Electrochromic Sheet Sealing for Controlled Processing Deformation
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Solution Overview
Problem
Electrochromic devices with gel-like electrolyte layers tend to deform during processing, leading to manufacturing challenges.
Innovation Solution
An electrochromic sheet design with controlled deformation, using a support layer, electrolyte layer, electrochromic layers, and sealing parts, with specific deformation limits and materials like urethane (meth)acrylate and polymethyl (meth)acrylate binders, to enhance processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electrolyte layer with gel-like form is sealed inside an electrochromic device, then the device can maintain color development state and reduce power consumption, but the device tends to be depressed in lamination direction during processing
Solution Approach 1:
The patent applies parameter changes by controlling the deformation amount of the electrochromic sheet within a specific range (0.01 mm to 0.09 mm) through pressing conditions (30 N for 30 seconds). This parameter control allows the sheet to be sufficiently deformable for processing while preventing excessive deformation that would compromise manufacturing precision. The deformation amount serves as a key parameter to balance processability and structural integrity.
Solution Approach 2:
The patent uses composite materials by combining the electrolyte layer with a sealing part that has curable resin properties. The sealing part forms a composite structure that encapsulates the electrolyte layer, providing both the necessary gel-like form for electrochromic function and the structural support needed to prevent excessive deformation during processing. The curable resin in the sealing part contributes to creating a composite material system with optimized mechanical properties.
2Ease of manufacture
If the electrochromic sheet is made more deformable to improve processability, then curved shapes can be achieved, but the yield point increases and manufacturing precision deteriorates
Solution Approach 1:
The patent optimizes the deformation amount parameter to fall within the range of 0.01 mm to 0.09 mm under standardized testing conditions. This parameter optimization enables the electrochromic sheet to achieve sufficient deformability for manufacturing processes such as forming curved lenses, while simultaneously maintaining control over the deformation to prevent excessive yielding. The controlled deformation amount represents an optimal balance between ease of manufacture and manufacturing precision.
3Strength
If a sealing part with curable resin is used to cover the electrolyte layer, then the electrolyte layer is protected and structural integrity is improved, but the device complexity increases
Solution Approach 1:
The patent merges the sealing function with the structural support function by integrating the sealing part directly onto the electrolyte layer. The sealing part with curable resin serves dual purposes: it protects the electrolyte layer from environmental degradation and provides structural reinforcement to prevent deformation during processing. This merging of functions reduces the need for separate protective layers, thereby managing device complexity while improving strength.
Solution Approach 2:
The sealing part exhibits multi-functionality by simultaneously providing protection for the electrolyte layer, structural support to prevent deformation, and potential optical functions. The curable resin material can be formulated to provide both mechanical strength and optical transparency, allowing a single component to fulfill multiple roles in the electrochromic device structure, thus improving strength without proportionally increasing device complexity.
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 design improves the electrochromic sheet's processability, allowing for stable deformation control and reduced yield points, facilitating applications like curved lenses without compromising color developability.
Implementation Method 1
The electrochromic element is known as an element that utilizes electrochromism, which is a phenomenon in which an oxidation-reduction reaction occurs reversibly by applying a voltage, and a transmittance changes reversibly
Implementation Method 2
an electrolyte layer provided on the support layer; an electrochromic layer provided on at least one surface of the electrolyte layer
Data Source
Figure 1~3
Figure 4~5
Figure 6(a)~6(d)
AI summary
An electrochromic sheet (100) according to the present invention includes a first support layer (1), an electrolyte layer (4) provided on the first support layer (1), a first electrochromic layer (3) provided on at least one surface of the electrolyte layer (4), and a sealing part (8) provided to cover at least a side surface of the electrolyte layer (4), and an amount of deformation measured according to the following procedure i is 0.01 mm to 0.09 mm. Procedure i: A test piece (having a maximum length of 20 mm or more) in which the electrolyte layer (4) is located at a central part and the sealing part (8) is located at an outer edge is produced by using the electrochromic sheet (100), the test piece is chucked at both ends by a chucking part, the central part of the test piece is pressed at 30 N for 30 seconds, and a difference in depth between the central part of the test piece before being pressed and the central part of the test piece after being pressed is defined as an amount of deformation (mm).