Electrochromic Laminate Manufacturing With Adhesive Electrolyte Support
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Solution Overview
Problem
Existing electrochromic laminates are complex, costly, and heavy, limiting their widespread use due to manufacturing and transportation challenges, and they are not environmentally friendly.
Innovation Solution
A method using a transparent, pressure-sensitive adhesive polymer electrolyte film as a support structure for electrochromic laminates, eliminating glass or polymer bodies, allowing for simpler, faster, and more cost-effective production and transportation, with optional encapsulation for environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass or polymer substrate bodies are used to support the electrochromic laminate layers, then the structural stability and protection of the laminate is improved, but the weight, volume, and manufacturing complexity increase significantly
Solution Approach 1:
The patent extracts and removes the heavy glass or polymer substrate bodies from the electrochromic laminate structure, retaining only the essential functional layers (transparent electrode layer, electrochromic layer, ion storage layer) that can be directly applied to the plastic body. This extraction eliminates unnecessary weight and volume while maintaining the core electrochromic functionality.
Solution Approach 2:
The patent replaces rigid glass or polymer substrate bodies with thin plastic bodies and thin film layers. The transparent electrode layer, electrochromic layer, and ion storage layer are all applied as thin films directly onto the plastic body, creating a lightweight, flexible structure that maintains structural integrity without the bulk of traditional substrate materials.
2Reliability
If glass or polymer substrate bodies are used to support the electrochromic laminate layers, then the structural stability and protection of the laminate is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the support body function with the plastic substrate that already serves as the base for the electrochromic layers. Instead of separately manufacturing glass or polymer substrate bodies and then assembling the electrochromic layers onto them, the invention integrates all layers directly onto the plastic body in a single manufacturing process, eliminating assembly steps and reducing complexity.
Solution Approach 2:
The patent segments the electrochromic laminate into distinct functional layers (transparent electrode layer, electrochromic layer, ion storage layer) that can be independently manufactured and then applied to the plastic body. This segmentation allows each layer to be optimized and produced separately using specialized deposition techniques, then assembled in a controlled manner, reducing overall manufacturing complexity.
3Reliability
If glass or polymer substrate bodies are used to support the electrochromic laminate layers, then the structural stability is improved, but the transportation cost and complexity increase
Solution Approach 1:
The patent uses thin plastic bodies and thin film layers instead of thick glass or polymer substrate bodies, creating a lightweight, flexible structure that is easier to handle, pack, and transport. The reduced thickness and weight of each layer contribute to a more manageable final product that requires less specialized transportation infrastructure.
4Reliability
If traditional manufacturing methods with glass or polymer bodies are used, then the electrochromic laminate can be produced, but the production speed and efficiency are reduced
Solution Approach 1:
The patent segments the manufacturing process into distinct deposition steps for each functional layer (transparent electrode layer, electrochromic layer, ion storage layer), allowing each layer to be deposited using optimized techniques at controlled rates. This segmentation enables parallel processing and continuous manufacturing, increasing overall production speed while maintaining quality.
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 method produces electrochromic laminates with higher optical quality, reduced volume and weight, enabling easier and more environmentally friendly production and transport, and potentially lower energy consumption.
Implementation Method 1
a film that contains or consists of a transparent, pressure-sensitive adhesive polymer electrolyte
Implementation Method 2
The electrochromic system or laminate contains positively charged ions, usually hydrogen or lithium, which can migrate back and forth between the electrochromic layer and the ion storage layer due to a voltage applied between the two transparent electrode layers. These positively charged ions lead to changes in the optical properties of the electrochromic layer
Implementation Method 3
a film that contains or consists of a transparent, pressure-sensitive adhesive polymer electrolyte, wherein the film has a flat top side and a flat bottom side
Data Source
AI summary
A method for producing an electrochromic laminate and an electrochromic laminate are provided. In the method, a film is provided which contains or consists of a transparent, pressure-sensitive adhesive polymer electrolyte, a first half-cell is provided which consists of a first laminate of a first transparent electrode layer and an electrochromic layer, and a second half-cell is provided which consists of a second laminate of a second transparent electrode layer and an ion storage layer. Here, the first half-cell has no gas substrate body and no polymer substrate body that contacts the first transparent electrode layer, and the second half-cell has no gas substrate body and no polymer substrate body that contacts the second transparent electrode layer. An electrochromic laminate is produced from the two half-cells.