Electrochromic Device Laser Patterning via Absorbing Layer
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Solution Overview
Problem
Conventional electrochromic devices face challenges in patterning due to uncontrollable depth of laser ablation, production of slag from low-energy laser light, and high capital and maintenance costs, leading to inefficient energy use and potential damage to underlying layers during laser ablation for patterning transparent conductive layers.
Innovation Solution
Incorporating an absorbing electrochromic layer that is darkened to control laser light absorption, allowing for precise laser ablation at specific depths and reducing energy consumption, while protecting non-targeted layers from damage, thereby minimizing kerf and slag formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser ablation is used to pattern transparent conductive layers in electrochromic devices, then patterning can be achieved, but uncontrollable depth of ablation and production of slag occur, causing damage to underlying layers and inefficient energy use
Solution Approach 1:
The patent changes the optical absorption parameter of the electrochromic layer by controlling its oxidation state. By adjusting the potential applied to the electrochromic layer, its absorption characteristics are modified to selectively absorb laser energy at specific wavelengths, enabling precise control over ablation depth and preventing slag production in underlying layers.
Solution Approach 2:
The electrochromic layer acts as an intermediary between the laser source and the transparent conductive layers. By controlling the absorption properties of this intermediate layer, the laser energy is selectively absorbed or transmitted, allowing precise patterning of target layers while protecting non-target layers from damage.
2Manufacturing precision
If higher laser fluence is used to ensure adequate ablation, then patterning depth is sufficient, but energy consumption increases and underlying layers may be damaged
Solution Approach 1:
The patent utilizes parameter changes in the electrochromic layer's optical properties to control laser energy absorption. By adjusting the oxidation state of the electrochromic layer, its absorption coefficient is modified, enabling selective absorption of laser energy at controlled depths and preventing excessive energy transmission to underlying layers.
Solution Approach 2:
The patent converts the potential harm of uncontrolled laser energy transmission into a benefit by using the electrochromic layer's tunable absorption to selectively block excess energy. The same property that enables patterning also prevents damage to underlying layers, turning a potential problem into a protective mechanism.
3Ease of manufacture
If conventional laser ablation is used without state control, then the process is simple, but temperature-to-fluence efficiency is low and unwanted material formation occurs
Solution Approach 1:
The patent introduces controlled parameter changes in the electrochromic layer's oxidation state to optimize laser energy absorption. By adjusting the potential applied to the electrochromic layer before and during laser processing, temperature-to-fluence efficiency is enhanced, reducing energy loss and preventing unwanted material formation.
Solution Approach 2:
The patent implements feedback control by monitoring and adjusting the electrochromic layer's state during laser processing. The potential applied to the electrochromic layer is controlled based on the desired absorption characteristics, enabling real-time optimization of energy efficiency and prevention of unwanted side effects.
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 enhances temperature-to-fluence efficiency, reduces energy costs, and minimizes material damage during laser scribing, resulting in a more efficient and cost-effective patterning process with predictable resistance and reduced unwanted material formation.
Implementation Method 1
Incorporating an absorbing electrochromic layer that is darkened to control laser light absorption
Implementation Method 2
allowing for precise laser ablation at specific depths and reducing energy consumption
Implementation Method 3
An electrochromic coating can reduce the amount of energy used for room heating and/or air conditioning
Implementation Method 4
causes reversible migration of ions between the anode and cathode resulting in the above oxidation-reduction reactions that change the absorption of the cathode, anode, or both
Data Source
AI summary
Varying the optical absorption of an electrochromic device in situ allows optimal control over the depth and quality of laser patterning lines when patterning electrochromic devices. Accordingly, an electrochromic device comprises a target conductive layer, an absorbing electrochromic layer formed below the target layer, and an electrolyte layer formed below the absorbing electrochromic layer. The absorbing electrochromic layer is placed in a darkened state, and the target layer is laser ablated using a wavelength that is minimally absorbed in the target layer and a fluence level that does not ablate layers of the electrochromic device that are below the absorbing electrochromic layer. The absorbing electrochromic layer is placed in the darkened state by applying a predetermined control voltage to the electrochromic device, forming the electrochromic device by dark-state deposition, or forming an electrochromic device that is in its darkened state in an equilibrium state.