Thin-Film Coatings, Electro-Optic Elements and Assemblies Incorporating These Elements

• US 20100215903A1
• Filed: 01/22/2010
• Published: 08/26/2010
• Est. Priority Date: 03/03/2006
• Status: Active Grant

• Current Assignee: Gentex Corporation
• Original Assignee: Gentex Corporation
• Inventors: Perron, Lansen M., Brummel, Nelson F., Poe, G. Bruce, Neuman, George A., Cammenga, David J., Tonar, William L., Anderson, John S., Luten, Henry A., Dozeman, Gary J., Forgette, Jeffrey A.
• Granted Patent: US 8,169,681 B2
• Time in Patent Office: Days
• US Class Current: 428/141
• CPC Class Codes: B60R 1/084 using a removable filtering or hiding screen associated with windows or windscreens B60J3/00
• CPC Class Codes: G02B 5/0808 having a single reflecting layer G02B5/0883, G02B5/0891 take precedence
• CPC Class Codes: G02F 1/0018 Electro-optical materials
• CPC Class Codes: G02F 1/155 Electrodes
• CPC Class Codes: G02F 1/157 Structural association of cells with optical devices, e.g. reflectors or illuminating devices
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/2495 Thickness [relative or absolute]

Abstract

Electro-optic elements are becoming commonplace in a number of vehicular and architectural applications. Various electro-optic element configurations provide variable transmittance and or variable reflectance for windows and mirrors. The present invention relates to various thin-film coatings, electro-optic elements and assemblies incorporating these elements.

Claims

1. An electro-optic element configured for use in a rearview automotive mirror, the electro-optic element comprising:

a first substrate including first and second surfaces, the first substrate having a first layer of electrically conductive material deposited on the second surface;

a second substrate including third and fourth surfaces, the first and second substrates disposed in a parallel and spaced-apart relationship to define a gap between the second and third surfaces, the gap containing an electro-optic medium,

the second substrate containing a metallic bi-layer, the metallic bi-layer including a base layer made of metal having a base bulk reflectance and a top layer made of metal having a top bulk reflectance, the base and top bulk reflectances measured in ambient light, the top bulk reflectance being higher than the base bulk reflectance, the base and top layers disposed consecutively on the third surface,

wherein a sheet resistance of the bi-layer does not exceed 6 Ohms per square, a thickness of the top layer does not exceed 50 percent of a thickness of the bi-layer, and a reflectance of the bi-layer measure in ambient light in air exceeds 90 percent of a theoretical maximum.

2. An electro-optic element according to claim 1, wherein the top layer includes a metal selected from a group consisting of aluminum, rhodium, ruthenium, iridium, palladium, platinum, cadmium, copper, cobalt, silver, gold, nickel, tungsten, and molybdenum.

3. An electro-optic element according to claim 1, wherein the base layer includes a metal selected from a group consisting of chromium, aluminum, cadmium, chromium, cobalt, copper, gold, iridium, iron, magnesium, molybdenum, nickel, osmium, palladium, platinum, rhodium, ruthenium, silver, tin tungsten, and zinc.

4. An electro-optic element according to claim 1, wherein the sheet resistance of the bi-layer does not exceed 5 Ohms per square.

5. An electro-optic element according to claim 4, wherein the thickness of the top layer does not exceed 25 percent of the thickness of the bi-layer.

6. An electro-optic element according to claim 1, wherein the sheet resistance of the bi-layer does not exceed 2.5 Ohms per square.

7. An electro-optic element according to claim 6, wherein the thickness of the top layer does not exceed 7.5 percent of the thickness of the bi-layer.

8. An electro-optic element according to claim 1, wherein a surface roughness of the bi-layer is less than 200 angstroms.

9. An electro-optic element according to claim 1, wherein a surface roughness of the bi-layer is less than 100 angstroms.

10. An electro-optic element according to claim 1, wherein a surface roughness of the bi-layer is less than 50 angstroms.

11. An electro-optic element according to claim 1, wherein a surface roughness of the bi-layer is less than 25 angstroms.

12. An electro-optic element according to claim 1, wherein the reflectance of the bi-layer exceeds 95 percent of the theoretical maximum.

13. An electro-optic element according to claim 1, wherein the base layer has a base sheet resistance and the top layer has a top sheet resistance, a ratio of the base sheet resistance to the top sheet resistance not exceeding two-thirds.

14. An electro-optic element according to claim 1, wherein a reflectance of the electro-optic element in ambient light is at least 55 percent.

15. An electro-optic element according to claim 1, wherein a reflectance of the electro-optic element in ambient light is at least 60 percent.

