Electrochromic Fill Port Plug Curing and Compatibility
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Solution Overview
Problem
Conventional fill port plugs in electrochromic devices often suffer from incomplete curing and compatibility issues with electrochromic media, leading to leakage and premature device failure, which can damage surrounding structures and compromise the longevity and functionality of the devices.
Innovation Solution
Incorporating antimonate photo initiators into the fill port plug formulation and using resins that are insoluble and immiscible with the electrochromic medium, along with a secondary plug material that provides necessary attributes such as low oxygen and moisture permeability, to enhance curing and compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fill port plugs are used in electrochromic devices, then the device can be manufactured with standard materials, but the plugs suffer from incomplete curing and compatibility issues leading to leakage and premature failure
Solution Approach 1:
The patent changes the chemical parameters of the plug material by incorporating antimonate photo initiators and selecting specific resins (e.g., acrylonitrile butadiene styrene copolymer, polyacrylic acid) that are incompatible with conventional curing methods but compatible with antimonate-based curing. This parameter change enables complete curing and eliminates compatibility issues with electrochromic media.
Solution Approach 2:
The patent uses composite plug materials combining multiple components: antimonate photo initiators, specific resins, and optional secondary plug materials. This composite approach allows the plug to simultaneously achieve complete curing, compatibility with electrochromic media, and necessary mechanical properties like low oxygen and moisture permeability.
2Duration of action of stationary object
If resins that are insoluble and immiscible with electrochromic media are selected for the plug, then intermixing is minimized and device longevity is extended, but the plug material formulation becomes more complex
Solution Approach 1:
The patent applies local quality by selecting resins with specific chemical properties (insolubility and immiscibility with electrochromic media) for the plug material. This local chemical property ensures that the plug maintains its integrity at the interface with the electrochromic media, preventing intermixing and extending device life, while the rest of the device can use conventional materials.
Solution Approach 2:
The patent segments the plug into multiple functional layers or components: a primary plug material made of insoluble/immiscible resins for chemical compatibility, and an optional secondary plug material for providing mechanical properties. This segmentation allows each layer to be optimized for its specific function while working together as a complete solution.
3Reliability
If antimonate photo initiators are incorporated into the plug formulation, then complete curing is achieved and plug reliability is improved, but the manufacturing process requires additional curing steps
Solution Approach 1:
The patent replaces conventional thermal or chemical curing methods with photo-initiated curing using antimonate photo initiators. This substitution allows curing to be initiated by light exposure rather than requiring extended thermal processing or complex chemical reactions, potentially reducing manufacturing cycle time while achieving complete curing.
Solution Approach 2:
The patent incorporates antimonate photo initiators into the plug formulation in advance, so that when the plug is installed, it can be cured quickly and completely by exposing it to appropriate light wavelengths. This preliminary incorporation of the curing agent eliminates the need for additional curing steps or materials to be added during the manufacturing process.
4Ease of manufacture
If conventional plug materials are used, then the manufacturing process is simpler, but gas permeability and barrier properties compromise device functionality
Solution Approach 1:
The patent changes the physical and chemical parameters of the plug material by selecting specific resins and incorporating antimonate photo initiators. These parameter changes result in a cured plug with improved gas permeability and barrier properties, preventing compromise of device functionality while maintaining ease of manufacture through a standardized curing process.
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 ensures complete curing and improved compatibility of the plug with the electrochromic medium, reducing the likelihood of leakage and extending the device's lifespan by minimizing intermixing and maintaining the integrity of the electrochromic medium.
Implementation Method 1
selective incorporation of one or more antimonate photo initiators into the fill port plug formulation facilitates a more complete cure of the same
Implementation Method 2
resins have been uncovered that are generally not miscible and/or soluble in the polar EC media
Implementation Method 3
resins that are substantially insoluble and/or substantially immiscible with an associated electrochromic medium
Data Source
AI summary
An electrochromic device including: (a) a first substantially transparent substrate having an electrically conductive material associated therewith; (b) a second substrate having an electrically conductive material associated therewith; (c) an electrochromic medium contained within a chamber positioned between the first and second substrates which includes: (1) a solvent; (2) an anodic material; and (3) a cathodic material, wherein both of the anodic and cathodic materials are electroactive and at least one of the anodic and cathodic materials is electrochromic; (d) wherein a seal member, the first substrate, the second substrate, and/or the chamber includes a plug associated with a fill port; and (e) wherein the plug is at least partially cured with an antimonate photo initiator and/or is one- or two-part plug which comprises a resin or mixture of resins that are substantially insoluble and/or substantially immiscible with an associated electrochromic medium while in the uncured state.