Thermoforming Curved Electrochromic Devices via Injection Molding
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Solution Overview
Problem
Existing electrochromic devices face challenges in forming desired curved shapes, particularly for optical uses like lenses, due to difficulties in bonding processes and achieving transparency and conductivity simultaneously in electrode layers.
Innovation Solution
The method involves forming an electrochromic device with a laminated body that includes a support, electrode layers, an electrochromic layer, and an electrolyte layer, which is then thermoformed to achieve a desired curved shape without the need for a bonding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a bonding process is used to form electrochromic device layers, then structural integrity is improved, but manufacturing complexity and difficulty of forming curved shapes increase
Solution Approach 1:
The patent combines multiple layers (substrate, electrode layers, electrochromic layer, electrolyte layer, sealing layer) into a single integrated structure that is formed and sealed as one piece through injection molding, eliminating the need for separate bonding processes while maintaining structural integrity
Solution Approach 2:
The patent uses a flexible sealing layer that can conform to curved surfaces and integrates with the substrate through injection molding, allowing the device to be formed into desired curved shapes without requiring rigid bonding structures
2Manufacturing precision
If vacuum film formation is used to form electrode layers, then transparency and conductivity are improved, but the device is limited to flat shapes and heat-resistant materials
Solution Approach 1:
The patent replaces the vacuum film formation process with an injection molding process that forms all layers including electrodes through mechanical injection, eliminating the need for vacuum equipment and enabling curved and three-dimensional shapes
Solution Approach 2:
The patent changes the material parameters by using injection-moldable conductive materials and electrochromic materials that can be processed at lower temperatures, expanding material choices beyond heat-resistant glass and enabling curved shapes
3Adaptability or versatility
If multiple substrates with different curves are prepared for mass production, then customization for different users is improved, but production cost and complexity increase
Solution Approach 1:
The patent makes the device shape dynamic and adjustable by forming a single integrally sealed structure that can be molded into different curves, allowing post-production customization without requiring multiple pre-formed substrates
Solution Approach 2:
The patent creates a universal injection molding process that can produce various curved configurations from a single integrated design, making the manufacturing system adaptable to different customization requirements without changing the fundamental production method
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the production of electrochromic devices with desired curved shapes, enhancing their optical applications while improving productivity and reducing the complexity and cost associated with multi-layered inorganic compound structures.
Implementation Method 1
wherein the laminated body is formed into a desired curve by thermoforming
Data Source
Figure 1A~2A
Figure 2B~3B
Figure 4A~5
AI summary
To provide an electrochromic device, including a laminated body, which includes: at least one support; a first electrode layer on the support; an electrochromic layer on the first electrode layer; a second electrode layer disposed to face the first electrode layer; and an electrolyte layer, which fills between the first electrode layer and the second electrode layer, and is on the electrochromic layer, the at least one support including a resin substrate, and the laminated body having a desired curve formed by thermoforming.