Electrochromic Device Density Gradient Layering
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Solution Overview
Problem
Existing electrochromic devices face challenges in productivity and stability due to high process costs and material degradation issues, particularly with vacuum deposition methods and coating processes, which affect their electrochromic rate and durability.
Innovation Solution
An electrochromic device with a laminate structure of electrochromic layers of varying densities, where the higher density layer is closer to the first electrode, reduces ion penetration and side reactions, enhancing electrochromic rate and durability by preventing ion degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum deposition method is used to form electrochromic thin film, then stable electrochromic characteristics are achieved, but process cost and maintenance cost increase significantly
Solution Approach 1:
The patent changes the deposition parameters by controlling the substrate temperature during sputtering to be at or above room temperature, which allows formation of dense electrochromic films with stable characteristics using a lower-cost sputtering method instead of vacuum deposition
Solution Approach 2:
The patent employs a cost-effective sputtering process that does not require expensive vacuum deposition equipment, replacing high-cost vacuum deposition with a more affordable alternative that still achieves the desired film quality
2Ease of manufacture
If coating method is used to form electrochromic thin film, then process cost is reduced, but adhesion between coating layer and base material decreases
Solution Approach 1:
The patent changes the physical state and density parameters of the electrochromic film by using sputtering deposition at controlled temperatures, producing denser films with improved adhesion properties compared to conventional coating methods
Solution Approach 2:
The patent replaces the chemical bonding mechanism of coating methods with a physical deposition mechanism (sputtering), which creates mechanically stronger bonds between the electrochromic film and the substrate
3Device complexity
If single-layer electrochromic structure is used, then manufacturing process is simple, but ion penetration and side reactions occur reducing durability
Solution Approach 1:
The patent divides the electrochromic layer into multiple sub-layers with different densities, where the first electrochromic layer has higher density and the second has lower density. This segmentation creates a barrier that prevents ion penetration and side reactions, improving durability
Solution Approach 2:
The patent applies different densities to different regions of the electrochromic layer. The first layer near the electrode has higher density to prevent ion penetration, while the second layer has lower density to maintain electrochromic performance
4Duration of action of stationary object
If electrochromic device operates for extended cycling, then electrochromic stability decreases and degradation is observed, but continuous operation is required for practical applications
Solution Approach 1:
The patent incorporates a first electrochromic layer with higher density as a protective barrier before the ions can reach and degrade the electrode materials. This pre-emptive structure cushions against ion penetration and prevents degradation during extended cycling operations
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 increases productivity and stability of electrochromic devices, enabling their use in applications like smart windows and electronic papers with improved electrochromic performance and extended lifespan.
Implementation Method 1
Electrochromism refers to a phenomenon in which optical properties such as color or transmittance of an electrochromic active material are changed by an electrochemical redox reaction of materials
Implementation Method 2
the electrochromic layer having a higher density among the two electrochromic layers having different densities may be disposed closer to the first electrode layer as compared to the electrochromic layer having a lower density
Data Source
AI summary
The present application relates to an electrochromic device and a method for manufacturing the electrochromic device. The present application can provide an electrochromic device having increased productivity and improved electrochromic rate and durability, and a method for manufacturing the electrochromic device. The electrochromic device may be advantageously used in various devices such as smart windows, smart mirrors, displays, electronic papers and adaptive camouflage.