Electro-Optic Assembly Sealing Structure for Uniform Cell Spacing
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Solution Overview
Problem
Existing electro-optic assemblies face challenges in achieving uniform cell spacing, leading to non-uniform darkening and clearing, and are prone to internal stress during the sealing and curing process, which affects the end-user experience.
Innovation Solution
The electro-optic assembly incorporates a primary seal and a break wall with spacer elements to maintain uniform cell spacing, using materials like epoxy for the seal and break wall, and opaque materials to conceal the seals and walls, ensuring consistent transmissibility and reducing stress by controlling thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional sealing methods are used in electro-optic assemblies, then the assembly can be manufactured, but non-uniform cell spacing occurs leading to non-uniform darkening and clearing
Solution Approach 1:
The seal is divided into multiple discrete seal elements positioned at specific locations around the perimeter of the electro-optic medium. These segmented seal elements, combined with spacer elements, create multiple defined regions that ensure uniform cell spacing throughout the assembly, preventing non-uniform darkening and clearing.
Solution Approach 2:
Spacer elements are introduced as intermediary components between the seal elements and the substrates. These spacers act as mediators that precisely control the spacing between components, ensuring uniform cell spacing and consistent electro-optic performance across the entire assembly.
2Ease of manufacture
If conventional sealing structures are used, then manufacturing is simplified, but internal stress occurs during sealing and curing process
Solution Approach 1:
The sealing structure incorporates break walls at specific locations where stress concentration is expected. These localized features allow stress to be managed at critical points without compromising the overall structural integrity or requiring complex manufacturing processes elsewhere in the assembly.
Solution Approach 2:
Break walls are pre-positioned in the sealing structure to anticipate and accommodate stress during the curing process. These features act as predetermined stress relief mechanisms that prevent internal stress buildup before it can cause manufacturing defects or assembly failure.
3Device complexity
If seals and break walls are left visible, then the structure is simplified, but the appearance and user experience are degraded
Solution Approach 1:
The seal elements and break walls are covered with opaque or colored materials that match the appearance of the surrounding electro-optic assembly. This coloring or obscuring technique allows the functional sealing structures to remain simple while achieving an aesthetically pleasing appearance that enhances user experience.
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
The solution provides consistent darkening and clearing capabilities while minimizing internal stress, enhancing user experience by hiding fill ports and reducing energy consumption through controlled electro-optic medium activation.
Implementation Method 1
An electro-optic medium is located in the cavity and retained in an inboard direction by the primary seal
Implementation Method 2
A plurality of first spacer elements are coupled to the primary seal. A plurality of second spacer elements are coupled to the break wall
Implementation Method 3
An electro-optic medium is located in the cavity and retained in an inboard direction by the primary seal
Data Source
AI summary
An electro-optic assembly comprises a first substrate and a second substrate. The first and second substrates are disposed in a parallel and spaced apart relationship so as to define a cavity therebetween. A primary seal extends between the first and second substrates. An electro-optic medium is located in the cavity and retained in an inboard direction by the primary seal. A plurality of first spacer elements are coupled to the primary seal. A break wall is located in the inboard direction or an outboard direction from the primary seal. The break wall extends between the first and second substrates and generally along the primary seal. A plurality of second spacer elements are coupled to the break wall. A space is defined between the primary seal and the break wall in the inboard-outboard directions.