Electrochromic windows and method of making the same

• US 20030137715A1
• Filed: 01/23/2003
• Published: 07/24/2003
• Est. Priority Date: 07/25/2000
• Status: Active Grant

• Current Assignee: David A. Theiste, David L. Poll, Kevin L. Ash, Thomas F. Guarr, William L. Tonar
• Original Assignee: David A. Theiste, David L. Poll, Kevin L. Ash, Thomas F. Guarr, William L. Tonar
• Inventors: Tonar, William L., Guarr, Thomas F., Poll, David L., Ash, Kevin L., Theiste, David A.
• Granted Patent: US 6,671,080 B2
• Time in Patent Office: Days
• US Class Current: 359/275
• CPC Class Codes: E06B 2009/2464 featuring transparency control by applying voltage, e.g. LCD, electrochromic panels
• CPC Class Codes: E06B 3/66 Units comprising two or more parallel glass or like panes permanently secured together reforming and uniting glass sheets by fusing C03B23/00; joining glass to glass or to other materials C03C27/00; laminated glass B32B17/10
• CPC Class Codes: E06B 3/66366 specially adapted for units comprising more than two panes or for attaching intermediate sheets
• CPC Class Codes: E06B 3/6722 with adjustable passage of light
• CPC Class Codes: E06B 3/6775 Evacuating or filling the gap during assembly
• CPC Class Codes: E06B 9/264 Combinations of lamellar blinds with roller shutters, screen windows, windows, or double panes; Lamellar blinds with special devices
• 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: G02F 2201/44 Arrangements combining different electro-active layers, e.g. electrochromic, liquid crystal or electroluminescent layers
• CPC Class Codes: Y10S 359/90 Methods

Abstract

An electrochromic window assembly is disclosed that includes a first substrate and a second substrate that is maintained in a parallel and spaced relation from the first substrate by means of a window frame and spacer. The window assembly further includes an electrochromic device mounted within the airtight chamber formed between the first and second substrates. Electrochromic device 22 may be mounted so as to provide an air chamber between first substrate 12, which is the external substrate, and electrochromic device 22. At least one of the chambers formed between substrates 12 and 14 and electrochromic device 22 may be filled with an insulating gas such as argon. Also disclosed are novel methods for manufacture of an electrochromic device for incorporation into such a window assembly. A novel electrochromic device is also disclosed having electrical bus clips secured about the entire periphery of the electrochromic device. Also disclosed is the use of steel bus clips for the electrochromic device.

Claims

1. A method of making an electrochromic device comprising the steps of:

providing an assembly including a first substrate and a second substrate spaced apart and joined by a seal to form a sealed chamber between inner surfaces of said substrates, one of said first and second substrates including an aperture extending between the outer surface of the substrate and the chamber;

filling said chamber with an electrochromic solution or an electrolytic solution through said conical-shaped aperture;

placing a plug in said aperture; and

adhering a thin plate over the plugged aperture using a UV-curable adhesive.

2. The method of claim 1, wherein said plug is a ball.

3. The method of claim 1, wherein said plug is a soft deformable ball.

4. The method of claim 3, wherein said ball is made of one of polyisobutylene, polyolefin, and butylnitrile.

5. The method of claim 3, wherein said ball is made of tetrafluoroethylene fluorocarbon, fluorinated ethylene-propylene, or copolymers thereof.

6. The method of claim 1, wherein said thin plate is transparent to UV radiation.

7. The method of claim 1, wherein said thin plate is a microscope slide.

8. The method of claim 1, wherein said thin plate is impermeable to oxygen.

9. The method of claim 1, wherein said aperture has a conical shape.

10. An electrochromic device made using the method of claim 1.

11. A window comprising an electrochromic device made using the method of claim 1.

12. A method of making an electrochromic device comprising the steps of:

providing a first substrate;

adhering a first surface of a pre-formed seal gasket onto a first surface of said first substrate proximate the periphery thereof, said seal gasket having adhesive pre-applied to a second surface opposite the first surface, and having a release liner attached to the adhesive on the second surface of said seal gasket;

removing the release liner from the second surface of said seal gasket; and

aligning a second substrate with said first substrate and pressing a first surface of said second substrate onto the adhesive on the second surface of the seal gasket.