16. An electro-optic element configured for use in a rearview automotive mirror, the electro-optic element comprising:

a first substrate including first and second surfaces, the first substrate having a first layer of electrically conductive material deposited on the second surface;

a second substrate including third and fourth surfaces, the first and second substrates disposed in a parallel and spaced-apart relationship to define a gap between the second and third surfaces, the gap containing an electro-optic medium,

the second substrate containing a metallic bi-layer, the metallic bi-layer including a base layer made of metal having a base bulk reflectance and a top layer made of metal having a top bulk reflectance, the base and top bulk reflectances measured in ambient light, the top bulk reflectance being higher than the based bulk reflectance, the base and top layers disposed consecutively on the third surface,

wherein a sheet resistance of the bi-layer does not exceed 3 Ohms per square, the thickness of the top layer does not exceed 25 percent of the thickness of the bi-layer, and the reflectance of the bi-layer on the second substrate measured in ambient light exceeds 85 percent of a theoretical maximum.

17. An electro-optic element according to claim 16, wherein the reflectance of the bi-layer exceeds 90 percent of the theoretical maximum.

18. An electro-optic element according to claim 16, wherein the reflectance of the bi-layer exceeds 95 percent of the theoretical maximum.

19. An electro-optic element according to claim 16, wherein the sheet resistance of the bi-layer does not exceed 1.5 Ohms per square.

20. An electro-optic element according to claim 16, wherein the thickness of the top layer does not exceed 14 percent of the thickness of the bi-layer.

21. An electro-optic element according to claim 16, wherein the base layer includes a metal selected from a group consisting of chromium, aluminum, cadmium, chromium, cobalt, copper, gold, iridium, iron, magnesium, molybdenum, nickel, osmium, palladium, platinum, rhodium, ruthenium, silver, tin tungsten, and zinc.

22. An electro-optic element according to claim 16, wherein the top layer the top layer includes a metal selected from a group consisting of aluminum, rhodium, ruthenium, iridium, palladium, platinum, cadmium, copper, cobalt, silver, gold, nickel, tungsten, and molybdenum.

23. An electro-optic element according to claim 16, wherein a reflectance of the electro-optic element measured in ambient light exceeds 60 percent.

24. An electro-optic element according to claim 16, wherein a surface roughness of the bi-layer is less than 50 angstroms.

25. An electro-optic element configured for use in a rearview automotive mirror, the electro-optic element comprising:

a first substrate including first and second surfaces, the first substrate having a first layer of electrically conductive material deposited on the second surface;

a second substrate including third and fourth surfaces, the first and second substrates disposed in a parallel and spaced-apart relationship to define a gap between the second and third surfaces, the gap containing an electro-optic medium,

the second substrate containing a metallic bi-layer, the metallic bi-layer including a base layer made of metal having a base bulk reflectance and a top layer made of metal having a top bulk reflectance, the base and top bulk reflectances measured in ambient light, the top bulk reflectance being higher than the based bulk reflectance, the base and top layers disposed consecutively on the third surface,

wherein a sheet resistance of the bi-layer does not exceed 0.5 Ohms per square, the thickness of the top layer does not exceed 7.5 percent of the thickness of the bi-layer, and the reflectance of the bi-layer on the second substrate measured in ambient light exceeds 75 percent of a theoretical maximum.

26. An electro-optic element according to claim 25, wherein the base layer comprises chromium and the top layer comprises at least one metal selected from the group consisting of aluminum, rhodium, ruthenium, iridium, palladium, platinum, copper, cobalt, silver, gold, nickel, tungsten, and molybdenum.

27. An electro-optic element according to claim 25, wherein the reflectance of the bi-layer exceeds 80 percent of the theoretical maximum.

28. An electro-optic element according to claim 25, wherein the reflectance of the bi-layer exceeds 90 percent of the theoretical maximum.

29. An electro-optic element according to claim 25, wherein a reflectance of the electro-optic element measured in ambient light is at least 60 percent.

30. An electro-optic element according to claim 25, wherein the base layer includes a metal selected from a group consisting of chromium, aluminum, cadmium, chromium, cobalt, copper, gold, iridium, iron, magnesium, molybdenum, nickel, osmium, palladium, platinum, rhodium, ruthenium, silver, tin tungsten, and zinc.

31. An electro-optic element according to claim 25, wherein the top layer the top layer includes a metal selected from a group consisting of aluminum, rhodium, ruthenium, iridium, palladium, platinum, cadmium, copper, cobalt, silver, gold, nickel, tungsten, and molybdenum.

32. An electro-optic element according to claim 35, wherein a surface roughness of the bi-layer is less than 50 angstroms.