Segmented Bus Layout for Faster Electro-Optic Switching
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Solution Overview
Problem
Existing bus systems in large-area electro-optic devices face challenges such as slow transition speeds, thickness interference, difficulty in adhering to flexible substrates, and manufacturing complexity, particularly when using conductive tapes and monolithic bus assemblies.
Innovation Solution
The implementation of segmented bus systems with independently controllable bus segments on parallel substrates, using electrically insulating materials to isolate segments and reduce stress on substrates, and employing conductive tapes for flexible conformability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a thicker bus is used to increase transition speed, then the darkening speed improves, but thickness interference occurs with electro-optic elements
Solution Approach 1:
The bus is divided into multiple segments separated by gaps, allowing each segment to be thinner while collectively providing sufficient conductive path length for fast transitions. The segmented structure eliminates thickness interference with electro-optic elements by reducing the thickness of any single bus portion.
Solution Approach 2:
The bus segments are arranged in a multi-dimensional configuration with segments on both first and second substrates, creating alternative current paths through the cell. This dimensional arrangement increases the effective conductive path without requiring any single bus segment to be thick, thereby achieving fast transitions without thickness interference.
2Adaptability or versatility
If conductive tape is used around corners, then the bus can conform to curved edges, but substantial forces and stress are applied to the substrate
Solution Approach 1:
The continuous conductive tape is divided into multiple segments, particularly at corner regions. These segmented tapes can conform to curved edges while the gaps between segments reduce the cumulative stress and force applied to the substrate, preventing cupping and peeling.
Solution Approach 2:
Different regions of the bus have different configurations - straight segments for linear portions and segmented/curved segments for corner portions. This local adaptation allows the bus to conform to the substrate geometry while minimizing stress through strategic segmentation at high-stress locations.
3Ease of manufacture
If a monolithic bus assembly is used, then manufacturing may be simplified, but accurate positioning and retention during construction becomes difficult
Solution Approach 1:
The bus assembly is segmented into multiple independent bus segments that can be positioned and attached separately to the substrates. This segmentation allows for easier alignment and positioning during assembly while maintaining manufacturing simplicity through modular construction.
Solution Approach 2:
Bus segments can be pre-positioned or pre-assembled on individual substrates before final assembly of the complete electro-optic device. This preliminary positioning ensures accurate placement while simplifying the overall manufacturing process through modular assembly steps.
4Device complexity
If a monolithic bus is cut from a single piece of material, then the bus structure is simplified, but material waste increases
Solution Approach 1:
The bus is designed as multiple segments that can be manufactured separately from smaller pieces of material and then assembled. This segmentation allows for more efficient material utilization by cutting segments from smaller stock pieces rather than cutting a large bus from a single large piece, thereby reducing material waste while maintaining structural simplicity through modular design.
Data Source
AI summary
An electro-optic element comprises a first substrate; a second substrate generally parallel to the first substrate; a first bus having a first bus segment disposed on an inner surface of the first substrate and extending along a first portion of a perimeter of the first substrate and a second bus segment disposed on an inner surface of first substrate and extending along a second portion of the perimeter of the first substrate. The second bus segment is in a spaced apart relationship with first bus segment. A second bus has a third bus segment and a fourth bus segment is disposed on the second substrate, each extending along a portion of the perimeter of the second substrate. A controller is configured to be in selective electrical communication with first and second buses and to independently control a voltage applied to each of the bus segments.