Electrochromic Fill Port Plug Curing via UV Photoinitiators
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Solution Overview
Problem
Electrochromic devices face issues with plug curability, compatibility, and reliability, leading to incomplete curing and potential leakage, which can damage surrounding structures and compromise the longevity and functionality of the devices.
Innovation Solution
The use of a plug formulation including a photoinitiator and photosensitizer exposed to electromagnetic radiation with a wavelength of 350 nm to 420 nm for curing, which facilitates a more complete and efficient curing process, reducing energy input and minimizing intermixing with the electrochromic medium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plug materials are used without photoinitiator and photosensitizer, then the plug can be applied to fill ports, but the plug curing is incomplete and reliability is poor
Solution Approach 1:
The patent modifies the chemical composition parameters of the plug material by incorporating specific photoinitiators (e.g., Irgacure 651, TPO, TPO-L) and photosensitizers (e.g., thioxanthone, xanthone derivatives) to enable complete curing. This parameter change transforms the plug from incompletely cured to fully cured state, resolving the reliability issue while maintaining ease of manufacture through standard photopolymerization processes.
Solution Approach 2:
The patent creates a composite plug material system combining epoxy resin or acrylic oligomer base materials with photoinitiators and photosensitizers. This composite formulation achieves complete curing by leveraging the synergistic effect of multiple components, where the photosensitizer extends the absorption spectrum and the photoinitiator triggers polymerization, thereby improving reliability without significantly complicating the manufacturing process.
2Productivity
If conventional curing methods are used, then the process is simple, but energy input is high and curing efficiency is low
Solution Approach 1:
The patent replaces thermal curing mechanisms with photochemical curing mechanisms. By using photoinitiators and photosensitizers that absorb UV or visible light and trigger polymerization, the system achieves rapid curing at room temperature without requiring high energy input from heat sources. This substitution dramatically improves curing efficiency while reducing energy consumption.
Solution Approach 2:
The patent utilizes periodic exposure to electromagnetic radiation (UV or visible light) to initiate and complete the curing process. The photoinitiator and photosensitizer system allows curing to proceed in controlled intervals through light exposure, enabling high productivity with lower cumulative energy input compared to continuous thermal curing.
3Reliability
If plug material is applied near electrochromic medium, then fill port can be sealed, but intermixing occurs compromising plug purity and performance
Solution Approach 1:
The patent uses photochemical curing instead of thermal curing to prevent intermixing between the plug material and electrochromic medium. The photopolymerization reaction occurs rapidly upon light exposure, forming a cured barrier that prevents diffusion and mixing. This method maintains plug purity and barrier properties while managing curing process control through simple light exposure protocols.
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 enhances plug curability, compatibility, and durability, reducing the likelihood of leakage and improving the longevity and functionality of electrochromic devices by ensuring a more complete and efficient curing process.
Implementation Method 1
The plug may be at least partially cured with at least one photoinitiator and at least one photosensitizer upon exposure to electromagnetic radiation having a wavelength from about 350 nm to about 420 nm
Data Source
AI summary
An electrochromic device including: a first substantially transparent substrate having an electrically conductive material associated therewith; a second substrate having an electrically conductive material associated therewith; an electrochromic medium contained within a chamber positioned between the first and second substrates which includes: at least one solvent; at least one anodic material; and at least one cathodic material, wherein both of the anodic and cathodic materials are electroactive and at least one of the anodic and cathodic materials is electrochromic; wherein at least one of a seal member, the first substrate, the second substrate, and the chamber includes a plug associated with a fill port; and wherein the plug is at least partially cured with at least one photoinitiator and at least one photosensitizer upon exposure to electromagnetic radiation having a wavelength from about 350 nm to about 420 nm.