Electrochromic Element Separator Structure for Flat, Low-Power Switching
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Solution Overview
Problem
Existing electrochromic (EC) elements face challenges in achieving large area, low power consumption, and maintaining performance due to side reactions between anodic and cathodic organic EC compounds, and separators with higher thermal expansion coefficients can wrinkle or separate during manufacturing.
Innovation Solution
The EC element is designed with a separator having a smaller thermal expansion coefficient than the electrodes, bonded with an acrylic adhesive to prevent wrinkling or sagging, and includes permselective layers to inhibit side reactions, using a structure that maintains constant gaps and reduces power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separator with a smaller thermal expansion coefficient than the electrodes is used, then the separator can prevent wrinkling and sagging during manufacturing, but the separator may separate from the electrodes through heating steps due to thermal expansion mismatch
Solution Approach 1:
The patent changes the thermal expansion coefficient parameter of the separator material to be smaller than that of the electrodes, which prevents wrinkling and sagging during manufacturing while maintaining reliable adhesion through proper material selection and bonding process control
Solution Approach 2:
The patent employs composite material structure combining separator with different thermal expansion characteristics and adhesive layers to achieve both dimensional stability during manufacturing and reliable thermal adhesion during heating steps
2Speed
If the EC layer is in the form of a solution or gel to allow rapid response, then organic EC compounds can move freely within the EC layer, but the anodic and cathodic organic EC compounds undergo charge exchange (side reaction) within the EC layer and relax their electrochemical behavior to neutral states
Solution Approach 1:
The patent segments the EC layer into distinct anodic and cathodic sections separated by a separator structure, which prevents charge exchange between anodic and cathodic compounds while maintaining free movement within each section for rapid response
Solution Approach 2:
The patent introduces a separator as an intermediary structure between anodic and cathodic EC compounds, which acts as a physical barrier to prevent harmful charge exchange while allowing each compound type to maintain its electrochemical activity independently
3Reliability
If a permselective film is provided using a gasket to avoid side reaction between reaction products, then side reactions are prevented, but the process for element fabrication is limited
Solution Approach 1:
The patent designs the separator structure to serve multiple functions simultaneously: it acts as a permselective barrier to prevent side reactions, provides mechanical support for the EC layer, and allows flexible fabrication processes, thereby eliminating the limitations of gasket-based approaches
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
The solution achieves high display quality with uniform coloration and low power consumption by preventing separator wrinkling and side reactions, ensuring efficient operation and reduced energy use.
Implementation Method 1
a separator that divides a gap between the first electrode and the second electrode into two sections
Implementation Method 2
Each of the first electrode and the second electrode is bonded to the separator with an acrylic adhesive
Implementation Method 3
The EC element is an active optical element that adjusts the hue or amount of light in the visible light region by applying a voltage between the pair of electrodes to oxidize or reduce a compound in the EC layer
Implementation Method 4
a permselective film that allows electrolyte ions to pass through but not the reaction molecules of the EC compounds
Data Source
AI summary
The present disclosure provides an EC element in which a separator divides the gap between a pair of electrodes into two sections defining a pair of EC layers, each containing an EC compound. The separator has a smaller thermal expansion coefficient than the electrodes and is bonded to each of the electrodes with an acrylic adhesive. The acrylic adhesive enables the separator to be provided without wrinkles or sagging.