Switchable objects and methods of manufacture
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Solution Overview
Problem
Current methods for manufacturing switchable objects, such as electrochromic materials, face challenges in high-throughput production due to complex sealing processes and exposure to ambient environments, leading to material waste and potential degradation of switchable material edges.
Innovation Solution
A method involving the application of a switchable material between substrates with a barrier material to create a sealed chamber, using high-throughput printing techniques like screen printing, which reduces handling and simplifies the sealing process, protecting the material from the environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-layer sequential deposition methods are used, then functional performance is achieved, but manufacturing complexity and processing time increase
Solution Approach 1:
The patent combines multiple functional layers (chromogenic layer, electrolyte layer, ion-intercalating layer) into a single integrated layer, eliminating the need for sequential deposition of separate layers. This single layer performs all necessary functions, significantly simplifying the manufacturing process while maintaining the required functional performance of the electrochromic device.
Solution Approach 2:
The single integrated layer is designed to perform multiple functions simultaneously: it provides chromogenic functionality, contains electrolyte, and facilitates ion intercalation. This multi-functional design eliminates the need for separate specialized layers, reducing manufacturing steps and complexity while achieving the same reliability and performance.
2Productivity
If continuous throughput coating methods are used, then production speed increases, but material waste and edge degradation occur
Solution Approach 1:
The patent uses a flexible mask that conforms to the substrate surface and precisely defines the deposition area. This mask prevents coating material from reaching the edges and unused portions, eliminating waste while allowing continuous throughput coating methods to be used at high production speeds.
Solution Approach 2:
The mask acts as an intermediary between the coating applicator and the substrate, controlling where the switchable material is deposited. It prevents material from reaching areas where it is not needed (edges and weed portions), thereby preventing both material waste and edge degradation while maintaining high production speed.
3Reliability
If chamber backfilling method is used, then encapsulation is achieved, but manufacturing steps and device complexity increase
Solution Approach 1:
The patent incorporates the seal material directly into the single integrated layer during its formation, before the encapsulation step. This preliminary inclusion of sealing functionality eliminates the need for separate chamber backfilling and seal application steps, reducing manufacturing complexity while maintaining reliable encapsulation of the switchable material.
Solution Approach 2:
The seal material is merged with the switchable material layers in a single integrated structure. This combination eliminates the need for separate encapsulation chambers and multiple assembly steps, simplifying the manufacturing process while achieving the same protective encapsulation function.
4Quantity of substance
If exposed cut edges are left, then material utilization improves, but environmental degradation occurs
Solution Approach 1:
The mask serves as an intermediary that prevents direct exposure of the switchable material edges to the ambient environment during and after coating. By controlling the deposition area precisely, it eliminates exposed cut edges that would otherwise be susceptible to solvent loss and interaction with air/oxygen, while still allowing efficient use of the switchable material within the defined area.
Solution Approach 2:
The patent converts the potential harm of exposed edges into a benefit by using the mask to define precise deposition boundaries. This approach eliminates the harmful exposure of edges to environmental factors while maintaining high material utilization efficiency within the controlled deposition area.
Data Source
AI summary
A simplified switchable object and methods of making same are provided. The methods may include steps of applying a switchable material on a first surface of a first substrate, the switchable material having a thickness and a shape; applying a barrier material on the first substrate, circumferential to the switchable material; and applying a second substrate over top of, and in contact with, the switchable material and the barrier material, the first substrate, second substrate and barrier material defining a closed chamber encapsulating the switchable material. The methods may further include a step of applying a seal material.