Electrochromic Device Laser Patterning for Flexible Production
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Solution Overview
Problem
The existing methods for producing electrochromic devices are inflexible and time-consuming, with the shape and size of the device fixed before the deposition process, leading to increased production costs and limited flexibility.
Innovation Solution
A method involving the application of a first electrically conductive layer, an active layer, and a second electrically conductive layer, with non-interconnected recesses introduced in a specified pattern, allowing for the final shape and size to be defined later through laser cutting, enabling flexible production and patterning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the shape and size of the electrochromic device are fixed before the deposition process, then the production process is well-defined and controlled, but the production flexibility is reduced and production time increases
Solution Approach 1:
The patent applies preliminary action by depositing complete layers across the entire substrate before any shaping operations. The conductive layers and electrochromic layers are deposited in full coverage, and then recesses are introduced to define the final device shape. This reverses the conventional sequence where shapes are defined before deposition, thereby gaining production flexibility without sacrificing control.
2Ease of manufacture
If the shape and size of the electrochromic device are fixed before the deposition process, then the process control is maintained, but the production costs increase
Solution Approach 1:
The invention deposits material layers in advance across the entire substrate area before introducing recesses to define the final shape. This preliminary deposition approach allows for more efficient material utilization and reduces the need for precise masking during deposition, thereby lowering production costs while simultaneously increasing flexibility to produce different device shapes and sizes.
3Manufacturing precision
If recesses are introduced early in the process, then the final shape is defined early, but the production flexibility and ability to optimize later are reduced
Solution Approach 1:
The patent inverts the conventional manufacturing sequence by depositing complete layers first and then introducing recesses to define shapes. Instead of creating recesses early to define shapes before deposition, the process deposits materials in full coverage and subsequently removes material through recesses to achieve the final shape. This inversion provides both precision in shape definition and flexibility in production optimization.
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 allows for the production of electrochromic devices with a transparent substrate and conductive layers, enabling flexible shaping and reducing production time and costs, while maintaining the electrochromic properties.
Implementation Method 1
introducing a specified proportion of the first recesses and the second recesses and/or connecting the first recesses and/or the second recesses to one another by means of a laser cut
Data Source
AI summary
A method for producing an electrochromic device includes the following procedures in the following order: providing a substrate, applying a first electrically conductive layer, applying at least one active layer, introducing first non-interconnected recesses in a specified first pattern, applying a second electrically conductive layer, and connecting a specified proportion of the first recesses by a laser cut through all previously applied layers.