Electrochromic Window Element Structure for Twist-Resistant Uniform Tint
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Solution Overview
Problem
Existing electrochromic elements suffer from issues such as non-uniform thickness, poor mechanical strength, peel strength, appearance, and electrolyte leakage, as well as susceptibility to deformation and mechanical shock.
Innovation Solution
The electrochromic element is designed with a specific structure comprising a first and second substrate, transparent electrodes, discoloration layers, and an electrolyte layer containing a curable resin composition, solvent, and metal salt, which provides improved thickness uniformity, mechanical strength, peel strength, and durability, with a twist test showing minimal transmittance and haze deviation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional electrochromic element structure is used, then the manufacturing process is simple, but the thickness uniformity is poor and mechanical strength is low
Solution Approach 1:
The electrochromic element is divided into multiple functional layers including first and second substrates, transparent electrodes, discoloration layers, and an electrolyte layer. Each layer is formed through separate deposition or coating processes, allowing independent control of thickness and properties for each layer, thereby achieving overall thickness uniformity while maintaining a manageable multi-layer structure.
Solution Approach 2:
The patent employs thin film deposition techniques to form uniformly thick layers of transparent electrodes, discoloration layers, and electrolyte layers. These thin films are deposited on flexible polymer substrates, ensuring consistent thickness across the entire element while maintaining structural integrity and flexibility.
2Speed
If the electrolyte layer is made thinner to improve response time, then the response speed increases, but electrolyte leakage increases
Solution Approach 1:
The electrolyte layer is formulated as a composite material containing a curable resin composition with specific molecular weight polymers (10,000-1,000,000), crosslinking agents, and metal salts. This composite structure provides both the thin-layer speed advantage and the leakage prevention through high viscosity and crosslinked network formation upon curing.
Solution Approach 2:
The patent controls the electrolyte layer thickness within a specific range (1-10 μm) and adjusts the molecular weight and concentration of the resin components to optimize the balance between response time and leakage prevention. The curable resin composition undergoes parameter changes through curing, transitioning from a liquid precursor to a solid crosslinked network that prevents leakage.
3Strength
If a rigid structure is used to improve mechanical strength, then the strength increases, but deformation resistance to mechanical shock decreases
Solution Approach 1:
The patent uses flexible polymer substrates (such as polyethylene terephthalate or polyimide) instead of rigid glass substrates. These flexible substrates provide adequate mechanical strength while allowing the element to deform under mechanical shock and return to its original shape, preventing permanent damage and maintaining optical performance.
Solution Approach 2:
The electrochromic element is designed with dynamic flexibility, allowing it to adapt to mechanical deformations. The flexible substrate and thin film structure enable the element to bend and deform temporarily under shock loads, then recover its original configuration, providing deformation resistance while maintaining structural integrity.
4Illumination intensity
If the discoloration layers are made more intense to improve optical performance, then the coloring transmittance improves, but the appearance quality and uniformity deteriorate
Solution Approach 1:
The discoloration layers are designed with specific local properties, using different metal oxide materials (such as WO3 for coloring and IrO2 for discoloring) in specific layers. Each layer is deposited with controlled thickness and composition to achieve optimal local optical performance while maintaining overall uniformity across the entire element.
Solution Approach 2:
The patent employs vacuum deposition or sputtering techniques to ensure homogeneous distribution of discoloration layer materials across the entire substrate surface. The curable resin composition is also uniformly distributed and cured to provide consistent optical properties and appearance quality across the element, preventing localized defects or non-uniformity.
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 element maintains uniform optical properties and discoloration performance under mechanical deformation, reduces electrolyte leakage, and enhances durability and appearance by utilizing a curable resin with high crosslinking density and appropriate elasticity.
Implementation Method 1
the electrolyte layer includes 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
Data Source
AI summary
An embodiment of the present invention provides an electrochromic element comprising: a first substrate; a first transparent electrode disposed on the first substrate; a first discoloration layer disposed on the first transparent electrode; an electrolyte layer disposed on the first discoloration layer, a second discoloration layer disposed on the electrolyte layer; a second transparent electrode disposed on the second discoloration layer; and a second substrate disposed on the second transparent electrode. The electrochromic element has a coloration transmittance variation of less than 0.4 after a twist test measured by the following measurement method.