethylene glycol) methyl ether methacrylate and a difunctional aliphatic urethane acrylate (Bomar BRC-843D) were combined. Aphotoinitiator of variable weight for each example was then dissolved in the combined monomers using a Speedmixer. The photoinitiator was a combination of 50 wt% Irgacure® IR184 (1-Hydroxy- cyclohexyl-phenyl-ketone) and 50% TPO (diphenyl(2,4,6-trimethylbenzoyl)-phosphine oxide). An ionic salt, specifically lithium perchlorate (IJCIO4), of fixed weight percentage was dissolved in a low- volatility solvent, specifically propylene carbonate, of a fixed weight percentage using a Speedmixer. The two solutions were then combined and mixed in a Speedmixer. Table 3 below summarizes the four examples. "Mon" means combined monomers. "PI" means photoinitiator. "IS" means ionic salt.

[0052] Each of the examples were then evaluated. Examples 3A-3C were determined to form soft and somewhat sticky gel that was conductive. Example 3D was determined to form a very soft and sticky gel that was barely conductive.

[0053] Examples 4A-4F - For these examples, fixed weights of poly(ethylene glycol) methyl ether methacrylate and a difunctional aliphatic urethane acrylate (Bomar BRC-843D) were combined. A photoinitiator of fixed weight for each example was then dissolved in the combined monomers using a Speedmixer. The photoinitiator was a combination of 50 wt% Irgacure® IR184 (1-Hydroxy- cyclohexyl-phenyl-ketone) and 50% TPO (diphenyl(2,4,6-trimethylbenzoyl)-phosphine oxide). An ionic salt, specifically lithium perchlorate ( IJCIO4), of variable weight percentage for each example was dissolved in a low-volatility solvent, specifically propylene carbonate, using a Speedmixer. The two solutions were then combined and mixed in a Speedmixer. Table 4 below summarizes the six examples. "Mon" means combined monomers. "PI" means photoinitiator. "IS" means ionic salt.

[0054] Each of the examples were then evaluated. Examples 4A-4E were determined to form a soft film that was easily torn and conductive. Example 4F was determined to form a soft film that was easily torn and not conductive.

[0055] According to a first aspect of the present disclosure, an ultraviolet-curable (UV-curable) electrolyte medium for an electrochromic device, the UV-curable electrolyte medium comprising: (a) a low-volatility solvent; (b) an ionic salt at least partially dissolved in the low-volatility solvent; (c) a UV-curable monomer or oligomer at least partially dissolved in the low-volatility solvent; and (d) a photoinitiator.

[0056] According to a second aspect of the present disclosure, the UV-curable electrolyte medium of the first aspect is presented, wherein the low-volatility solvent exhibits a boiling point that is greater than or equal to 150 °F ("'65.56 °C).

[0057] According to a third aspect of the present disclosure, the UV-curable electrolyte medium of any one of the first through second aspects is presented, wherein the low-volatility solvent comprises one or more of propylene carbonate, acetonitrile, y-butyrolactone, y-valerolactone, and 3- methoxypropionitrile.

[0058] According to a fourth aspect of the present disclosure, the UV-curable electrolyte medium of any one of the first through third aspects is presented, wherein the electrolyte medium is substantially free of a non-low-volatility solvent.

[0059] According to a fifth aspect of the present disclosure, the UV-curable electrolyte medium of any one of the first through fourth aspects is presented, wherein the ionic salt comprises a metal salt or an ammonium salt.

[0060] According to a sixth aspect of the present disclosure, the UV-curable electrolyte medium of the fifth aspect is presented, wherein (i) the ionic salt comprises a metal salt, and (ii) the metal salt comprises one or more of lithium triflate, lithium perchlorate, sodium triflate, and sodium perchlorate.

[0061] According to a seventh aspect of the present disclosure, the UV-curable electrolyte medium of the fifth aspect is presented, wherein (i) the ionic salt comprises an ammonium salt, and (ii) the ammonium salt comprises a cation of one or more of tetramethylammonium, tetraethylammonium, and tetrabutylammonium.

[0062] According to an eighth aspect of the present disclosure, the UV-curable electrolyte medium of any one of the first through seventh aspects is presented, wherein the ionic salt comprises one ormore of the following cations: H+, Li+, Na+, K+, Ca2+, Ba2+, Sr2+, Mg+, NR (where each R' is individually H, alkyl, or cycloalkyl).

