Electrochromic Device Partitioning for Maskless Connector Access
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Solution Overview
Problem
Current electrochromic device fabrication techniques face challenges due to the use of adhesive masks, which are difficult to apply and remove, leading to potential short-circuits, layer disintegration, and high costs, especially when accessing the lower electrode for connector contact.
Innovation Solution
The electrochromic device features a multilayer stack with selective and total partitions that isolate the upper electrode into free and active regions, allowing for connector placement without masks, using ultrasonic soldering and laser-produced partitions to ensure electrical isolation and minimize free regions, thereby reducing the risk of short-circuits and improving manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive masks are used to access the lower electrode for connector contact, then the lower electrode can be accessed, but the masks are difficult to apply and remove, leading to potential short-circuits, layer disintegration, and high costs
Solution Approach 1:
The device is segmented into distinct functional regions: an active area for electrochromic functionality and a contact area for electrical connections. The partition structure divides the substrate into these separate zones, allowing connectors to be placed in the contact area without interfering with the active electrochromic layers, thereby eliminating the need for adhesive masks and their associated reliability issues.
Solution Approach 2:
The connection function is extracted from the active electrochromic area and placed in a separate contact area. This separation allows the lower electrode to be accessed for connector placement without requiring masks that cover and protect the active area during manufacturing, thus removing the source of potential short-circuits and layer disintegration.
2Ease of manufacture
If adhesive masks are used during fabrication, then the lower electrode can be accessed, but manufacturing time increases and costs rise
Solution Approach 1:
By segmenting the substrate into contact areas and active areas during the deposition process, the patent enables direct access to the lower electrode in the contact area without requiring subsequent mask application and removal steps. This segmentation is built into the device structure itself, streamlining the manufacturing process and reducing both time and cost.
Solution Approach 2:
The partition structure is created preliminarily during the layer deposition process, before connector placement is needed. This preliminary action establishes the contact areas where the lower electrode is naturally accessible, eliminating the need for later mask-related operations and thereby reducing manufacturing time and cost.
3Reliability
If free regions are minimized in the electrode design, then the risk of short-circuits is reduced, but the area available for connector placement is limited
Solution Approach 1:
The substrate is segmented into clearly defined contact areas and active areas. The contact areas are specifically designated for connector placement and are electrically isolated from the active electrochromic areas by partitions. This segmentation allows the free regions in contact areas to be minimized for reliability while still providing sufficient area for connector placement in the isolated contact zones.
Solution Approach 2:
The partition structure acts as an intermediary element that electrically isolates the contact areas from the active areas. This intermediary structure allows the lower electrode in the contact area to have minimal free regions (reducing leakage currents) while still providing a dedicated area for connector placement, as the partition prevents electrical interference with the active region.
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 eliminates the need for masking tapes, reduces manufacturing time, enhances the reliability of the devices by minimizing leakage currents, and allows for faster response times while maximizing the active area and controlling the occultation profile, resulting in more efficient and cost-effective electrochromic devices.
Implementation Method 1
electrochromic material capable of inserting, reversibly and simultaneously, ions and electrons, the oxidation states of which, corresponding to the inserted and ejected states, have a distinct color when they are supplied via a suitable power supply, one of these states having a higher light transmission than the other
Implementation Method 2
using ultrasonic soldering and laser-produced partitions
Data Source
AI summary
The present invention relates to an electrochromic device comprising:at least one partition (12) that separates the surface of the upper electrode (9) into two regions isolated from each other, namely a free region (9a) and an active region;at least one partition (5) that separates the surface of the lower electrode (4) into two regions electrically isolated from each other, namely a free region (4a) and an active region (4b);at least one free region (9a) of the upper electrode (9) receives a first current-supply connector (15) soldered to the active zone (4b) of the lower electrode (4); andthe active area (9b) of the upper electrode (9) is in electrical contact with the connection means (20, 21a) connected to a second current-supply connector (21) electrically isolated from the free zone (9a) connected to the lower electrode (4).