Electrochromic Device Seal Positioning for Uniformity
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Solution Overview
Problem
Existing manufacturing methods for electrochromic devices face issues such as diffusion-induced property differences between the periphery and middle parts, delamination of substrates, and incompatibility with industrial production volumes, leading to non-uniform thickness and functionality issues at the edges.
Innovation Solution
A method involving the lamination of plastic substrates with electron conducting and electrochromic layers, followed by forming a seal through the electrochromic laminate sheet at a distance from the peripheral edge, using techniques like ultrasonic or laser welding to create a hermetic seal and prevent diffusion, while cutting the devices to size after sealing to maintain uniformity and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing is performed at the peripheral edge of the device, then hermetic sealing is achieved, but diffusion-induced property differences occur between periphery and middle parts
Solution Approach 1:
The device structure is segmented into a functional interior portion and a sealed peripheral region. The seal is positioned at a distance from the peripheral edge, creating a distinct separation between the hermetically sealed region and the functional electrochromic region, preventing diffusion effects from compromising the uniformity of the device properties in the functional area.
Solution Approach 2:
The hermetic seal is formed in advance at a predetermined distance from the peripheral edge before the device is fully assembled or used. This preliminary sealing action prevents diffusion of electrolyte components or contamination into the interior portion, ensuring uniform device properties are maintained throughout the functional area.
2Reliability
If adhesive sealing is used to seal the device edges, then hermetic sealing is achieved, but an additional curing step is required
Solution Approach 1:
The adhesive chemical bonding system is replaced with a mechanical welding system. Ultrasonic or laser welding provides hermetic sealing through direct mechanical fusion of the substrate edges, eliminating the need for adhesive application and curing steps, thereby reducing manufacturing complexity while maintaining sealing reliability.
3Reliability
If sealing adds substance to the device thickness, then hermetic sealing is achieved, but non-functioning or badly functioning parts are created at the periphery
Solution Approach 1:
The sealing function is extracted from the functional electrochromic area. By positioning the seal at a distance from the peripheral edge and using welding instead of adhesive, the sealing substance does not intrude into the functional region, maintaining uniform device thickness and ensuring the functional area remains free from non-functioning parts.
4Ease of operation
If substrates are handled before sealing is completed, then manufacturing flexibility is maintained, but delamination occurs at the edges
Solution Approach 1:
The hermetic seal is formed as a preliminary action before final device assembly and handling. This preliminary sealing creates a protective barrier that prevents delamination at the edges during subsequent manufacturing operations, allowing manufacturing flexibility to be maintained without compromising substrate bonding strength.
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 prevents diffusion-related property changes, ensures a mechanically strong joint, and is compatible with industrial production volumes, resulting in electrochromic devices with uniform thickness and functionality across the entire surface, including the edges.
Implementation Method 1
using techniques like ultrasonic or laser welding to create a hermetic seal
Implementation Method 2
using techniques like ultrasonic or laser welding to create a hermetic seal
Implementation Method 3
diffusion into or out of the electrolyte before the edges are sealed
Data Source
AI summary
A manufacturing method of electrochromic devices (10) includes the steps of providing a first and second sheet including a first (22) and second (24) plastic substrate, respectively, at least partially coated with a first (12) and second (14) electron conducting layer, respectively. The first sheet is at least partially coated with a first electrochromic layer (16). The second sheet is at least partially coated with a counter electrode layer (18). The first and second sheets are laminated with an electrolyte layer (20) interposed in-between into an electrochromic laminate sheet (30). The electrochromic device is at least partially defined by forming a seal (50) through the electrochromic laminate sheet (30) at a distance (D) from a peripheral edge (31). The distance (D) is preferably larger than the mean diffusion lengths of oxygen, water or an electrolyte component in the electrolyte during a predetermined time period.