[0063] According to a ninth aspect of the present disclosure, the UV-curable electrolyte medium of any one of the first through eighth aspects is presented, wherein the ionic salt comprises one or more of the following anions: F“, Cl-, Br“, I", BFT, PFe“, SbFe“, AsFe“, CIO4-, SO3CF3“, N(CF3SO2)2“, C(CF3SO2)3“, N(SO2C2F5)2, AI(OC(CF3)3)4", Bar4 ", where Ar is an aryl or fluorinated aryl group.

[0064] According to a tenth aspect of the present disclosure, the UV-curable electrolyte medium of any one of the first through ninth aspects is presented, wherein the UV-curable monomer or oligomer comprises one or more of an acrylate, a methacrylate, and a vinyl ether.

[0065] According to an eleventh aspect of the present disclosure, the UV-curable electrolyte medium of any one of the first through tenth aspects is presented, wherein the UV-curable monomer or oligomer comprises one or more of poly(ethylene glycol) methyl ether methacrylate, a difunctional aliphatic urethane acrylate, 1,4-butanediol diacrylate, tris[2-(acryloyloxy)ethyl] isocyanurate, polypropylene glycol) diacrylate, polypropylene glycol) dimethacrylate, poly(ethylene glycol) diacrylate, trimethylolpropane propoxylate triacrylate, 1,4-butanediol divinyl ether, methyl methacrylate, methyl acrylate, isocyanatoethyl methacrylate, 2-isocyanatoethyl acrylate, 2- hydroxyethyl methacrylate, 2-hydroxyethyl acrylate, 3-hydroxypropyl methacrylate, glycidyl methacrylate, 4-vinylphenol, acetoacetoxy methacrylate, and acetoacetoxy acrylate.

[0066] According to a twelfth aspect of the present disclosure, the UV-curable electrolyte medium of any one of the first through eleventh aspects is presented, wherein the photoinitiator comprises one or more of 1-Hydroxy-cyclohexyl-phenyl-ketone (Irgacure® 184), 2-Hydroxy-2- methylpropiophenone, 2,2-dimethoxy-2-phenylacetophenone (Irgacure® 651), 2,2- diethoxyacetophenone, (diphenyl(2,4,6-trimethylbenzoyl)-phosphine oxide) (TPO), and phenyl bis(2,4,6-trimethylbenzoyl)phosphine oxide (Irgacure® 819).

[0067] According to a thirteenth aspect of the present disclosure, a method of manufacturing an electrochromic device, the method comprising: (a) a translating step comprising translating (i) a first workpiece comprising a first substrate, a first conductive layer disposed on the first substrate, and a first electrode layer disposed on the first conductive layer and (ii) a second workpiece comprising a second substrate, a second conductive layer disposed on the second substrate, and a second electrode layer disposed on the second conductive layer; (b) a depositing step comprising depositing a UV-curable electrolyte medium onto either the first electrode of the first workpiece or the secondelectrode of the second workpiece; (c) a wet-laminating step comprising bringing together the first workpiece and the second workpiece such that the UV-curable electrolyte medium is sandwiched between the first electrode layer and the second electrode layer thus forming a laminated workpiece; and (d) a curing step comprising irradiating the UV-curable electrolyte medium with ultraviolet electromagnetic radiation while translating the laminated workpiece.

[0068] According to a fourteenth aspect of the present disclosure, the method of the thirteenth aspect is presented, wherein the depositing step further comprises flowing the UV-curable electrolyte medium through an outlet of a slot die onto either the first electrode layer of the first workpiece or the second electrode layer of the second workpiece.

[0069] According to a fifteenth aspect of the present disclosure, the method of any one of the thirteenth through fourteenth aspects is presented, wherein a period of time of less than 10 seconds elapses between (i) when the electrolyte medium is deposited during the deposition step and (ii) when the deposited electrolyte medium is sandwiched between the first electrode layer and the second electrode layer during the wet-laminating step.

[0070] According to a sixteenth aspect of the present disclosure, the method of any one of the thirteenth through fifteenth aspects is presented, wherein the wet-laminating step further comprises translating the first workpiece and the second workpiece, at least one of which further comprises the UV-curable electrolyte medium, between a pair of laminating rollers.

[0071] According to a seventeenth aspect of the present disclosure, the method of any one of the thirteenth through sixteenth aspects is presented, wherein an ambient environment surrounds the first workpiece and the second workpiece during both the translating step, the depositing step, and the wet-laminating step, as well as the laminated workpiece during the curing step.

