Electrochromic layer

• US 6,515,787 B1
• Filed: 03/07/2001
• Issued: 02/04/2003
• Est. Priority Date: 03/07/2000
• Status: Expired due to Term

• Current Assignee: Eclipse Energy Systems Inc.
• Original Assignee: Eclipse Energy Systems Inc.
• Inventors: Kislov, Nikolai, Westfall, Raymond T.
• Primary Examiner(s): Epps, Georgia
• Assistant Examiner(s): TRA, TUYEN Q
• Application Number:
  US09/800,869
• Time in Patent Office: 699 Days
• Field of Search: 359/265, 359/266, 359/267, 359/268, 359/269, 359/270, 359/271, 359/272, 359/273, 359/274, 359/275, 429/304, 429/33, 429/188
• US Class Current: 359/265
• CPC Class Codes: G02F 1/1523 comprising inorganic material
• CPC Class Codes: G02F 1/1524 Transition metal compounds
• CPC Class Codes: G02F 1/1525 characterised by a particular ion transporting layer, e.g. electrolyte
• CPC Class Codes: G02F 1/155 Electrodes
• CPC Class Codes: H01M 6/18 with solid electrolyte

Abstract

An improved electrochromic device comprising a substrate and a first conductive layer located on the transparent substrate. An ion storage layer is located on the first conductive layer. An electrolyte layer is located on the ion storage layer with an active layer being located on the electrolyte layer. A second conductive layer is located on the active layer.

Claims

1. An improved electrochromic device, comprising:

a substrate;

a first conductive layer located on said substrate;

an ion storage layer located on the first conductive layer;

an electrolyte layer located on the ion storage layer;

said electrolyte layer having a thickness less than 1000 angstroms;

an active layer located on the electrolyte layer; and

a second conductive layer located on the active layer.

4. An improved electrochromic device as set forth in claim 1, wherein said substrate is substantially transparent.

5. An improved electrochromic device as set forth in claim 1, wherein said first conductive layer located on said substrate is indium-tin-oxide (ITO).

6. An improved electrochromic device as set forth in claim 1, wherein said ion storage layer located on the first conductive layer is vanadium pentoxide (V₂O₅).

7. An improved electrochromic device as set forth in claim 1, wherein said electrolyte layer located on the ion storage layer is a solid state electrolyte.

8. An improved electrochromic device as set forth in claim 1, wherein said electrolyte layer located on the ion storage layer is selected from the group consisting of tantalum pentoxide (Ta₂O₅), magnesium fluoride (MgF), lithium nitride (LiN₃) and lithium phosphate (Li₃PO₄).

9. An improved electrochromic device as set forth in claim 1, wherein said electrolyte layer located on the ion storage layer is lithium phosphate (Li₃PO₄).

10. An improved electrochromic device as set forth in claim 1, wherein said active layer located on the electrolyte layer is a transition metal oxide.

11. An improved electrochromic device as set forth in claim 1, wherein said active layer located on the electrolyte layer is selected from the group consisting of tungsten trioxide (WO₃) and nickel oxide (NiO).

12. An improved electrochromic device as set forth in claim 1, wherein said active layer located on the electrolyte layer is tungsten trioxide (WO₃).

13. An improved electrochromic device as set forth in claim 1, wherein said second conductive layer located on the active layer is transparent.

14. An improved electrochromic device as set forth in claim 1, wherein said second conductive layer located on the active layer is transparent indium-tin-oxide (ITO).

15. An improved electrochromic device a set forth in claim 1, wherein said second conductive layer located on the active layer is reflective.

16. An improved electrochromic device as set forth in claim 1, wherein said second conductive layer located on the active layer is reflective aluminum (Al).

17. An improved electrochromic device as set forth in claim 1, wherein at least one of said layers is disposed by vacuum deposition.

18. An improved electrochromic device as set forth in claim 1, wherein at least one of said layers is disposed by plasma enhanced chemical vapor deposition (PECVD).

19. An improved electrochromic device as set forth in claim 1, wherein said electrolyte layer totally overlays said first conductive layer and said ion storage layer.

2. An improved electrochromic device, comprising:

a substrate;

a first conductive layer located on said substrate;

a first and a second conductive bus bars located on said first conductive layer;

said first and second conductive bus bars being separated for testing the conductivity of said first conductive layer;

an ion storage layer located on the first conductive layer;

an electrolyte layer located on the ion storage layer;

an active layer located on the electrolyte layer; and

a second conductive layer located on the active layer.

