Electrochromic Lens Stack with Nanostructured Ceramic Layers
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Solution Overview
Problem
Current electrochromic eyeglass lenses face limitations such as inability to block light across the visible spectrum cosmetically, poor environmental stability, short material life cycles, lack of frame-independent manufacturing processes, and difficulty in supplying electrical power, hindering their commercial viability.
Innovation Solution
An electrochromic optical system comprising an optical substrate with an electrochromic stack of at least five ceramic layers, including nanostructured materials like tungsten oxide and nickel oxide, and an ion-conducting layer, which can be easily applied to existing ophthalmic lens blanks, providing controllable variable transmission performance under low voltage without bulky batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If electrochromic materials are used in eyeglass lenses, then light blocking capability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The electrochromic system is divided into multiple functional layers including electrochromic ceramic layers, ion-conducting layers, and transparent conducting oxide layers. Each layer performs a specific function, allowing the complex electrochromic functionality to be achieved through manageable, specialized components that can be deposited sequentially using sputtering techniques.
Solution Approach 2:
The patent employs porous or nanostructured ceramic materials (such as tungsten oxide, nickel oxide, or mixed metal oxides) as the electrochromic active layers. The porous structure increases surface area and ion transport pathways, enhancing the electrochromic effect while maintaining thin film geometry suitable for eyeglass lenses.
2Object-affected harmful factors
If electrochromic coatings are applied to provide broad spectrum light blocking, then UV and visible light protection is improved, but cosmetic appearance and optical quality deteriorate
Solution Approach 1:
Different layers in the electrochromic stack are designed with specific optical properties tailored to their functions. The electrochromic ceramic layers provide broad-spectrum absorption when activated, while ion-conducting and transparent conducting oxide layers maintain high transparency in the visible range when inactive, allowing the lens to remain cosmetically appealing in the clear state while providing protection when activated.
Solution Approach 2:
The patent uses composite structures combining multiple ceramic materials (e.g., tungsten oxide with nickel oxide, or mixed metal oxides containing iron, cobalt, or manganese). These composite materials provide synergistic effects, achieving broad-spectrum light blocking across UV and visible ranges while maintaining appropriate optical properties and cosmetic appearance.
3Adaptability or versatility
If photochromic materials are used, then automatic response to ambient illumination is improved, but controllability and activation timing worsen
Solution Approach 1:
The electrochromic system incorporates transparent conducting oxide layers (such as indium tin oxide or fluorine-doped tin oxide) that serve as both electrodes and conductive pathways. These layers enable electrical control of the electrochromic effect, allowing the lens to be activated or deactivated on demand through applied voltage, providing precise controllability while maintaining adaptability through programmable control schemes.
4Reliability
If electrochromic stack with multiple ceramic layers is used, then light blocking performance and stability are improved, but manufacturing precision and application difficulty increase
Solution Approach 1:
The sputtering deposition process is configured with controlled parameters (power, gas flow, substrate temperature) that enable self-regulating deposition rates. The ion-conducting and transparent conducting oxide layers are deposited in sequence with the electrochromic ceramic layers, forming integrated thin film stacks where each layer's thickness and composition are automatically controlled by the deposition process parameters, reducing the need for post-manufacturing adjustments.
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 enables a compact, robust, and fast-responding electrochromic film stack that can be applied to various transparent surfaces, offering improved light blocking, stability, and extended material life, while reducing bulkiness and operational complexity.
Implementation Method 1
electrochromic materials can be activated and deactivated when desired
Implementation Method 2
an ion-conducting layer
Data Source
AI summary
Devices and methods related generally to electrochromic materials and their use. In some embodiments, the electrochromic materials are for use on an optical substrate, such as a lens, a semi-finished lens blank, and the like. Some embodiments include an electrochromic stack including nanostructured materials. Some embodiments include an electrochromic stack including nanostructured electrochromic materials. Some embodiments include one or more ion-conducting layers. Methods of making electrochromic stacks having nanostructured materials and/or ion-conducting layers are also discussed.