SBIR PHASE I: Lithium Ion Conductor Films for Electrochromic Windows by Spray Coating

SAGE Electrochromics公司提出了SBIR一期项目，以评估使用喷涂技术生产用于电致变色窗口的溶液衍生陶瓷锂离子导体（IC）薄膜的可行性。电致变色（EC）玻璃技术的全球发展受到无法识别和开发满足建筑玻璃应用性能，耐用性和成本要求的电解质的严重阻碍。SAGE相信，通过专利解决方案衍生的集成电路，它已经独特地实现了性能和稳定性目标。尽管在某种程度上用于商业应用，但当生产吞吐量、处理和制造成本对最终的商业潜力至关重要时，浸涂是一种昂贵且不切实际的批量工艺。作为一项由汽车工业发展起来的技术，喷涂在要求极高的EC车窗应用中具有巨大的潜力。一个关键的挑战是将这种连续工艺技术应用于难以加工的薄膜陶瓷材料，同时保持SAGE浸涂开发的集成电路的基本功能和性能。与此相关的具体问题包括微观结构、成分、厚度、离子和电子导电性以及表面形貌。在第一阶段，SAGE的主要目标是通过成功制造功能性小面积EC装置来证明锂离子导体薄膜喷涂的可行性。为了实现这一目标，SAGE将1)在玻璃基板上喷涂锂IC薄膜，以评估均匀性、厚度和成分；2)制造部分器件结构，以建立成分均匀性、离子电导率、电子电阻和相关接口的功能；3)将喷涂的IC集成到完整的EC器件中，以展示集成系统的性能。如果成功，这项研究将提高生产率，提高安全性和工艺可靠性，并降低制造成本-解决成本效益高的电致变色玻璃的一个主要技术障碍。这些结果估计代表了在完全市场渗透的基础上节省25%的成本。电致变色玻璃将对建筑玻璃行业产生重大影响，因为这是第一次，建筑居住者和业主将能够电子控制窗户玻璃的阴影-从透明到暗度。EC玻璃可以应用于任何需要太阳能控制的窗户，通过提供大量节能和提高舒适度，使住宅、商业和政府建筑部门受益。除建筑窗户外，EC玻璃将非常适合汽车和其他运输工具，以及许多特殊应用-包括大面积电子显示器，娱乐产品和消费电器和小玩意。除了在电致变色方面的应用之外，这种提出的喷涂技术还可以在其他大面积薄膜应用中找到用途，包括可充电锂电池、传感器和光学涂层。

This SBIR Phase I project is proposed by SAGE Electrochromics, Inc. to evaluate the feasibility of using spray coating technology to produce solution-derived, ceramic lithium-ion conductor (IC) films for electrochromic windows. The worldwide development of electrochromic (EC) glazing technology has been severely impeded by the inability to identify and develop an electrolyte that satisfies the performance, durability and cost requirements demanded for architectural glass applications. SAGE believes it has uniquely achieved the performance and stability objectives with a patented solution-derived IC. Although used to some extent in commercial applications, dip coating is an expensive and impractical batch process when production throughput, handling and manufacturing costs are critical to the ultimate commercial potential. A technology well-developed by the automotive industry, spray coating has tremendous potential in the extremely demanding EC window application. A key challenge will be to adapt this continuous process technology to the difficult-to-process thin-film ceramic materials in a way that preserves the essential functionality and performance of SAGE's dip coating developed IC. Specific issues associated with this include microstructure, composition, thickness, ionic and electronic conductivity's and surface morphology. During Phase I, SAGE's principal objective is to demonstrate the feasibility of spray coating for lithium ion-conductor films by successfully making a functional small-area EC device. To achieve this goal, SAGE will 1) spray coat lithium IC films on glass substrates to evaluate uniformity, thickness, and composition, 2) fabricate partial device structures to establish compositional uniformity, ion conductivity, electronic resistance and functionality of the relevant interfaces, and 3) incorporate the spray coated IC into a complete EC device to demonstrate the performance of the integrated system. If successful, this research will raise production rates, improve safety and process reliability, and reduce manufacturing costs - resolving the one major technological barrier to cost-effective electrochromic glazing. These results are estimated to represent a 25% cost savings based on costs at full market penetration. Electrochromicglazing will have a large impact on the architectural glass industry since, for the first time, building occupants and owners will have the ability to electronically control the shading of their window glass - anywhere from clear to heavily darkened. EC glazing will find application in any window where solar control is an issue - benefiting the residential, commercial and government building sectors by providing substantial energy savings and enhanced comfort. In addition to architectural windows, EC glazing will be ideally suited for automobiles and other transportation vehicles, and also for numerous specialty applications - including large-area electronic displays, recreational products, and consumer appliances and gadgetry. Beyond its application in electrochromics, this proposed spray coating technology may find uses in other large-area thin-film applications that include rechargeable lithium batteries, sensors, and optical coatings.