Reflective Electrochromic Electrode Structure for Simpler Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of dimmable devices with electrochromic materials is challenging due to complex processes and issues related to sealing and diffusion, necessitating an efficient and reliable manufacturing process.
Innovation Solution
The electrochromic device incorporates a reflective structure with a bottom and top electrode layer, optionally including PET and ITO, and employs a vacuum-and-siphon process for electrolyte layer formation, potentially omitting a separate reflective layer to simplify the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a separate reflective layer is added to the electrochromic device, then the reflectance performance is improved, but the device structure and manufacturing process become more complex
Solution Approach 1:
The patent combines the reflective function with the electrode layer by making one of the electrodes (typically the bottom electrode) reflective. This integration eliminates the need for a separate reflective layer, simplifying the device structure while maintaining the desired reflectance performance. The electrode layer serves dual purposes: electrical conduction and light reflection.
Solution Approach 2:
The electrode layer is designed to perform multiple functions simultaneously: it provides electrical conduction for electrochromic switching and acts as a reflective surface for enhancing reflectance. This multi-functional design reduces the total number of layers needed in the device structure.
2Reliability
If conventional manufacturing processes are used for electrochromic devices, then the device functionality is achieved, but the manufacturing process becomes complicated and less efficient
Solution Approach 1:
The manufacturing process benefits from the structural simplification where the reflective electrode serves multiple functions. This reduces the number of deposition steps, alignment operations, and quality control checks needed compared to devices with separate reflective layers, thereby improving ease of manufacture while maintaining device functionality.
3Illumination intensity
If multiple separate layers (electrode layer and reflective layer) are used, then the optical performance is optimized, but the manufacturing efficiency decreases
Solution Approach 1:
By integrating the reflective function into the electrode layer, the patent reduces the total number of layers that need to be manufactured and assembled. This simplification directly improves manufacturing efficiency and productivity while the optimized electrode design maintains the necessary optical performance through its dual function as both conductor and reflector.
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 simplifies the device structure and manufacturing process, enhancing efficiency by eliminating the need for a separate reflective film and improving the manufacturing process through the use of a vacuum-and-siphon method.
Implementation Method 1
Electrochromic materials can change their optical characteristics, such as transmittance, reflectance, absorptance or emittance under electrical current or voltage
Implementation Method 2
The cavity may then be filled with an electrolyte solution through a vacuum-and-siphon process
Implementation Method 3
The cavity may then be filled with an electrolyte solution through a vacuum-and-siphon process
Data Source
AI summary
Electrochromic devices with reflective structure and related manufacturing methods are provided. One of the electrochromic devices includes a bottom electrode layer, an electrochromic layer on the bottom electrode layer, an electrolyte layer on the electrochromic layer, a charge storage layer on the electrolyte layer, and a top electrode on the charge storage layer. The transmittance of the electrochromic device changes in response to a voltage applied between the bottom electrode layer and the top electrode layer. One of the bottom and the top electrode layers is a reflective conductive layer, while the other being a transparent conductive layer. This electrochromic device has a simplified structure due to the removal of a separated reflective film, which also results in simplified manufacturing process.