Electrochromic Window Edge Isolation Without Laser Scribes
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Solution Overview
Problem
Electrochromic devices, particularly electrochromic windows, face issues such as unwanted coloration and charge buildup due to edge defects and isolation scribes, which hinder their commercial potential.
Innovation Solution
The method involves forming a bus bar pad by selectively removing portions of the conductor layers and applying edge treatments to ensure appropriate isolation and prevent charge buildup, thereby simplifying the fabrication process and eliminating the need for certain laser isolation scribes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If isolation scribes are used to address edge defects, then device reliability is improved, but device complexity and fabrication difficulty increase
Solution Approach 1:
The patent removes the isolation scribe element from the device structure entirely. By designing the conductor layer to extend beyond the electrochromic material boundaries, the patent eliminates the need for isolation scribes that were previously used to prevent edge defects and charge buildup, thereby simplifying fabrication while maintaining reliability
Solution Approach 2:
Instead of using isolation scribes to separate the conductor from edge defects, the patent inverts the approach by having the conductor layer intentionally overlap the electrochromic material boundaries. This inversion eliminates the need for isolation structures while still preventing charge buildup through the overlapping conductor design
2Ease of manufacture
If conductor layers are extended to substrate edges, then manufacturing is simplified, but charge buildup and edge defects occur
Solution Approach 1:
The patent introduces an intermediary conductive layer configuration where the first conductor layer extends beyond the electrochromic material and overlaps with the second conductor layer. This overlapping conductor structure acts as an intermediary that provides a discharge path for charges, preventing charge buildup while maintaining manufacturing simplicity
Solution Approach 2:
The patent changes the geometric parameters of the conductor layers, specifically extending the first conductor layer beyond the electrochromic material boundaries and creating an overlapping region. This parameter change transforms the conductor configuration to eliminate charge buildup while keeping the manufacturing process simple
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 more robust and better-performing electrochromic devices with reduced edge defects and improved optical properties, enhancing their commercial viability.
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. The optical property is typically one or more of color, transmittance, absorbance, and reflectance.
Implementation Method 2
When electrochemical oxidation takes place, tungsten oxide transitions from blue to a bleached state.
Data Source
Figure 1A~1B
Figure 1C
Figure 1D
AI summary
Thin-film devices, for example electrochromic devices for windows, and methods of manufacturing are described. Particular focus is given to methods of patterning optical devices. Various edge deletion and isolation scribes are performed, for example, to ensure the optical device has appropriate isolation from any edge defects. Methods described herein apply to any thin-film device having one or more material layers sandwiched between two thin film electrical conductor layers. The described methods create novel optical device configurations.