3. An improved electrochromic device, comprising:

a substrate;

a first conductive bus bar located on said substrate;

a first conductive layer located on said substrate;

a second conductive bus bar located on said first conductive layer;

an ion storage layer located on the first conductive layer;

an electrolyte layer located on the ion storage layer;

an active layer located on the electrolyte layer;

a second conductive layer located on the active layer; and

a hermetic layer overlaying said layers and said conductive bus bars for bonding with the transparent substrate for sealing the electrochromic device.

20. An improved electrochromic device, comprising:

a substrate;

a first conductive layer located on said substrate;

a taper defined in said first conductive layer;

an ion storage layer located on the first conductive layer;

an electrolyte layer located on the ion storage layer;

an active layer located on the electrolyte layer; and

a second conductive layer located on the active layer.

21. An improved transmissive electrochromic device, comprising a monolithic stack of solid state inorganic materials deposited directly onto a transparent or translucent substrate comprised of glass, polymer, or fiberglass reinforced polymer, comprising:

a first electrically conductive layer, which is substantially transparent, comprised of ITO, fluorine doped tin oxide, or a grid of metallic or electrically conductive material, located on the top surface of said transparent or translucent substrate;

an ion storage layer, comprised of vanadium pentoxide (V₂O₅), located on the top surface of the first electrically conductive layer;

an electrolyte layer, comprised of amorphous Li₃PO₄, located on the top surface of the ion storage layer;

said electrolyte layer having a thickness less than 1000 angstroms;

an active layer located on the electrolyte layer, comprised of amorphous or polycrystalline WO₃, located on the top surface of the electrolyte layer;

a second electrically conductive layer, which is substantially transparent, comprised of ITO, fluorine doped tin oxide, or a grid of metallic or electrically conductive material, located on the top surface of the active layer,

an electrical contact for the first electrically conductive layer comprised of a Ni pad, suitable for establishing an electrical connection, located on the top surface of the first electrically conductive layer in an area not covered by the ion storage layer, the ion conductor layer, the active layer, or the second electrically conductive layer; and

an electrical contact for the second electrically conductive layer comprised of a Ni pad, suitable for establishing an electrical connection, located on the top surface of the substrate in an area not covered by any layers except the second electrically conductive layer.

22. An improved electrochromic device as set forth in claim 21, wherein said substrate is a substantially rigid substrate.

23. An improved electrochromic device as set forth in claim 21, wherein said substrate is a substantially flexible substrate.

24. An improved electrochromic device as set forth in claim 21, including conductive bus bars located on the first conductive layer and located on the transparent substrate.

25. An improved electrochromic device as set forth in claim 21, wherein at least one of said layers is disposed by vacuum deposition.

26. An improved electrochromic device as set forth in claim 21, wherein at least one of said layers is disposed by plasma enhanced chemical vapor deposition (PECVD).

27. An improved electrochromic device as set forth in claim 21, including a protective layer comprised of SiO₂ which covers the entire electrochromic stack and bonds to the periphery of the substrate providing a hermetic encapsulation for the electrochromic device.

28. An improved transmissive electrochromic device, comprising a monolithic stack of solid state inorganic materials deposited directly onto a transparent or translucent substrate comprised of glass, polymer, or fiberglass reinforced polymer, comprising:

a first electrically conductive layer, which is substantially transparent, comprised of ITO located on the top surface of said transparent or translucent substrate with the following properties;

said layer covers the top surface of the substrate except for a narrow strip around the periphery at the edges of the substrate and a larger rectangular area along one edge with the longer dimension of the rectangle being aligned with the edge of the substrate;

the edge of the ITO bordering the uncovered rectangular area is smoothly tapered from the top of the ITO layer to the top surface of the underlying substrate to provide a smooth transition for the subsequently applied layers whose electrical and mechanical properties can be adversely affected by an abrupt transition;

an ion storage layer, comprised of vanadium pentoxide (V₂O₅), located on the top surface of the first electrically conductive layer and extending across the tapered edge of the ITO to the uncoated area of the substrate;

an electrolyte layer, comprised of amorphous Li₃PO₄, located on the top surface of the ion storage layer and extending across the tapered edge of the ITO beyond the edge of the Li₃PO₄ to the uncoated area of the substrate;

an active layer located on the electrolyte layer, comprised of amorphous or polycrystalline WO₃, located on the top surface of the electrolyte layer;

a nickel contact for the second electrically conductive layer located on the top surface of the substrate in the uncoated rectangular area;

a second electrically conductive layer, which is substantially transparent, comprised of ITO, fluorine doped tin oxide, or a grid of metallic or electrically conductive material, located on the top surface of the active layer and extending across the tapered edge of the ITO onto the top of a portion of the nickel contact;

an electrical contact for the first electrically conductive layer comprised of a Ni pad, suitable for establishing an electrical connection, located on the top surface of the second electrically conductive layer; and

a protective layer comprised of SiO₂ which covers the entire electrochromic stack and bonds to the periphery of the substrate providing a hermetic encapsulation for the electrochromic device.

