Gradient Electrochromic Device With Perimeter Isolation Line
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Solution Overview
Problem
Conventional electrochromic devices face challenges in maintaining electrical isolation during manufacturing, leading to increased costs due to complex bus bar designs, which require predetermined placements.
Innovation Solution
A method of manufacturing electroactive devices with a continuous electrical isolation line around the substrate perimeter, allowing for gradient tinting without predetermining device locations, involving deposition of conductive and electroactive layers followed by laser formation of the isolation line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bus bar designs are used with predetermined placements, then electrical isolation can be maintained, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent extracts the electrical isolation function from the complex bus bar design by introducing a dedicated isolation line that runs along the perimeter of the electroactive device. This separation allows the bus bars to be placed freely for gradient tinting while the isolation line independently maintains electrical isolation between adjacent devices on the substrate.
Solution Approach 2:
The patent segments the electrical isolation function from the overall device structure by creating a distinct isolation line component. This segmentation enables independent optimization of bus bar placements for gradient functionality while the isolation line handles electrical separation, reducing overall system complexity.
2Reliability
If complex bus bar designs are used for gradient tinting, then electrical isolation is maintained, but manufacturing costs increase
Solution Approach 1:
The isolation line serves multiple functions: it provides electrical isolation between adjacent electroactive devices, acts as a structural boundary, and enables free placement of bus bars for gradient tinting. This multi-functionality eliminates the need for complex predetermined bus bar designs, simplifying manufacturing.
Solution Approach 2:
By extracting the electrical isolation function into a separate isolation line component, the patent allows bus bars to be placed freely for gradient tinting without being constrained by isolation requirements, thereby simplifying the manufacturing process and reducing costs.
3Reliability
If predetermined bus bar placements are used, then electrical isolation is ensured, but device adaptability decreases
Solution Approach 1:
The patent segments the electrical isolation function from the bus bar placement by introducing a dedicated isolation line. This allows electroactive devices to be placed at any location on the substrate and oriented in any direction, as the isolation line independently handles electrical separation without constraining bus bar positions.
Solution Approach 2:
The isolation line provides universal electrical isolation across the substrate, enabling free placement of multiple electroactive devices with different orientations and positions. This universality enhances device adaptability while maintaining reliable electrical isolation.
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
Enables electroactive devices to achieve a continuously graded transmission state while maintaining electrical isolation, reducing manufacturing complexity and costs.
Implementation Method 1
involving deposition of conductive and electroactive layers followed by laser formation of the isolation line
Implementation Method 2
Gradient electrochromic device
Data Source
AI summary
A method of manufacturing one or more electroactive devices is disclosed. The method of manufacturing one or more electroactive devices can include creating a continuous electrical isolation line in a first conductive layer around substantially an entire perimeter of a substrate and depositing an electroactive material and a second conductive layer over the formed first conductive layer to form one or more electroactive devices on the substrate.