[0072] According to an eighteenth aspect of the present disclosure, the method of any one of the thirteenth through seventeenth aspects is presented, wherein the UV-curable electrolyte medium comprises: (i) a low-volatility solvent; (ii) an ionic salt at least partially dissolved in the low-volatility solvent; (iii) a UV-curable monomer or oligomer at least partially dissolved in the low-volatility solvent; and (iv) a photoinitiator.

[0073] According to a nineteenth aspect of the present disclosure, the method of the eighteenth aspect is presented, wherein the low-volatility solvent comprises one or more of propylene carbonate, acetonitrile, y-butyrolactone, y-valerolactone, and 3-methoxypropionitrile.

[0074] According to a twentieth aspect of the present disclosure, the method of any one of the eighteenth through nineteenth aspects is presented, wherein the UV-curable monomer or oligomer comprises one or more of poly(ethylene glycol) methyl ether methacrylate, a difunctional aliphatic urethane acrylate, 1,4-butanediol diacrylate, tris[2-(acryloyloxy)ethyl] isocyanurate, polypropylene glycol) diacrylate, polypropylene glycol) dimethacrylate, polypthylene glycol) diacrylate, trimethylolpropane propoxylate triacrylate, 1,4-butanediol divinyl ether, methyl methacrylate, methyl acrylate, isocyanatoethyl methacrylate, 2-isocyanatoethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxyethyl acrylate, 3-hydroxypropyl methacrylate, glycidyl methacrylate, 4- vinylphenol, acetoacetoxy methacrylate, and acetoacetoxy acrylate.

[0075] For purposes of this disclosure, the term "coupled" (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

[0076] It is also important to note that the construction and arrangement of the elements of the disclosure, as shown in the exemplary embodiments, is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts, or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and / or members or connector or other elements of the system may be varied, and the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and / or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Othersubstitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

[0077] It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

Claims

What is claimed is:

1. An ultraviolet-curable (UV-curable) electrolyte medium for an electrochromic device, the UV- curable electrolyte medium comprising: a low-volatility solvent; an ionic salt at least partially dissolved in the low-volatility solvent; a UV-curable monomer or oligomer at least partially dissolved in the low-volatility solvent; and a photoinitiator.

2. The UV-curable electrolyte medium of claim 1, wherein the low-volatility solvent exhibits a boiling point that is greater than or equal to 150 °F ("'65.56 °C).

3. The UV-curable electrolyte medium of any one of claims 1-2, wherein the low-volatility solvent comprises one or more of propylene carbonate, acetonitrile, y- butyrolactone, y-valerolactone, and 3-methoxypropionitrile.

4. The UV-curable electrolyte medium of any one of claims 1-3, wherein the electrolyte medium is substantially free of a non-low-volatility solvent.

5. The UV-curable electrolyte medium of any one of claims 1-4, wherein the ionic salt comprises a metal salt or an ammonium salt.

6. The UV-curable electrolyte medium of claim 5, wherein the ionic salt comprises a metal salt, and the metal salt comprises one or more of lithium triflate, lithium perchlorate, sodium triflate, and sodium perchlorate.

7. The UV-curable electrolyte medium of claim 5, wherein the ionic salt comprises an ammonium salt, andthe ammonium salt comprises a cation of one or more of tetramethylammonium, tetraethylammonium, and tetrabutylammonium.

8. The UV-curable electrolyte medium of any one of claims 1-7, wherein the ionic salt comprises one or more of the following cations: H+, Li+, Na+, K+, Ca2+, Ba2+, Sr2+, Mg+, NR'4+(where each R' is individually H, alkyl, or cycloalkyl).

9. The UV-curable electrolyte medium of any one of claims 1-8, wherein the ionic salt comprises one or more of the following anions: F“, Cl-, Br“, I", BF4“, PFe“, SbFe“, ASF6“, CIO4", SO3CF3“, N(CF3SO2)2“, C(CF3SO2)3-, N(SO2C2F5)2, AI(OC(CF3)3)4", Bar4“, where Ar is an aryl or fluorinated aryl group.

10. The UV-curable electrolyte medium of any one of claims 1-9, wherein the UV-curable monomer or oligomer comprises one or more of an acrylate, a methacrylate, and a vinyl ether.