29. An improved electrochromic device as set forth in claim 28, wherein said substrate is a substantially rigid substrate.

30. An improved electrochromic device as set forth in claim 28, wherein said substrate is a substantially flexible substrate.

31. An improved reflective electrochromic device, comprising a monolithic stack of solid state inorganic materials deposited directly onto a transparent or translucent substrate comprised of glass, polymer, or fiberglass reinforced polymer;

comprising;

a first electrically conductive layer, which is substantially transparent, comprised of ITO, fluorine doped tin oxide, or a grid of metallic or electrically conductive material, located on the top surface of said transparent or translucent substrate;

an ion storage layer, comprised of vanadium pentoxide (V₂O₅), located on the top surface of the first electrically conductive layer;

an electrolyte layer, comprised of amorphous Li₃PO₄, located on the top surface of the ion storage layer;

said electrolyte layer having a thickness less than 1000 angstroms;

an active layer located on the electrolyte layer, comprised of amorphous or polycrystalline WO₃, located on the top surface of the electrolyte layer;

and a second electrically conductive layer, which is optically reflective, comprised of aluminum, silver, or any optically reflective and electrically conductive material, located on the top surface of the active layer;

an electrical contact for the first electrically conductive layer comprised of a Ni pad, suitable for establishing an electrical connection, located on the top surface of the first electrically conductive layer in an area not covered by the ion storage layer, the ion conductor layer, the active layer, or the second electrically conductive layer; and

an electrical contact for the second electrically conductive layer comprised of a Ni pad, suitable for establishing an electrical connection, located on the top surface of the substrate in an area not covered by any layers except the second electrically conductive layer.

32. An improved reflective electrochromic device, comprising a monolithic stack of solid state inorganic materials deposited directly onto a flexible transparent or translucent substrate comprised of glass, polymer, or fiberglass reinforced polymer, comprising:

a first electrically conductive layer, which is substantially transparent, comprised of ITO located on the top surface of said transparent or translucent substrate with the following properties;

said layer covers the top surface of the substrate except for a narrow strip around the periphery at the edges of the substrate and a larger rectangular area along one edge with the longer dimension of the rectangle being aligned with the edge of the substrate;

the edge of the ITO bordering the uncovered rectangular area is smoothly tapered from the top of the ITO layer to the top surface of the underlying substrate to provide a smooth transition for the subsequently applied layers whose electrical and mechanical properties can be adversely affected by an abrupt transition;

an ion storage layer, comprised of vanadium pentoxide (V₂O₅), located on the top surface of the first electrically conductive layer and extending across the tapered edge of the ITO to the uncoated area of the substrate;

an electrolyte layer, comprised of amorphous Li3PO4, located on the top surface of the ion storage layer and extending across the tapered edge of the ITO beyond the edge of the Li₃PO₄ to the uncoated area of the substrate;

an active layer located on the electrolyte layer, comprised of amorphous or polycrystalline WO₃, located on the top surface of the electrolyte layer;

a nickel contact for the second electrically conductive layer located on the top surface of the substrate in the uncoated rectangular area;

a second electrically conductive layer, which is optically reflective, comprised of silver, aluminum, or other electrically conductive and optically reflective material, located on the top surface of the active layer and extending across the tapered edge of the ITO onto the top of a portion of the nickel contact;

an electrical contact for the first electrically conductive layer comprised of a Ni pad, suitable for establishing an electrical connection, located on the top surface of the second electrically conductive layer; and

a protective layer comprised of SiO₂ which covers the entire electrochromic stack and bonds to the periphery of the substrate providing a hermetic encapsulation for the electrochromic device.

33. An improved electrochromic device as set forth in claim 32, wherein said substrate is a substantially rigid substrate.

34. An improved electrochromic device as set forth in claim 32, wherein said substrate is a substantially flexible substrate.