Modular Electrochromic Window Assembly Fabrication
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Solution Overview
Problem
The complexity and cost associated with fabricating window assemblies that incorporate electrochromic materials and electrical components, due to the need for precise sizing and custom designs for various dimensions, hinder efficient manufacturing and installation processes.
Innovation Solution
A method for fabricating window assemblies that involves determining the size and location of glass units and electrical components based on specific dimensions and energy ratings, using a limited number of standard sizes for electrical components and trim panels to simplify the manufacturing process, and ensuring compatibility with electrochromic devices that change optical properties in response to electrical potential.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom designs and precise sizing are used for various window assembly dimensions, then the optical properties and energy ratings can be optimized for each specific application, but the manufacturing complexity and costs increase significantly
Solution Approach 1:
The window assembly is divided into separate modular components: glass units with electrochromic devices, electrical components, and trim panels. Each component can be manufactured independently using standard sizes, then assembled to create custom-dimensional window assemblies. This segmentation allows precise sizing through assembly rather than custom manufacturing of each component.
Solution Approach 2:
A finite set of standard-sized electrical components and trim panels is designed to work across multiple window assembly configurations. These universal components can be combined with differently sized glass units to accommodate various window dimensions while maintaining consistent manufacturing processes and component inventories.
2Reliability
If custom designs are created for each window assembly size, then the energy ratings can be precisely matched to specific applications, but the manufacturing costs and process complexity increase
Solution Approach 1:
The patent establishes predetermined relationships between glass unit dimensions, electrical component sizes, and expected energy ratings. By pre-defining these associations and using standard-sized components, the system enables reliable energy rating matching through selection rather than custom design, simplifying the manufacturing process while maintaining application-specific optimization.
3Productivity
If a finite number of standard electrical component sizes are used, then manufacturing complexity and costs are reduced, but the ability to precisely match components to specific window sizes may be limited
Solution Approach 1:
The patent compensates for the limited number of standard electrical component sizes by utilizing the dimensional variability of glass units and trim panels. By adjusting the dimensions of these other components, the system achieves precise window assembly sizing and application matching without requiring custom electrical components for each configuration, thus maintaining manufacturing efficiency while preserving adaptability.
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 manufacturing complexity and costs by allowing for the use of a finite number of standard electrical component sizes, improving the matching of components to specific window sizes and energy ratings, and enhancing the integration of electrochromic technology in window assemblies.
Implementation Method 1
Window assemblies can include electrochromic materials that can change their optical properties in response to the application of an electrical potential. Such a change can make glazings within the assemblies more or less transparent or more or less reflective.
Data Source
AI summary
Different window assemblies can be fabricated and installed where the size of an electrical component is sized for a particular geometry of the window assembly. In a particular embodiment, an energy rating, which may include an energy consumption rate, a recharge rate, a recharge capacity, an electrical current leakage rate, another suitable parameter, or any combination thereof, may be used when determining the size of the electrical component to be used. If needed or desired, one or more trim panels can be used to cover portions of a window assembly to make the window more aesthetically pleasing.