For the application in flexible electrochromic devices (ECDs) on plastic substrates, a new polyurethane-based gel electrolyte was manufactured. In this context, the curing behavior and the influence of the proportion of solvent and salt on the ion conductivity as well as the optical and mechanical properties were investigated. Furthermore, the stoichiometric ratio of the polyurethane matrix was varied to influence the ion conductivity. As an isocyanate component, the aliphatic difunctional polyisocyanate prepolymer, synthesized by Hexamethylen-1,6-diisocyanat (HDI), was chosen since the resulting polyurethane is considered to be particularly lightfast, color-stable and temperature-resistant and therefore frequently used for paints and coatings. As polyol a trifunctional polyetherpolyol was selected to form a wide-meshed crosslinked matrix to achieve a mechanically stable but flexible electrolyte, that enables the processing and bending of film-based ECDs. The additives amount and the matrix stoichiometric ratio affected the curing behavior and curability. The salt content had almost no influence on the measured properties in the chosen experimental space. Solvent content had a great influence on ion conductivity and mechanical properties. An understoichiometric ratio of the polyurethane matrix (0.85) increases the ion conductivity and the mechanical flexibility, but also the optical properties in a negative manner. The best specific ion conductivity with 10−5 S/cm was reached with an understoichiometric ratio of 0.85 and a high solvent content (30 wt%). Concluding, due to its high flexibility and transmittance, color neutrality and sufficient ion conductivity, the application of the researched electroyte in ECDs might be suitable. A demonstrator ECD was successfully manufactured and conducted.

A recently described flexible polyurethane electrolyte was artificially weathered at 25/50 °C and 50% r.h. in air and at 25 °C in a dry nitrogen atmosphere, each with and without UV irradiation. Different formulations and the polymer matrix, used as a reference, were weathered in order to investigate the influence of the amount of conductive lithium salt and the solvent propylene carbonate. The complete loss of the solvent at a standard climate was already observed after a few days, strongly influencing the conductivity and mechanical properties. The essential degradation mechanism appears to be the photo-oxidative degradation of the polyol’s ether bonds, which leads to chain scission, oxidation products and negative changes in the mechanical and optical properties. A higher salt content has no effect on the degradation; however, the presence of propylene carbonate intensifies the degradation.

The influence of thermomechanical stress on the conductivity of indium tin oxide (ITO)-coated polycarbonate (PC) films was investigated. PC is the industry’s standard material for window panes. ITO coatings on polyethylene terephthalate (PET) films are the main commercially available option; as such, most investigations refer to this combination. The investigations in this study aim to investigate the critical crack initiation strain at different temperatures and crack initiation temperatures for two different coating thicknesses and for a commercially available PET/ITO film for validation purposes. Additionally, the cyclic load was investigated. The results show the comparatively sensitive behavior of the PC/ITO films, with a crack initiation strain at room temperature of 0.3–0.4% and critical temperatures of 58 °C and 83 °C, with high variation depending on the film’s thickness. Under thermomechanical loading, the crack initiation strain decreases with increasing temperatures.

Electrochromic (EC) windows on glass for thermal and glare protection in buildings, often referred to as smart (dimmable) windows, are commercially available, along with rearview mirrors or windows in aircraft cabins. Plastic-based applications, such as ski goggles, visors and car windows, that require lightweight, three-dimensional (3D) geometry and high-throughput manufacturing are still under development. To produce such EC devices (ECDs), a flexible EC film could be integrated into a back injection molding process, where the films are processed into compact 3D geometries in a single automized step at a low processing time. Polycarbonate (PC) as a substrate is a lightweight and robust alternative to glass due to its outstanding optical and mechanical properties. In this study, an EC film on a PC substrate was fabricated and characterized for the first time. To achieve a highly transmissive and colorless bright state, poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOT:PSS) was used as the working electrode, while titanium dioxide (TiO2) was used as the counter electrode material. They were deposited onto ITO-coated PC films using dip- and slot-die coating, respectively. The electrodes were optically and electrochemically characterized. An ECD with a polyurethane containing gel electrolyte was investigated with regard to optical properties, switching speed and cycling behavior. The ECD exhibits a color-neutral and highly transmissive bright state with a visible light transmittance of 74% and a bluish-colored state of 64%, a fast switching speed (7 s/4 s for bleaching/coloring) and a moderately stable cycling behavior over 500 cycles with a decrease in transmittance change from 10%to 7%.