Electrochromic Window Edge Deletion for Yield
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Solution Overview
Problem
Electrochromic windows face challenges in achieving high quality and yield due to defects and non-uniformities in the electrochromic device, which are often introduced during the tempering process, leading to reduced commercial potential despite advancements in electrochromic technology.
Innovation Solution
A method of manufacturing electrochromic windows where the electrochromic device is first fabricated on a glass sheet, and a cutting pattern is defined post-fabrication to exclude defective areas, with optical, electrical, and mechanical inspections used to identify and mitigate defects, and edge deletion techniques applied to enhance the quality and strength of the panes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrochromic devices are fabricated on glass sheets and then cut into panes, then defects and non-uniformities introduced during tempering reduce product quality and yield
Solution Approach 1:
The patent applies preliminary action by fabricating the electrochromic device on the entire glass sheet before cutting it into individual panes. This allows defects to be identified and mapped beforehand, enabling the cutting pattern to be optimized to exclude defective areas while maximizing usable pane production. The process includes probing the device to locate defects, defining a cutting pattern that avoids these defects, and then cutting the panes accordingly.
2Manufacturing precision
If the complete device sheet is inspected to determine leakage current and resistivity, then the cutting pattern can be optimized to exclude defective areas, but the process complexity and time increase
Solution Approach 1:
The patent applies self-service by using the electrochromic device itself to identify its own defects through probing. The device's electrical characteristics (leakage current, resistivity) are measured to automatically locate defective areas, which then inform the cutting pattern definition. This eliminates the need for separate manual inspection processes and integrates quality control directly into the fabrication workflow.
3Strength
If edge deletion techniques are applied to enhance pane strength and uniformity, then the quality of electrochromic windows improves, but additional manufacturing steps are required
Solution Approach 1:
The patent applies the extraction principle by removing edge portions of the electrochromic device through edge deletion techniques. This eliminates defective edge areas that could compromise pane strength and uniformity. The edge deletion is performed as a targeted removal of problematic regions, allowing the core functional areas to maintain their full electrochromic properties while eliminating structural weaknesses at the boundaries.
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 results in high-quality electrochromic windows with improved yield by excluding defective regions and enhancing the strength and uniformity of the panes, leading to more efficient use of glass sheets and reduced rejection rates.
Implementation Method 1
Electrochromism is a phenomenon in which a material exhibits a reversible electrochemically-mediated change in an optical property when placed in a different electronic state, typically by being subjected to a voltage change. One well known electrochromic material is tungsten oxide (WO3). Tungsten oxide is a cathodic electrochromic material in which a coloration transition, transparent to blue, occurs by electrochemical reduction.
Data Source
AI summary
Methods of manufacturing electrochromic windows are described. Insulated glass units (IGU's) are protected, e.g. during handling and shipping, by a protective bumper. The bumper can be custom made using IGU dimension data received from the IGU fabrication tool. The bumper may be made of environmentally friendly materials. Laser isolation configurations and related methods of patterning and/or configuring an electrochromic device on a substrate are described. Edge deletion is used to ensure a good seal between spacer and glass in an IGU and thus better protection of an electrochromic device sealed in the IGU. Configurations for protecting the electrochromic device edge in the primary seal and maximizing viewable area in an electrochromic pane of an IGU are also described.