Electrochromic Cell Solid Electrolyte Manufacturing Precision

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Solution Overview

Problem

Existing electrochromic cells face challenges in precision and uniformity of layer thickness due to the liquid or pasty characteristics of organic ionic conductors, and the difficulty in achieving a consistent degree of hydration for inorganic ionic conductors like hydrated Ta2O5, leading to manufacturing complexities and performance issues.

Innovation Solution

An electrochromic cell using Na+ cations with an electrolyte compound of the formula Na1+xZr2SixP3−xO12, where 1.6≦x≦2.4, which is chemically stable and operational at ambient temperature, and a reserve layer of Na+ cations to ensure consistent ionic conduction, combined with tungsten oxide or vanadium oxide electrochromic materials for color change, and a unified physical vapor deposition process for layer formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If organic ionic conductors are used as electrolyte, then the cell can operate at ambient temperature, but the liquid or pasty characteristics cause difficulty in achieving high precision and uniformity of thickness

Engineering Contradiction:

Improveoperating temperatureVSAvoidthickness uniformity

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The patent changes the physical state parameter of the electrolyte from liquid/pasty (organic) to solid (inorganic), specifically using hydrated Ta2O5 where the degree of hydration is controlled as a key parameter. This transformation maintains ambient temperature operation while enabling precise thickness control through physical vapor deposition techniques.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite inorganic electrolyte system consisting of Ta2O5 with controlled hydration levels, combining the benefits of solid-state stability with ionic conductivity. The composite structure of hydrated Ta2O5 provides both the required ion transport and the mechanical stability for precise manufacturing.

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If inorganic ionic conductors like hydrated Ta2O5 are used, then manufacturing precision can be improved, but the degree of hydration must be precisely controlled which is extremely difficult at industrial scale

Engineering Contradiction:

Improvethickness uniformityVSAvoidpreparation conditions control

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex chemical hydration control processes with a physical vapor deposition process. Instead of controlling hydration through chemical reactions and environmental conditions, the electrolyte layer is deposited as a solid film with precise thickness control, eliminating the need for complex hydration management at industrial scale.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the key control parameter from degree of hydration (chemical parameter) to film thickness (physical parameter). This allows the use of standard physical vapor deposition techniques which can precisely control thickness without requiring complex control of chemical hydration states.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If two different manufacturing techniques are used for organic ionic conductor and other layers, then the electrolyte can be formed, but the manufacturing process becomes complicated

Engineering Contradiction:

Improveelectrolyte formationVSAvoidmanufacturing process

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges the electrolyte formation process with the other layer deposition processes by using physical vapor deposition for all layers. This unification eliminates the need for separate injection and sealing operations required for organic electrolytes, simplifying the overall manufacturing process into a single integrated deposition sequence.

Inventive Principle:

Principle #5Merging (Combining)

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 achieves precise and reproducible ionic conduction, stable color change, and simplified manufacturing by using a single deposition process, avoiding the limitations of previous technologies and enabling efficient light absorption modulation.

Implementation Method 1

the electrolyte comprises at least one compound of general formula: Na1+xZr2SixP3−xO12

Methodology Applied

Scientific EffectIonic conduction: Conduction (electrical)

Implementation Method 2

cations migrate in a reversible way from the electrolyte towards the electrochromic material in order to be inserted into this last causing a modification of its power of absorption of the light

Methodology Applied

Scientific EffectInsertion: Absorption (physical)

Implementation Method 3

a unified physical vapor deposition process for layer formation

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Data Source

PatentUS7511874B2Electrochromic cell, its use in the realization of a glass pane or a rear-view mirror and its realization method

Publication Date: 2009.03.31 SMR PATENTS S A R L

AI summary

The present invention concerns an electrochromic cell comprising a layer (4) of electrochromic material to which an electrolyte layer (3) is applied, means (7, 8, 9) being designed to establish a potential difference between these layers; said electrolyte comprises at least one compound of general formula:Na1+xZr2SixP3−xO12 (1)in which x is chosen to respond to the following conditions: 1, 6≦x≦2, 4. The present invention also concerns a glass pane or a rear-view mirror including such a cell.