Non-Rectangular Electrochromic Bus Bars for Uniform Tinting
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Solution Overview
Problem
Existing electrochromic devices face challenges in achieving uniform optical transitions and preventing hotspots when fabricated in non-rectangular shapes, due to difficulties in applying bus bar configurations that equalize effective voltage across complex geometries.
Innovation Solution
The development of bus bar configurations and methods for laser edge deletion and bus bar pad expose operations on non-rectangular electrochromic devices, using angled and non-rectangular laser patterns, allows for uniform voltage distribution and smooth optical transitions by determining optimal bus bar lengths and positions based on the device's geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard rectangular bus bar configurations are used on non-rectangular devices, then manufacturing is simpler, but uniform voltage distribution and optical transitions are compromised
Solution Approach 1:
The patent applies asymmetry by configuring bus bars in non-rectangular patterns that match the device geometry. Instead of using standard rectangular bus bar arrangements, the invention positions and dimensions bus bars asymmetrically to equalize the effective voltage distribution across non-rectangular device faces, thereby achieving uniform coloration while maintaining manufacturing feasibility.
Solution Approach 2:
The patent implements local quality by varying the bus bar configuration specifically for non-rectangular devices. The bus bars are positioned and sized according to the local geometric characteristics of the device face, with different configurations for different device shapes (triangular, trapezoidal, curved edges), ensuring that each region receives appropriate voltage distribution tailored to its specific geometry.
2Ease of manufacture
If laser patterns are oriented parallel or perpendicular to local edges, then processing is easier for rectangular devices, but implementation becomes difficult for complex shapes
Solution Approach 1:
The patent applies dynamics by making the laser pattern orientation adaptable rather than fixed. The laser patterns are oriented at angles dynamically determined by the local geometry of the device edges, allowing the same laser processing system to effectively handle various shapes including triangular, trapezoidal, and curved-edge devices by adjusting the pattern orientation to match each specific geometric configuration.
3Reliability
If bus bars are positioned to equalize distance across device surface, then uniform optical transitions are achieved, but device complexity increases
Solution Approach 1:
The patent implements equipotentiality by positioning and dimensioning bus bars to equalize the effective voltage distribution across the device face. The bus bar configurations are specifically designed so that points at equal distances from opposing bus bars experience equal voltage potentials, ensuring uniform effective voltage and thereby achieving uniform optical transitions and coloration across the entire device surface.
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 ensures uniform coloration and speedy optical transitions across non-rectangular electrochromic devices, minimizing the risk of hotspots and improving the reliability and performance of these devices.
Implementation Method 1
at least one layer of electrochromic material that changes its optical properties in response to the application of an electrical potential
Implementation Method 2
an ion conductor (IC) layer that allows ions, such as lithium ions, to move through it, into and out from the electrochromic material to cause the optical property to change
Implementation Method 3
directing a laser spot from the laser tool onto the one or more layers at a region of the substrate proximate the at least one edge that does not form a right angle with an adjacent edge to thereby remove the one or more layers at the region
Data Source
AI summary
Bus bar configurations and fabrication methods for non-rectangular shaped (e.g., triangular, trapezoidal, circular, pentagonal, hexagonal, arched, etc.) optical devices.