11. The UV-curable electrolyte medium of any one of claims 1-10, wherein the UV-curable monomer or oligomer comprises one or more of poly(ethylene glycol) methyl ether methacrylate, a difunctional aliphatic urethane acrylate, 1,4-butanediol diacrylate, tris[2- (acryloyloxy)ethyl] isocyanurate, polypropylene glycol) diacrylate, polypropylene glycol) dimethacrylate, poly(ethylene glycol) diacrylate, trimethylolpropane propoxylate triacrylate, 1,4- butanediol divinyl ether, methyl methacrylate, methyl acrylate, isocyanatoethyl methacrylate, 2- isocyanatoethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxyethyl acrylate, 3-hydroxypropyl methacrylate, glycidyl methacrylate, 4-vinylphenol, acetoacetoxy methacrylate, and acetoacetoxy acrylate.

12. The UV-curable electrolyte medium of any one of claims 1-11, wherein the photoinitiator comprises one or more of 1-Hydroxy-cyclohexyl-phenyl-ketone (Irgacure® 184), 2-Hydroxy-2-methylpropiophenone, 2,2-dimethoxy-2-phenylacetophenone (Irgacure® 651), 2,2-diethoxyacetophenone, (diphenyl(2,4,6-trimethylbenzoyl)-phosphine oxide) (TPO), and phenyl bis(2,4,6-trimethylbenzoyl)phosphine oxide (Irgacure® 819).

13. A method of manufacturing an electrochromic device, the method comprising: a translating step comprising translating (i) a first workpiece comprising a first substrate, a first conductive layer disposed on the first substrate, and a first electrode layer disposed on the first conductive layer and (ii) a second workpiece comprising a second substrate, a second conductive layer disposed on the second substrate, and a second electrode layer disposed on the second conductive layer; a depositing step comprising depositing a UV-curable electrolyte medium onto either the first electrode of the first workpiece or the second electrode of the second workpiece; a wet-laminating step comprising bringing together the first workpiece and the second workpiece such that the UV-curable electrolyte medium is sandwiched between the first electrode layer and the second electrode layer thus forming a laminated workpiece; and a curing step comprising irradiating the UV-curable electrolyte medium with ultraviolet electromagnetic radiation while translating the laminated workpiece.

14. The method of claim 13, wherein the depositing step further comprises flowing the UV-curable electrolyte medium through an outlet of a slot die onto either the first electrode layer of the first workpiece or the second electrode layer of the second workpiece.

15. The method of any one of claims 13-14, wherein a period of time of less than 10 seconds elapses between (i) when the electrolyte medium is deposited during the deposition step and (ii) when the deposited electrolyte medium is sandwiched between the first electrode layer and the second electrode layer during the wet-laminating step.

16. The method of any one of claims 13-15, wherein the wet-laminating step further comprises translating the first workpiece and the second workpiece, at least one of which further comprises the UV-curable electrolyte medium, between a pair of laminating rollers.

17. The method of any one of claims 13-16, wherein an ambient environment surrounds the first workpiece and the second workpiece during both the translating step, the depositing step, and the wet-laminating step, as well as the laminated workpiece during the curing step.

18. The method of any one of claims 13-17, wherein the UV-curable electrolyte medium comprises: a low-volatility solvent; an ionic salt at least partially dissolved in the low-volatility solvent; a UV-curable monomer or oligomer at least partially dissolved in the low-volatility solvent; and a photoinitiator.

19. The method of claim 18, wherein the low-volatility solvent comprises one or more of propylene carbonate, acetonitrile, y- butyrolactone, y-valerolactone, and 3-methoxypropionitrile.

20. The method of any one of claims 18-19, wherein the UV-curable monomer or oligomer comprises one or more of poly(ethylene glycol) methyl ether methacrylate, a difunctional aliphatic urethane acrylate, 1,4-butanediol diacrylate, tris[2- (acryloyloxy)ethyl] isocyanurate, polypropylene glycol) diacrylate, polypropylene glycol) dimethacrylate, polypthylene glycol) diacrylate, trimethylolpropane propoxylate triacrylate, 1,4- butanediol divinyl ether, methyl methacrylate, methyl acrylate, isocyanatoethyl methacrylate, 2- isocyanatoethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxyethyl acrylate, 3-hydroxypropyl methacrylate, glycidyl methacrylate, 4-vinylphenol, acetoacetoxy methacrylate, and acetoacetoxy acrylate.

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