Electrochromic Stack Fabrication via Integrated Deposition
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Solution Overview
Problem
Electrochromic devices suffer from defects such as electrical shorts and pinholes, which limit their reliability and scalability, particularly in large-area applications like architectural glass, due to issues during the fabrication process, especially in the ion conducting layer and the integration of layers in a controlled environment.
Innovation Solution
A method for fabricating electrochromic stacks using a single integrated deposition system with a controlled ambient environment, where the electrochromic layer, ion conducting layer, and counter electrode layer are sequentially deposited without exposing the substrate to external environments, reducing defects and enhancing the reliability of the electrochromic device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fabrication processes are used with multiple handling steps, then device complexity is reduced, but defectivity increases due to exposure to external environments
Solution Approach 1:
The patent combines multiple deposition steps (electrochromic layer, ion conducting layer, counter electrode layer) into a single integrated deposition chamber, eliminating the need to expose the substrate to external environments between steps. This merging of processes reduces contamination and defects while maintaining manufacturing feasibility.
Solution Approach 2:
The patent introduces a controlled ambient environment within the deposition chamber as an intermediary between the external environment and the substrate. This controlled environment acts as a protective medium that prevents contamination during layer deposition and handling.
2Reliability
If layers are deposited in separate steps with substrate handling, then process flexibility is improved, but reliability decreases due to increased defects
Solution Approach 1:
The patent combines multiple deposition steps into a single continuous process within one chamber, eliminating substrate handling and exposure to external environments. This significantly reduces defects and improves reliability while the integrated chamber design maintains manufacturing efficiency.
Solution Approach 2:
The patent uses a controlled ambient environment (inert atmosphere) within the deposition chamber to protect the substrate and deposited layers from contamination. This inert environment prevents defects during the entire deposition sequence, improving device reliability.
3Productivity
If traditional fabrication methods are used, then manufacturing simplicity is maintained, but scalability to large-area applications is limited
Solution Approach 1:
The patent employs a single integrated deposition chamber capable of processing large-area substrates in one continuous operation. This approach enables scalability to large-area applications like architectural glass while maintaining low defectivity by eliminating multiple handling steps and exposures to external environments.
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 approach significantly reduces defectivity, allowing for high-performance electrochromic devices with improved reliability and scalability, enabling them to cycle between optical states over 50,000 times with maintained transmissivity and color quality, suitable for long-term use in architectural applications.
Implementation Method 1
Electrochromism is a phenomenon in which a material exhibits a reversible electrochemically-mediated change in an optical property when placed in a different electronic state, typically by being subjected to a voltage change.
Implementation Method 2
a single integrated deposition system having a controlled ambient environment in which the pressure, temperature, and/or gas composition are controlled independently of an external environment
Data Source
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AI summary
Prior electrochromic devices frequently suffer from high levels of defectivity. The defects may be manifest as pin holes or spots where the electrochromic transition is impaired. This is unacceptable for many applications such as electrochromic architectural glass. Improved electrochromic devices with low defectivity can be fabricated by depositing certain layered components of the electrochromic device in a single integrated deposition system. While these layers are being deposited and/or treated on a substrate, for example a glass window, the substrate never leaves a controlled ambient environment, for example a low pressure controlled atmosphere having very low levels of particles. These layers may be deposited using physical vapor deposition. In certain embodiments, the device includes a counter electrode having an anodically coloring electrochromic material in combination with an additive.