Integrated Electrochromic Layer Deposition for Low-Defect Glass
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Solution Overview
Problem
Existing electrochromic devices suffer from high levels of defectivity, such as pin holes and spots where the electrochromic transition is impaired, which is unacceptable for applications like electrochromic architectural glass.
Innovation Solution
The fabrication of improved electrochromic devices with low defectivity is achieved by depositing layered components in a single integrated deposition system with a controlled ambient environment, ensuring that the substrate never leaves this environment during deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrochromic devices are fabricated using conventional deposition methods with multiple environment transitions, then manufacturing flexibility is improved, but defectivity increases due to particle contamination
Solution Approach 1:
The patent combines multiple deposition steps (electrochromic layer, ion conducting layer, counter electrode layer) into a single integrated deposition system, eliminating the need to exit and re-enter the controlled environment between steps. This merging of previously separate processes prevents particle contamination while maintaining manufacturing flexibility.
Solution Approach 2:
The patent maintains a controlled ambient environment (inert atmosphere) throughout the entire deposition process, preventing particle contamination by keeping the substrate within the controlled environment. This continuous inert environment protection resolves the contradiction by enabling both manufacturing flexibility and low defectivity.
2Adaptability or versatility
If substrate exits controlled environment between deposition steps, then process flexibility is improved, but particle contamination increases
Solution Approach 1:
The patent merges multiple deposition operations into a single continuous process within the controlled environment, eliminating the need to exit and re-enter the environment. This resolves the contradiction by maintaining process flexibility through integrated deposition while preventing particle contamination during transitions.
Solution Approach 2:
The patent ensures continuous deposition of all layers without interruption or exit from the controlled environment, maintaining the beneficial controlled atmosphere throughout the entire fabrication process. This continuity prevents particle contamination while preserving process adaptability.
3Adaptability or versatility
If multiple separate deposition systems are used, then process adaptability is improved, but device reliability decreases due to defects
Solution Approach 1:
The patent combines multiple deposition systems into a single integrated deposition system that can deposit electrochromic layers, ion conducting layers, and counter electrode layers sequentially without exiting the controlled environment. This merging maintains process adaptability while eliminating defects caused by environmental transitions, thereby improving device reliability.
4Device complexity
If conventional fabrication processes are used, then manufacturing simplicity is maintained, but defectivity increases causing visual distractions
Solution Approach 1:
The patent uses a controlled ambient environment (inert atmosphere) throughout the deposition process to prevent particle contamination. While this adds some system complexity, it dramatically reduces defectivity by preventing pinholes and spots that cause visual distractions, resolving the contradiction between manufacturing simplicity and manufacturing precision.
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 results in highly reliable electrochromic devices with reduced defectivity, preventing bright spots or "constellations" on electrochromically darkened windows, thus minimizing distractions and improving performance.
Implementation Method 1
In some embodiments, the layers of interest are deposited using physical vapor deposition.
Implementation Method 2
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.
Implementation Method 3
Tungsten oxide is a cathodic electrochromic material in which a coloration transition, transparent to blue, occurs by electrochemical reduction.
Data Source
AI summary
Prior electrochromic devices frequently suffer from high levels of defectivity. The defects may be manifest as pin holes or spots where the electrochromic transition is impaired. This is unacceptable for many applications such as electrochromic architectural glass. Improved electrochromic devices with low defectivity can be fabricated by depositing certain layered components of the electrochromic device in a single integrated deposition system. While these layers are being deposited and/or treated on a substrate, for example a glass window, the substrate never leaves a controlled ambient environment, for example a low pressure controlled atmosphere having very low levels of particles. These layers may be deposited using physical vapor deposition.