Electrochromic window fabrication methods

• US 10,684,524 B2
• Filed: 02/04/2019
• Issued: 06/16/2020
• Est. Priority Date: 11/08/2010
• Status: Active Grant

• Current Assignee: View Incorporated
• Original Assignee: View Incorporated
• Inventors: Collins, Mark A., Parker, Ronald M., Rozbicki, Robert T., Shrivastava, Dhairya
• Primary Examiner(s): Pinkney, Dawayne
• Application Number:
  US16/267,260
• Publication Number:
  US 20190243204A1
• Time in Patent Office: 498 Days
• Field of Search: 359265-275, 359277, 359245-247, 359254, 359242, 345 49, 345105, 250 70, 348817, 438929
• CPC Class Codes: B32B 17/10055 with at least one intermediate air space
• CPC Class Codes: B32B 17/10128 Treatment of at least one glass sheet
• CPC Class Codes: B32B 17/10183 being not continuous, e.g. in edge regions
• CPC Class Codes: B32B 17/10513 Electrochromic layer
• CPC Class Codes: B32B 17/10697 being cross-linked
• CPC Class Codes: B32B 17/10908 in liquid form
• CPC Class Codes: B32B 17/1099 After-treatment of the layered product, e.g. cooling
• CPC Class Codes: B32B 2333/12 Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
• CPC Class Codes: E06B 2009/2464 featuring transparency control by applying voltage, e.g. LCD, electrochromic panels
• CPC Class Codes: E06B 3/6722 with adjustable passage of light
• CPC Class Codes: E06B 3/673 Assembling the units E06B3/677 takes precedence ; making hollow glass sheets or bricks C03B23/24
• CPC Class Codes: E06B 9/24 Screens or other constructions affording protection against light, especially against sunshine; Similar screens for privacy or appearance; Slat blindsoperating, guiding or securing devices or arrangements for roll-type closures E06B9/56; free-hanging flexible screens A47H23/00
• CPC Class Codes: G02B 1/14 Protective coatings, e.g. hard coatings
• CPC Class Codes: G02F 1/133308 Support structures for LCD panels, e.g. frames or bezels
• CPC Class Codes: G02F 1/133311 Environmental protection, e.g. against dust or humidity
• CPC Class Codes: G02F 1/153 Constructional details
• CPC Class Codes: G02F 1/1533 structural features not otherwise provided for
• CPC Class Codes: G02F 1/155 Electrodes
• CPC Class Codes: G02F 1/161 Gaskets; Spacers; Sealing of cells; Filling or closing of cells
• CPC Class Codes: Y10T 156/1052 with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 156/1062 : Prior to assembly
• CPC Class Codes: Y10T 29/49004 : including measuring or testing of device or component part
• CPC Class Codes: Y10T 29/49124 : On flat or curved insulated base, e.g., printed circuit, etc.

Abstract

Methods of manufacturing electrochromic windows are described. An electrochromic device is fabricated to substantially cover a glass sheet, for example float glass, and a cutting pattern is defined based on one or more low-defectivity areas in the device from which one or more electrochromic panes are cut. Laser scribes and/or bus bars may be added prior to cutting the panes or after. Edge deletion can also be performed prior to or after cutting the electrochromic panes from the glass sheet. Insulated glass units (IGUs) are fabricated from the electrochromic panes and optionally one or more of the panes of the IGU are strengthened.

Claims

1. A method of manufacturing one or more electrochromic panes, the method comprising:

(a) fabricating an electrochromic device on a glass sheet;

(b) defining a cutting pattern for cutting the glass sheet; and

(c) cutting the glass sheet according to the cutting pattern to create said one or more electrochromic panes;

wherein the cutting pattern is configured to maximize efficient use of the glass sheet, the cutting pattern determined by an algorithm or logic.

2. The method of claim 1, wherein the algorithm or logic defines the one or more electrochromic panes in the cutting pattern to comprise varying sizes.

3. The method of claim 1, wherein the cutting pattern is defined, at least in part, by characterizing one or more physical features of the glass sheet and/or electrochromic device after fabrication of the electrochromic device.

4. The method of claim 3, wherein said one or more physical features are selected from the group consisting of:

1) identifying one or more low-defectivity areas on the electrochromic device,

2) identifying one or more areas of non-uniformity in the electrochromic device,

3) identifying one or more areas where materials used to make the electrochromic device were deposited on the back side of the glass sheet;

4) identifying one or more performance characteristics of the electrochromic device; and

5) identifying one or more defects in the glass sheet.

5. The method of claim 1, wherein characterizing the one or more physical features of the glass sheet and/or electrochromic device comprises testing the electrochromic device to determine its leakage current and/or the resistivity of a transparent conductive oxide.

6. The method of claim 1, further comprising, after (a):

(i) creating a first mapping data set based on one or more low-defectivity areas on the electrochromic device;

(ii) creating a second mapping data set based on another one or more low-defectivity areas on a second electrochromic device on a second glass sheet; and

(iii) comparing the first and second mapping data sets;

wherein defining the cutting pattern employs a comparison of the first and second mapping data sets generated in (iii).

7. The method of claim 1, further comprising scribing isolation trenches for said one or more electrochromic panes after (b) and before (c).

8. The method of claim 7, further comprising applying bus bars to the one or more electrochromic panes.

9. The method of claim 8, wherein the bus bars are non-penetrating bus bars.

10. The method of claim 1, further comprising strengthening a first electrochromic pane.

11. The method of claim 10, wherein the strengthening comprises laminating a second pane to the first electrochromic pane.

12. The method of claim 10, wherein strengthening comprises cutting the first electrochromic pane with a laser.

13. The method of claim 1, wherein the glass sheet is about 120 inches long and about 72 inches wide.

14. The method of claim 1, wherein the electrochromic device is all solid state and all inorganic.

15. The method of claim 1, wherein (c) comprises laser induced scoring by tension.

16. The method of claim 1, further comprising forming a transparent conducting oxide layer on the glass sheet before forming the electrochromic device.

17. The method of claim 16, further comprising forming a diffusion barrier on the glass sheet prior to forming the transparent conducting oxide layer.

18. The method of claim 1, wherein the glass sheet is float glass.

19. The method of claim 1, wherein the cutting pattern comprises 1 inch to 10 inches of some or all edges of the glass sheet to be trimmed away, not part of the one or more electrochromic panes.

20. The method of claim 1, wherein an edge deletion is performed on the one or more electrochromic panes after (c), or, on the glass sheet prior to (c).

21. The method of claim 1, wherein an edge finishing is performed on the one or more electrochromic panes after (c).