Laminated Electrochromic Devices Using Pre-Formed Polymeric Sheets

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Solution Overview

Problem

Existing electrochromic (EC) devices for windows and displays are costly to produce due to sensitive thin film stacks and high power consumption, requiring additional coatings and processing steps, which increases production costs and sensitivity to defects.

Innovation Solution

The development of cost-effective laminated EC devices using pre-formed solid polymeric sheets with integrated anodic and cathodic redox layers, laminated onto conductive substrates, which enhance durability and reduce power consumption by maintaining desired optical states with minimal power usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If additional electrochromic and ion storage coatings are deposited on substrates to improve memory, then power consumption is reduced, but production cost increases due to additional processing steps

Engineering Contradiction:

Improvepower consumptionVSAvoidproduction cost

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The patent combines multiple functional layers (electrochromic layer, ion storage layer, and electrolyte layer) into a single integrated polymeric membrane. This merging eliminates the need for separate deposition of multiple coatings and their associated processing steps, thereby reducing production cost while maintaining the memory function that reduces power consumption.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention uses a composite polymeric membrane that integrates multiple functionalities (electrochromism, ion storage, and ion conduction) into a single material structure. This composite approach achieves the desired performance with fewer manufacturing steps compared to depositing separate functional coatings on substrates.

Inventive Principle:

Principle #40Composite materials

2Device complexity

If thin film stacks are used on a single substrate to reduce device complexity, then manufacturing is simplified, but yield is reduced due to sensitivity to defects in thin coatings

Engineering Contradiction:

Improvedevice structureVSAvoidyield

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent employs a flexible polymeric membrane that is inherently more tolerant to defects compared to rigid thin film stacks. The membrane's flexibility allows for greater defect tolerance during lamination, improving yield while maintaining a relatively simple device structure with fewer discrete layers to deposit.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The functional layers are pre-formed within the polymeric membrane before lamination to the substrate. This preliminary action ensures proper layer formation and alignment, reducing the risk of defects during the assembly process and improving overall manufacturing yield.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If physical vapor deposition is used to deposit thick conductor layers, then conductivity is improved, but production cost increases

Engineering Contradiction:

ImproveconductivityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the physical vapor deposition process with a lamination process that uses mechanically applied pressure and heat. This substitution eliminates the expensive PVD equipment and processing requirements while achieving sufficient conductivity through the integration of conductive layers within the polymeric membrane structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This approach reduces production costs, improves durability, and enables EC devices to maintain desired optical states with low power consumption, ensuring efficient energy use and longer memory periods, especially in varying temperatures.

Implementation Method 1

The electrochromic medium is disposed between two conductive electrodes, at least one of which is typically transparent, and causes the medium to undergo reversible electrochemical reactions when potential differences are applied across them

Methodology Applied

Scientific EffectElectrochromism: Electrochromism

Implementation Method 2

causes the medium to undergo reversible electrochemical reactions when potential differences are applied across them

Methodology Applied

Scientific EffectElectrochemical reactions: Electrolysis

Implementation Method 3

a polymeric solid electrolyte with good ion conductivity

Methodology Applied

Scientific EffectIon conduction: Conduction (electrical)

Data Source

PatentUS8115984B2Laminated electrochromic devices and processes for forming the same

Publication Date: 2012.02.14 AJJER LLC

AI summary

This invention discloses pre-formed electrochromic films that are used in assembly of electrochromic devices. These films are laminated to conductive substrates to form the electrochromic devices. The invention also discloses optical characteristics of the substrates for imparting durability to the electrochromic devices from solar radiation.