Electrochromic Coating Reduction via Discrete Redox Agent Deposition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for reducing electrochromic coatings on large or curved surfaces are complex, require adaptation of electrochemical systems, and struggle with uniformity and scalability, especially for continuous processes like electrochromic panes.
Innovation Solution
A method involving the deposition of a redox agent on electrochromic coatings in discrete points, ensuring electrical contact with a conductive substrate, allowing for indirect oxidation-reduction reactions with a liquid electrolyte, enabling homogeneous reduction or oxidation across the entire surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional electrochemical reduction systems are used for large surfaces, then the reduction process can be performed, but the device complexity increases and uniformity deteriorates
Solution Approach 1:
The patent extracts the redox function from the complex multi-electrode electrochemical system and concentrates it into a single sacrificial counter-electrode containing the reducing agent. This simplifies the apparatus while maintaining the ability to treat large surfaces, as the reducing agent is delivered directly to the coating without requiring complex electrode geometries adapted to surface size.
Solution Approach 2:
The sacrificial counter-electrode serves multiple functions: it acts as the counter-electrode in the electrochemical cell, contains and releases the reducing agent, and can be used for treating various surface sizes and geometries without requiring geometric adaptation. This universal approach resolves the contradiction between handling large areas and maintaining simple device architecture.
2Area of stationary object
If traditional electrochemical reduction systems are used for large surfaces, then the reduction process can be performed, but the manufacturing precision deteriorates due to non-uniform reduction
Solution Approach 1:
The patent applies local quality by concentrating the reducing agent at the interface between the sacrificial counter-electrode and the electrochromic coating. This localized delivery ensures that the reduction occurs uniformly across the entire coating surface through direct contact and electrochemical reaction, rather than relying on diffusion through a large bath volume which causes non-uniformity.
3Reliability
If traditional electrochemical reduction systems are used, then batch processing can be performed, but the productivity deteriorates for continuous processes
Solution Approach 1:
The patent enables dynamic processing by allowing the substrate to move through the electrochemical cell while the sacrificial counter-electrode continuously supplies reducing agent. The liquid electrolyte medium allows for flexible substrate handling and continuous processing, transforming the static batch process into a dynamic continuous operation while maintaining process stability through the robust sacrificial electrode mechanism.
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 simplifies the reduction process, ensures uniform coverage, and is suitable for large areas and continuous processes, overcoming the limitations of traditional electrochemical systems.
Implementation Method 1
an indirect oxidation-reduction reaction takes place, via the underlying conductive layer, between the redox agent and the electrochromic compound deposited thereon
Implementation Method 2
The electrochromic dyes of the two electrochromic layers are then chosen so that one of them is colored in the reduced and colorless state or weakly colored in the oxidized state
Data Source
AI summary
The present invention relates to a process for manufacturing an electrochromic article, comprising the following successive steps: (a) deposition of a layer of an electrochromic compound on the surface of a transparent or translucent electroconductive substrate; (b) deposition of a redox agent, which is a reducing agent or an oxidizing agent for the electrochromic compound, on the layer of electrochromic compound at a multitude of discrete points or areas thereon; (c) bringing the layer of electrochromic compound, deposited in step (a), and the redox agent, deposited in step (b), into contact with a liquid electrolyte for a time long enough to allow the electrochromic compound to be reduced or oxidized by the redox agent; and (d) elimination of the electrolyte by rinsing and/or drying, the layer of electrochromic compound being a porous layer of open porosity and/or an electrically conductive layer.