13. The method of claim 12 and further including the step of filling an area between the first surfaces of said first and second substrates with an electrochromic solution.

14. The method of claim 12 and further including the step of filling an area between the first surfaces of said first and second substrates with an electrolytic solution.

15. The method of claim 12, wherein the first and second substrates each include a transparent conductive layer on the first surfaces thereof.

16. The method of claim 12, wherein the seal is made of silicone.

17. The method of claim 12, wherein the seal is made of butyl rubber.

18. The method of claim 12 and further including the step of applying a sealant to the periphery of the joined first and second substrates.

19. The method of claim 18, wherein the sealant is impermeable to air and moisture.

20. The method of claim 19, wherein the sealant is an epoxy resin.

21. An electrochromic device made using the method of claim 12.

22. A window comprising an electrochromic device made using the method of claim 12.

23. An electrochromic device comprising:

a first substrate and a second substrate spaced apart and joined by a seal to form a sealed chamber between inner surfaces of said substrates, said substrates being positioned to have at least a first edge aligned with the first edge of the other substrate;

a first electrode disposed on the inner surface of said first substrate;

a second electrode disposed on the inner surface of said second substrate, said first and second electrodes being electrically isolated from one another;

an electrochromic medium disposed within said sealed chamber;

a first electrical connector clip electrically coupled to said first electrode and physically coupled to said first substrate along at least the first edge thereof; and

a second electrical connector clip electrically coupled to said second electrode and physically coupled to said second substrate along at least the first edge thereof,

wherein said first and second electrical connector clips include a plurality of spaced-apart fingers that respectively contact said first and second electrodes, the fingers of one connector clip being spaced apart from one another by a distance greater than the width of the fingers of the other connector clip such that the fingers of said both the connector clips intermesh without physically contacting the fingers of the other connector clip.

24. The electrochromic device of claim 23, wherein said first electrical connector clip is electrically coupled to said first electrode about the entire perimeter of said first electrode and said second electrical connector clip is electrically coupled to said second electrode about the entire perimeter of said second electrode.

25. The electrochromic device of claim 23, wherein said first and second connector clips are made of steel.

26. A window comprising a window frame and the electrochromic device of claim 23 mounted to said frame.

27. A window comprising the electrochromic device of claim 23 and further including first and second transparent substrates and a spacer for spacing and maintaining said first and second transparent substrates in a parallel, spaced-apart relation with said electrochromic device provided between said transparent substrates.

28. The window of claim 27 and further including a seal for providing an airtight cavity between said transparent elements, wherein said electrochromic device is disposed in said cavity.

29. The window of claim 28, wherein at least a portion of the airtight cavity is filled with argon.

30. An electrochromic device comprising:

first and second transparent elements joined by a seal in a parallel, spaced-apart relation to form a chamber therebetween;

a first transparent electrode disposed over the inner surface of said first element;

a second transparent electrode disposed over the inner surface of said second element, said first and second electrodes being electrically isolated from one another;

an electrochromic medium disposed within said sealed chamber;

a first electrical conductor electrically coupled to said first electrode about the entire perimeter of said first electrode; and

a second electrical conductor electrically coupled to said second electrode about the entire perimeter of said second electrode.

31. The electrochromic device of claim 30, wherein at least one of said first and second conductors is a connector clip that includes a plurality of spaced-apart fingers that respectively extend from a spine and contact said first and second electrodes.

32. The electrochromic device of claim 30, wherein at least one of said first and second conductors is an exposed wire.

33. The electrochromic device of claim 30, wherein at least one of said first and second conductors is foil strip.

34. The electrochromic device of claim 30, wherein said first and second conductors are made of steel.

35. A window comprising a window frame and the electrochromic device of claim 30 mounted to said frame.

36. A window comprising the electrochromic device of claim 30 and further including first and second transparent substrates and a spacer for spacing and maintaining said first and second transparent substrates in a parallel, spaced-apart relation with said electrochromic device provided between said transparent substrates.

37. The window of claim 36 and further including a seal for providing an airtight cavity between said transparent substrates, wherein said electrochromic device is disposed in said cavity.

38. The window of claim 37, wherein at least a portion of the airtight cavity is filled with argon.