Stepped Edge Electrical Connections for Thin Electro-Optic Displays
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Solution Overview
Problem
Existing electro-optic elements face challenges in reducing material and processing costs, improving aesthetics, and enhancing functionality in vehicular and building applications, such as rearview display devices and variably transmissive windows.
Innovation Solution
The design involves a configuration of two substantially transparent substrates with a primary seal between them, creating a cavity with a thickness of less than 75 µm, where at least one edge is stepped to define a channel, and an electro-optic material is positioned within the cavity, along with a conductive bus and electrical connections that can be polymeric films with metallic coatings, allowing for efficient electrical isolation and reduced resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the cavity thickness is reduced to less than 75 µm, then the aesthetic appearance and functionality are improved, but the cross-sectional area for electrical connections is reduced, increasing resistance
Solution Approach 1:
The patent applies dimensionality change by creating a stepped edge configuration that extends the electrical connection path in a different spatial dimension (along the stepped surface) rather than increasing the cavity thickness. This allows maintaining thin cavity profile while providing sufficient electrical connection area through the stepped geometry.
Solution Approach 2:
The electrical connection elements are nested within the stepped edge structure itself, where the conductive bus and electrical connections are positioned within the stepped region. This nesting allows the electrical connection pathway to be integrated into the structural geometry without adding external volume or increasing cavity thickness.
2Ease of manufacture
If conventional electrical connections are used in a thin cavity, then material costs are reduced, but the electrical resistance increases and aesthetics are compromised
Solution Approach 1:
The patent changes the geometric parameters of the electrical connection pathway by creating a stepped edge with specific dimensions (first edge at first position, second edge at second position). This parameter change increases the effective cross-sectional area for electrical conduction without changing the materials used, thereby reducing resistance while maintaining cost-effectiveness.
Solution Approach 2:
The stepped edge configuration utilizes additional spatial dimensions to extend the electrical connection pathway. By creating a multi-level stepped structure, the patent increases the effective conduction area in three-dimensional space without increasing the overall cavity thickness or using additional expensive materials.
3Ease of manufacture
If the edges are made straight and aligned, then manufacturing is simplified, but the cross-sectional area for electrical connections is limited
Solution Approach 1:
The edge is segmented into multiple levels (first edge at first position, second edge at second position) rather than being a single straight line. This segmentation creates the stepped configuration that increases electrical connection area while maintaining relative manufacturing simplicity through standardized cutting and polishing operations.
Solution Approach 2:
The patent transitions from a two-dimensional straight edge view to a three-dimensional stepped edge structure. This dimensional change allows the electrical connection area to be increased by utilizing the vertical and horizontal surfaces of the stepped configuration, providing additional conduction pathways without complicating the manufacturing process excessively.
Data Source
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AI summary
An electro-optic element of a display of a vehicle includes a first substantially transparent substrate defining a first surface and a second surface. A first edge extends around the first substrate. A second substantially transparent substrate defines a third surface and a fourth surface. A second edge extends around the second substrate. A primary seal is disposed between the first and second substrates. The seal and the first and second substrates define a cavity therebetween. At least one of the first and second edges is stepped proximate the seal to define a channel. An electro-optic material is positioned within the cavity.