Electrochromic Window Lamination With Stable Electrolyte Thickness
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Solution Overview
Problem
Existing electrochromic elements face challenges in achieving high thickness uniformity, improved mechanical strength, enhanced peel strength, reduced electrolyte leakage, and increased durability against mechanical deformation, while maintaining excellent appearance and long-term reliability.
Innovation Solution
A method of fabricating an electrochromic element involves preparing a first laminate with a substrate, transparent electrode, discoloration layer, and electrolyte composition layer, and laminating it with a second laminate, using a curable resin composition and metal salt to ensure minimal transmittance and haze changes over time, with specific measurement methods to maintain optical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrochromic films are fabricated using conventional methods with multiple deposition steps and high-frequency bonding, then the basic electrochromic function is achieved, but the thickness uniformity, mechanical strength, and peel strength are insufficient
Solution Approach 1:
The fabrication process is divided into two separate laminates (first laminate with substrate, transparent electrode, and discoloration layer; second laminate with electrolyte composition layer) that are laminated together. This segmentation allows each layer to be optimized independently for thickness uniformity while simplifying the overall fabrication process.
Solution Approach 2:
The electrolyte composition layer is prepared in advance as a separate laminate with controlled thickness and composition before lamination. This preliminary preparation ensures uniform thickness distribution and proper curing state, directly improving manufacturing precision without requiring complex in-situ fabrication steps.
2Strength
If conventional bonding methods are used to assemble electrochromic layers, then the basic structure is formed, but the mechanical strength and durability against mechanical deformation are poor
Solution Approach 1:
The electrolyte composition layer is cured to a specific degree (50-90% curing state) before final assembly, which optimizes its mechanical properties. This controlled parameter change provides both flexibility for assembly and sufficient strength for durability, resolving the contradiction between mechanical strength and deformation resistance.
Solution Approach 2:
The device uses a composite structure combining organic electrolyte composition with curable resin and inorganic components. This composite material system provides enhanced mechanical strength while maintaining the electrochromic functionality, improving both strength and reliability simultaneously.
3Speed
If the electrolyte layer is made thin to improve response time, then the electrochromic performance is enhanced, but the electrolyte leakage increases
Solution Approach 1:
The electrolyte composition is cured to a specific degree (50-90%) rather than fully cured, which maintains the necessary ionic conductivity for fast response while reducing solvent mobility that causes leakage. This partial curing state optimizes the balance between response speed and leakage prevention.
Solution Approach 2:
The electrolyte composition uses a composite system combining ionic liquids, solvents, and curable resins in specific ratios. This composite structure provides both fast ion transport (quick response) and reduced solvent evaporation/leakage, resolving the contradiction between speed and harmful factor reduction.
4Ease of manufacture
If the electrochromic element is assembled in multiple steps at different locations, then manufacturing flexibility is improved, but the optical properties and appearance quality deteriorate
Solution Approach 1:
The device is divided into two laminates that can be manufactured separately at different locations and times. The first laminate contains the substrate, transparent electrode, and discoloration layer, while the second contains the electrolyte composition layer. This segmentation enables flexible manufacturing without compromising optical quality.
Solution Approach 2:
The electrolyte composition layer is prepared in advance with controlled curing (50-90% cured state) and protected with a release film. This preliminary preparation ensures that when the laminates are assembled later, the optical properties remain consistent and high-quality appearance is maintained, despite the separated manufacturing process.
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 method results in an electrochromic element with improved optical properties, reduced haze, and enhanced durability, allowing for efficient and cost-effective manufacturing even with separate production times and locations of the laminates.
Implementation Method 1
it may include a curable resin composition, a solvent and a metal salt
Implementation Method 2
Electrochromic films, whose colors change due to coloring and discoloring through oxidation-reduction reactions at each oxidation electrode and reduction electrode depending on an applied potential
Implementation Method 3
coloring and discoloring through oxidation-reduction reactions at each oxidation electrode and reduction electrode
Data Source
AI summary
An embodiment provides a method for manufacturing an electrochromic device, the method comprising the steps of: preparing a first laminate; arranging a second laminate on the first laminate; and laminating the first and second laminates, wherein the first laminate comprises a first substrate; a first transparent electrode arranged on the first substrate; a first electrochromic layer arranged on the first transparent electrode; and an electrolyte composition layer arranged on the first electrochromic layer and containing a curable resin composition, a solvent, and a metal salt, and the second laminate comprises a second electrochromic layer arranged on the electrolyte composition layer and a second substrate arranged on the second electrochromic layer, the first laminate having a transmittance reduction of 5% or less after 90 days as measured by the following measurement method.