Segmented Dimming Panel for Custom Smart Window Production
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Solution Overview
Problem
Current production methods for smart window products result in low efficiency and high costs due to the need for a wide variety of sizes, which are not efficiently met by existing technologies.
Innovation Solution
A dimming panel and glass manufacturing method that allows for cutting into multiple preset shapes using a dimming module with a deformable structure, comprising an expandable core and thermoplastic polymer, enabling mass production and efficient size customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom production methods are used for each size, then product customization is achieved, but production efficiency is low and cost is high
Solution Approach 1:
The dimming layer is segmented into multiple dimming parts separated by definition parts. The definition parts act as pre-defined cutting regions that allow the panel to be divided into multiple smaller products. This segmentation enables a single large panel to serve multiple custom-sized products, improving production efficiency while maintaining customization capability.
Solution Approach 2:
A single dimming panel with multiple dimming parts can be used to produce different sized products by cutting along different definition parts. The panel structure is designed to be universal, where the same panel can yield multiple products of various sizes and shapes, reducing the need for separate production lines for each product size.
2Adaptability or versatility
If custom production methods are used for each size, then product customization is achieved, but manufacturing cost is high
Solution Approach 1:
Multiple dimming parts are combined into a single dimming panel during manufacturing. By producing one panel that contains multiple dimming parts separated by definition parts, the manufacturing process is simplified and economies of scale are achieved. The panel can then be cut into multiple smaller products, reducing per-unit manufacturing cost while maintaining customization options.
Solution Approach 2:
The definition parts are incorporated into the panel during the initial manufacturing process, creating pre-defined cutting regions. This preliminary action of embedding the cutting guides during mass production eliminates the need for complex post-processing or custom tooling for each product size, thereby reducing manufacturing costs.
3Productivity
If a single large panel is produced, then production efficiency is improved, but flexibility in product sizes is reduced
Solution Approach 1:
The panel design incorporates dynamic flexibility through the definition parts that can be selectively removed or used as cutting guides. This allows the same panel structure to adapt to different product size requirements by cutting along different definition parts, providing size flexibility while maintaining high production efficiency through mass production of the base panel.
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 significantly improves production efficiency and reduces costs by enabling the production of dimming panels and glasses in various shapes and sizes, meeting market demands for customized smart window products.
Implementation Method 1
the expandable structure comprises an inner core layer and a cladding layer surrounding the inner core layer, a material of the inner core layer comprises a foaming agent, and a material of the cladding layer comprises a thermoplastic polymer; the definition part is configured to be obtained after the expandable structure is thermally expanded and cured
Implementation Method 2
the dimming part is configured to control transmittances of lights under an action of an electric field
Data Source
AI summary
The present disclosure provides a dimming panel and a manufacturing method therefor, and a dimming glass and a manufacturing method therefor. The dimming panel includes at least one dimming module; the dimming module includes a first substrate and a second substrate disposed oppositely, and a dimming layer disposed between the first substrate and the second substrate; the dimming layer includes a region to be cut and a dimming region connected to the region to be cut, the region to be cut includes at least one definition part, the dimming region includes a plurality of dimming parts, the definition part is disposed between adjacent dimming parts, and configured to be capable of being cut to segment the adjacent dimming parts, and the dimming part is configured to control transmittances of lights under an action of an electric field.