Electrochromic Window Edge Patterning Without Isolation 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 despite advancements in technology.
Innovation Solution
The development of optical devices with novel configurations, including specific edge treatments and fabrication methods that eliminate the need for isolation scribes, ensuring proper isolation and reducing charge buildup by selectively removing conductor layers and using edge tapering to avoid stress and cracking in electrochromic devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If isolation scribes are used to address edge defects, then device reliability is improved, but unwanted coloration and charge buildup occur in isolated areas
Solution Approach 1:
The patent removes the first conductor layer from a perimeter area of the substrate before depositing the electrochromic device layers. This extraction of the conductor layer from edge regions eliminates the source of charge buildup and unwanted coloration that would otherwise occur in isolated areas, while still allowing the device to function reliably in the central region.
Solution Approach 2:
The conductor layer removal is performed as a preliminary step before depositing the electrochromic device layers. By preparing the substrate in advance by removing the conductor layer from perimeter areas, the patent prevents edge defects and charge buildup issues from occurring during device operation, rather than attempting to address them after device assembly.
2Object-generated harmful factors
If conductor layers are removed from perimeter areas, then charge buildup is reduced, but device area is decreased
Solution Approach 1:
The patent applies different configurations of the conductor layer to different regions of the substrate. The first conductor layer is present in the central region where the electrochromic device is deposited, but removed from the perimeter area. This local differentiation allows the device to maintain full area in the functional region while eliminating charge buildup in the edge regions.
3Manufacturing precision
If edge treatments are applied during fabrication, then manufacturing precision is improved, but fabrication complexity increases
Solution Approach 1:
The edge treatment is performed as a preliminary step using laser ablation to remove the first conductor layer from perimeter areas before the electrochromic device layers are deposited. By performing this precise edge preparation in advance, the patent achieves accurate edge definition and prevents subsequent fabrication issues without requiring complex multi-step processes during device assembly.
Solution Approach 2:
The patent uses laser ablation to remove the conductor layer from perimeter areas, replacing what would otherwise require mechanical machining or chemical etching. This substitution provides more precise edge definition and better control over the removal process, achieving superior manufacturing precision while simplifying the overall fabrication workflow.
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 proposed solution results in more robust and better-performing electrochromic devices with improved uniformity and reduced defects, enhancing their energy-saving capabilities and 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
Various edge deletion and isolation scribes are performed, for example, to ensure the optical device has appropriate isolation from any edge defects
Data Source
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.