Protective coating materials for electrochromic devices

• US 6,261,641 B1
• Filed: 11/04/1999
• Issued: 07/17/2001
• Est. Priority Date: 10/07/1997
• Status: Expired due to Term

• Current Assignee: Viavi Solutions, Inc. (Lumentum Holdings Inc.)
• Original Assignee: Optical Coating Laboratory, Inc. (Lumentum Holdings Inc.)
• Inventors: OʼBrien, Nada O., Hruska, Curtis Ross, Zieba, Jerry, Cumbo, Michael J., Sapers, Steven P.
• Primary Examiner(s): Beck, Shrive
• Assistant Examiner(s): Calcagni, Jennifer
• Application Number:
  US09/433,441
• Time in Patent Office: 621 Days
• Field of Search: 427/160, 427/162, 427/164, 427/165, 427/168, 427/169, 427/385.5, 427/389.7, 427/372.2, 427/240, 427/428, 359/265, 359/267, 359/274, 359/275, 156/99, 420/411.1, 420/412, 420/473.5
• US Class Current: 427/389.7
• CPC Class Codes: G02F 1/153 Constructional details
• CPC Class Codes: G02F 1/161 Gaskets; Spacers; Sealing of cells; Filling or closing of cells
• CPC Class Codes: G02F 2001/1536 additional, e.g. protective, layer inside the cell
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31507 Of polycarbonate
• CPC Class Codes: Y10T 428/31721 Of polyimide

Abstract

Polymeric coating materials used to protect electrochromic devices from environmental and mechanical damage arc provided. The protective polymeric coating materials are physically, chemically and optically compatible with the electrochromic cell layers of electrochromic devices. The polymeric coating materials are polymers having generic polymer back-bones selected from the group of polyimides, polybenzimidazoles, polybenzothiazoles, polybenzoxazoles, poly(phenylene ethers), polyquinolines, polycarbonates, and polysulfones.

Claims

1. A process for manufacturing an electrochromic device, comprising the steps of:

preparing a polymeric solution which when dried will be chemically inert, have high optical qualities and be thermally stable;

out-gassing the polymeric solution under low pressure to remove any micro-bubbles and dissolved gasses from the polymeric solution;

coating an electrochromic cell of an electrochromic device with the polymeric solution in an inert atmosphere; and

annealing the polymeric coating by heating the electrochromic device to a temperature above about 65°

C.

2. The process of claim 1, wherein the coating step is performed by a method selected from the group consisting of spin coating, spraying, extrusion, roll coating, and dip coating.

3. The process of claim 1, wherein the polymeric solution has a polymer concentration in a range from about 0.2 weight percent to about 10 weight percent.

4. The process of claim 1, wherein the polymeric solution has a polymer concentration in a range from about 0.5 weight percent to about 10 weight percent.

5. The process of claim 1, wherein a humidity level of less than about 45 percent relative humidity is maintained during the coating step.

6. The process of claim 1, wherein the annealing step is performed in a temperature range from about 75°

C. to about 250°

C.

7. The process of claim 1, further comprising the step of filtering the polymeric solution prior to coating the electrochromic cell with the polymeric solution.

8. The process of claim 1, wherein the coating step is performed in a low oxygen atmosphere.

9. The process of claim 1, wherein the polymeric solution comprises a polymer with the following recurring structural unit:

[poly[2,5-benzoxazolediyl[2,2,2-trifluoro-1-(trifluoromethyl)ethylidene]-5,2-benzoxazolediyl-4,4′

-phenylether]]n′

, wherein n′

is an integer number.

10. The process of claim 1, wherein the polymeric solution comprises a polymer with the following recurring structural unit:

[α

-[1,4-Biphenylyl]-ω

-[4-[[4-(4-phenylphenoxy)phenyl]phenylphosphinyl]phenoxy]-poly[oxy-1,4-phenylene(phenylphosphinylidene)-1,4-phenyleneoxy-1,4-phenylene-[9H-fluoren-9-ylidene-1,4-phenylene]]n′

, wherein n′

is a real number.

11. The process of claim 1, wherein the polymeric solution comprises a polymer with the following recurring structural unit:

[α

-[1,4-Biphenylyl]-ω

-[4-[[4-(4-phenylphenoxy)phenyl]phenylphosphinyl]phenoxy]-poly[oxy-1,4-phenylene(phenylphosphinylidene)-1,4-phenyleneoxy-1,4-phenylene-[2,2,2-trifluoro-1-(trifluoromethyl)ethylidene]-1,4-phenylenel]n′

, wherein n′

is a real number.

12. The process of claim 1, wherein the electrochromic device is transparent.

13. The process of claim 1, wherein the electrochromic device is a mirror.

14. The process of claim 1, wherein the electrochromic device has a low emissivity.

15. The process of claim 1, wherein the polymeric coating has a thickness in a range from about 0.1 micrometers to about 100 micrometers.

16. The process of claim 1, wherein the polymeric coating has a thickness in a range from about 0.1 micrometers to about 20 micrometers.

17. The process of claim 1, wherein the electrochromic cell comprises an electrochromic layer, an ion conducting layer, and a counter electrode layer.

18. The process of claim 1, wherein the polymeric coating is thermally stable in a temperature range from about −

50°

C. to about 150°

C.

19. A process for manufacturing an electrochromic device, comprising the steps of:

coating an electrochromic cell of an electrochromic device with a polymeric solution comprising a polymer with the following recurring structural unit;

[poly[2,5-benzoxazolediyl [2,2,2-trifluoro- 1-(trifluoromethyl)ethylidene]-5,2-benzoxazolediyl-4,4′

-phenylether]]n′

, wherein n′

is an integer number; and

annealing the polymeric coating by heating the electrochromic device to a temperature above about 65°

C.

20. A process for manufacturing an electrochromic device, comprising the steps of:

coating an electrochromic cell of an electrochromic device with a polymeric solution comprising a polymer with the following recurring structural unit;

[α

-[1,4-Biphenylyl]-ω

-[4-[[4-(4-phenylphenoxy)phenyl]phenylphosphinyl]phenoxy]-poly[oxy-1,4-phenylene(phenylphosphinylidene)-1,4-phenyleneoxy-1,4-phenylene-9H-fluoren-9-ylidene-1,4-phenylene]]n′

, wherein n′

is a real number; and

annealing the polymeric coating by heating the electrochromic device to a temperature above about 65°

C.

21. A process for manufacturing an electrochromic device, comprising the steps of:

coating an electrochromic cell of an electrochromic device with a polymeric solution comprising a polymer with the following recurring structural unit;

[α

[1,4-Biphenylyl]-ω

-[[4-(4-phenylphenoxy)phenyl]phenylphosphinyl]phenoxy]-poly[oxy-1,4-phenylene(phenylphosphinylidene)-1,4-phenyleneoxy-1,4-phenylene[2,2,2-trifluoro-1-(trifluoromethyl)ethylidene]-1,4-phenylene]]n′

, wherein n′

is a real number; and

annealing the polymeric coating by heating the electrochromic device to a temperature above about 65°

C.

22. A process for manufacturing an electrochromic device, comprising the steps of:

coating an electrochromic cell of an electrochromic device with a polymeric solution which when dried forms a polymeric layer that is chemically inert, has high optical qualities and is thermally stable, wherein the coating step is performed in a low humidity, low oxygen atmosphere so that substantially no moisture, oxygen or other chemical is captured under the polymeric layer; and

annealing the polymeric coating by heating the electrochromic device to a temperature above about 65°

C.