Electrochromic Composite Pane With Active-Layer Concentration Gradient
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Solution Overview
Problem
Existing composite panes with electrically controllable functional elements, such as sun visors, suffer from undesirable aging phenomena like brightening and changes in shading due to diffusion of compounds from thermoplastic laminating films, leading to visible edges and reduced optical quality, particularly in the through-vision region.
Innovation Solution
A composite pane with a functional element embedded in a thermoplastic intermediate layer, featuring a concentration gradient of the active substance within the active layer, allowing for location-dependent control of optical properties via voltage, eliminating the need for multiple functional elements and reducing visible edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple functional elements with uniform active substance concentration are used to cover different opacity regions, then the optical quality and visibility control are improved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The patent applies local quality by creating a concentration gradient of the active substance within the functional element. Different regions of the same functional element have different concentrations of electrochromic material, allowing each region to provide different optical properties (different opacity levels) while being part of a single integrated structure. This eliminates the need for multiple separate functional elements with uniform concentration.
Solution Approach 2:
The patent merges multiple functional elements that would traditionally be required to cover different opacity regions into a single functional element. By implementing a concentration gradient within one continuous functional element, the patent combines what would have been separate components into one integrated unit, simplifying both the device structure and assembly process.
2Illumination intensity
If multiple functional elements are used to cover different opacity regions, then the optical quality is improved, but the assembly process becomes more complex
Solution Approach 1:
The patent merges multiple functional elements into a single integrated functional element with a concentration gradient. This eliminates the need to assemble multiple separate components, thereby simplifying the assembly process while maintaining the optical quality benefits of having different opacity regions.
3Ease of manufacture
If uniform concentration of active substance is used throughout the functional element, then the manufacturing process is simpler, but the ability to provide location-dependent optical control is reduced
Solution Approach 1:
The patent implements local quality by varying the concentration of the active substance at different locations within the functional element. This allows each region to be optimized for its specific function (different opacity levels) while still being manufactured as a single integrated component, thus maintaining manufacturing simplicity while enhancing adaptability.
4Ease of manufacture
If visible edges are present at transitions between functional elements, then the assembly is simpler, but the aesthetic quality and optical performance are reduced
Solution Approach 1:
The patent merges multiple functional elements into a single continuous functional element with a concentration gradient. This eliminates the physical edges and boundaries that would exist between separate components, thereby removing visible transition lines and improving aesthetic quality while maintaining assembly simplicity.
Solution Approach 2:
The concentration gradient creates smooth transitions between regions of different opacity by gradually varying the active substance concentration. This eliminates sharp edges and visible boundaries that would otherwise be present at the interfaces between discrete functional elements, improving both aesthetics and optical performance.
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 solution enables higher optical quality and simplified assembly by allowing a single functional element to cover various opacity regions without visible transitions, enhancing both functionality and aesthetics while reducing production costs and edge sealing requirements.
Implementation Method 1
functional element having electrically controllable optical properties
Implementation Method 2
PDLC functional elements (polymer dispersed liquid crystal). Their active layer contains liquid crystals that are embedded in a polymer matrix. When no voltage is applied, the liquid crystals are oriented in a disorderly fashion, resulting in strong scattering of the light passing through the active layer. When a voltage is applied on the surface electrodes, the liquid crystals align themselves in a common direction and the transmittance of light through the active layer is increased.
Implementation Method 3
the concentration of the active substance in the matrix varies over the surface of the functional element
Implementation Method 4
The diffusion of compounds, in particular of plasticizers, out of the thermoplastic laminating films of the composite pane into the active layer of the functional element is considered to be the cause
Data Source
AI summary
A composite pane includes a functional element having electrically controllable optical properties, includes an inner pane including an inner and outer side and an outer pane including an inner and outer side, a thermoplastic intermediate layer, which joins the inner side) of the inner pane to the inner side of the outer pane, a functional element embedded in the thermoplastic intermediate layer and having electrically controllable optical properties at least including a multilayer film containing, arranged surface-to-surface one above the other in this sequence, a first carrier film, a first surface electrode, an active layer, a second surface electrode, and a second carrier film. The active layer includes a matrix and an active substance, and the concentration of the active substance varies over the area of the functional element.