Tempering Electrochromic Devices on Glass Substrates
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Solution Overview
Problem
Conventional methods for tempering glass with electrochromic devices fabricated on it result in damage or degradation due to high temperatures, leading to issues like lithium loss, redistribution, morphology changes, and interfacial modifications that impact device performance.
Innovation Solution
Fabricating electrochromic devices on glass substrates before tempering, using techniques such as lithium management, diffusion barriers, and graded layer compositions to minimize damage during the tempering process, and employing chemical strengthening methods like ion exchange to enhance glass strength without compromising device functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass is tempered after electrochromic device fabrication, then glass strength is improved, but device functionality is destroyed
Solution Approach 1:
The patent applies preliminary action by fabricating the electrochromic device on the glass substrate before tempering, rather than after. This sequence allows the device to be created on annealed glass, then the glass is tempered while the device is already in place. The device structure is designed to withstand the tempering process, enabling both glass strengthening and device functionality to be achieved.
Solution Approach 2:
The patent utilizes parameter changes by controlling the tempering process parameters (temperature, time, atmosphere) to ensure the electrochromic device survives the tempering cycle. The device layers and materials are selected and configured to maintain stability during the thermal tempering process, allowing the glass to be strengthened without destroying the device.
2Strength
If glass is tempered at high temperature, then glass strength is improved, but lithium is lost or redistributed in the electrochromic device
Solution Approach 1:
The patent introduces an intermediary lithium reservoir layer between the electrochromic active layers and the glass substrate. This reservoir acts as a buffer that prevents lithium loss to the glass during tempering and compensates for lithium redistribution. The reservoir layer maintains lithium availability for the electrochromic function while protecting against tempering-induced lithium loss.
Solution Approach 2:
The patent applies beforehand cushioning by pre-positioning excess lithium in the reservoir layer before the tempering process. This excess lithium serves as a cushion or buffer that compensates for the lithium that will be lost or redistributed during the high-temperature tempering cycle, ensuring the electrochromic device maintains its functionality after tempering.
3Ease of manufacture
If electrochromic device is fabricated on tempered glass, then manufacturing process is simplified, but device performance is degraded
Solution Approach 1:
The patent applies preliminary action by fabricating the electrochromic device on annealed glass before tempering, rather than attempting to fabricate on already-tempered glass. This sequence simplifies the manufacturing process by allowing standard deposition techniques to be used on the annealed glass, then the entire assembly is tempered in a single subsequent step, achieving both ease of manufacture and device performance.
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 allows for the production of high-quality, functional electrochromic devices on tempered glass substrates by mitigating thermal damage and maintaining device performance, enabling efficient energy management and optical state transitions.
Implementation Method 1
Glass tempering is a process by which glass is thermally treated to increase its strength. During tempering the glass is subjected to high heat until its softening point is reached
Implementation Method 2
lithium loss, redistribution, morphology changes, and interfacial modifications that impact device performance
Implementation Method 3
morphism changes, and interfacial modifications that impact device performance
Data Source
AI summary
This disclosure provides systems, methods, and apparatus for tempering or chemically strengthening glass substrates having electrochromic devices fabricated thereon. In one aspect, an electrochromic device is fabricated on a glass substrate. The glass substrate is then tempered or chemically strengthened. The disclosed methods may reduce or prevent potential issues that the electrochromic device may experience during the tempering or the chemical strengthening processes, including the loss of charge carrying ions from the device, redistribution of charge carrying ions in the device, modification of the morphology of materials included in the device, modification of the oxidation state of materials included in the device, and the formation of an interfacial region between the electrochromic layer and the counter electrode layer of the device that impacts the performance of the device.