Electrochromic device having a seal including an epoxy resin cured with a cycloaliphatic amine

• US 6,963,439 B2
• Filed: 02/13/2004
• Issued: 11/08/2005
• Est. Priority Date: 04/02/1997
• Status: Expired due to Fees

• Current Assignee: Gentex Corporation
• Original Assignee: Gentex Corporation
• Inventors: Tonar, William L.
• Primary Examiner(s): Lester, Evelyn A.
• Application Number:
  US10/778,439
• Publication Number:
  US 20040165248A1
• Time in Patent Office: 634 Days
• Field of Search: 359265-275, 252/583, 252/586
• US Class Current: 359/267
• CPC Class Codes: B60Q 1/2665 on rear-view mirrors lighting devices for vehicle interior on or for rear-view mirrors B60Q3/258
• CPC Class Codes: B60R 1/088 using a cell of electrically changeable optical characteristic, e.g. liquid-crystal or electrochromic mirrors
• CPC Class Codes: B60R 1/1207 with lamps; with turn indicators
• CPC Class Codes: B60R 2001/1215 with information displays
• CPC Class Codes: B60R 2001/1223 with sensors or transducers
• CPC Class Codes: G02F 1/1506 caused by electrodeposition, e.g. electrolytic deposition of an inorganic material on or close to an electrode
• 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: G02F 2001/1502 complementary cell
• CPC Class Codes: G02F 2001/15145 the electrochromic layer comprises a mixture of anodic and cathodic compounds
• CPC Class Codes: G02F 2201/34 reflector
• CPC Class Codes: G02F 2203/02 reflective
• CPC Class Codes: H10K 50/87 Arrangements for heating or cooling

Abstract

An electrochromic variable reflectance mirror for a vehicle includes a front element and a rear element. A seal is provided to sealably bond the elements together in a spaced-apart relationship to define a chamber, and an electrochromic material is disposed in the chamber. The seal comprises an epoxy resin cured with a cycloaliphatic amine. The cycloaliphatic amine may be a bis(cycloaliphatic) amine, or more specifically, bis(aminocyclohexyl) methane (PACM). The epoxy resin may be an epoxy novolac resin such as an epoxy phenolic novolac (e.g., DEN431) or an epoxy cresol novolac resin, a bisphenol A epoxy resin, a bisphenol F epoxy resin, a tetraglycidyl methylenebisbenzenamine, or a glycidyl benzenamine.

Claims

1. An electrochromic mirror comprising:

a front element;

a rear element;

a seal provided to form a sealed chamber, the sealed chamber being between said elements;

an electrochromic material disposed in said chamber; and

a reflector disposed on a surface of said rear element,

wherein said seal comprises an epoxy resin at least partially cured with a cycloaliphatic amine.

2. The electrochromic mirror of claim 1, and further comprising a coating disposed on one of the surfaces of said elements, said coating comprising a first layer of indium tin oxide, a layer comprising a metal, and a second layer of indium tin oxide.

3. The electrochromic mirror of claim 1, wherein said elements are made of glass.

4. The electrochromic mirror of claim 1 and further comprising a display positioned behind said rear element.

5. The electrochromic mirror of claim 4, wherein said display is a compass display for displaying vehicle heading.

6. The electrochromic mirror of claim 1, wherein said front and rear elements are shaped and positioned relative to one another such that there is no offset of the edges of said elements.

7. The electrochromic mirror of claim 1, wherein said chamber further contains a cross-linked polymer matrix.

8. The electrochromic mirror of claim 7, wherein said electrochromic material is in a solution that is interspersed in said cross-linked polymer matrix.

9. The electrochromic mirror of claim 7, wherein said electrochromic material is a solution-phase electrochromic material.

10. The electrochromic mirror of claim 7, wherein said cross-linked polymer matrix cooperatively interacts with said front and rear elements.

11. The electrochromic mirror of claim 1, wherein said electrochromic material is a solution-phase electrochromic material.

12. The electrochromic mirror of claim 1, wherein said reflector is disposed on a front surface of said rear element, said reflector having a reflector/electrode including at least a layer of reflective material.

13. The electrochromic mirror of claim 12, wherein said reflector/electrode has a sheet resistance below 2 ohms per square.

14. The electrochromic mirror of claim 1 and further comprising a layer of transparent conductive material disposed on a rear surface of said front element.

15. The electrochromic mirror of claim 14, wherein said layer of transparent conductive material has a sheet resistance ranging from about 0.1 ohms per square to about 20 ohms per square.

16. The electrochromic mirror of claim 15, wherein said layer of transparent conductive material has a sheet resistance ranging from about 0.2 ohms per square to about 6 ohms per square.

17. The electrochromic mirror of claim 1, wherein said reflector is disposed on a front surface of said rear element, said reflector having at least one layer of a reflector/electrode comprising a reflective material covering an inner portion of said front surface of said rear element and extending to a small area of an edge thereof.

18. The electrochromic mirror of claim 1, wherein said mirror is an outside mirror adapted for mounting to a vehicle exterior.

19. The electrochromic mirror of claim 18, wherein said mirror has a reflectance of at least about 50 percent.

20. The electrochromic mirror of claim 1, wherein said mirror is an inside minor adapted for mounting to a vehicle interior.

21. The electrochromic mirror of claim 1, wherein said mirror has a reflectance of at least about 70 percent.

22. The electrochromic mirror of claim 1, wherein said electrochromic material is a solution-phase electrochromic material contained within said chamber in contact with said reflector.

23. The electrochromic mirror of claim 1, wherein said cycloaliphatic amine is a bis(cycloaliphatic) amine.

24. The electrochromic mirror of claim 1, wherein said seal comprises a bisphenol A epoxy resin.

25. The electrochromic mirror of claim 24, wherein said bisphenol A epoxy resin has the following structural formula:

wherein n has an average value less than about 3.

26. The electrochromic mirror of claim 25, wherein n has an average value between about 0.15 and about 3.

27. The electrochromic device of claim 1, wherein said epoxy resin is an epoxy novolac resin.

28. The electrochromic mirror of claim 27, wherein said epoxy novolac resin has the following structural formula:

wherein n has an average value from about 0 to about 3.

29. The electrochromic mirror of claim 28, wherein said epoxy novolac resin is an epoxy phenol novolac resin.

30. The electrochromic mirror of claim 28, wherein X in said formula is hydrogen.

31. The electrochromic mirror of claim 30, wherein n has an average value from about 0 to about 1.8.

32. The electrochromic mirror of claim 31, wherein n has an average value of about 0.2.

33. The electrochromic mirror of claim 29, wherein n□

0 and said epoxy phenol novolac resin is a bispenol F resin.

34. The electrochromic device of claim 28, wherein said epoxy novolac resin is an epoxy cresol novolac resin.

35. The electrochromic device of claim 28, wherein X in said formula is CH₃.

36. The electrochromic device of claim 35, wherein n is between about 0.8 and about 3.

37. The electrochromic mirror of claim 1, wherein said epoxy resin is a tetraglycidyl methylenebisbenzenamine.

38. The electrochromic mirror of claim 1, wherein said epoxy resin is a glycidyl benzenamine.

39. The electrochromic mirror of claim 1, wherein said cycloaliphatic amine is a bis(aminocyclohexyl) methane.

40. An electrochromic mirror comprising:

a front element;

a rear element;

a seal provided to form a sealed chamber, the sealed chamber being between said elements;

an electrochromic material disposed in said chamber; and

a reflector disposed on a surface of said rear element,

wherein said seal comprises a bisphenol A epoxy resin at least partially cured with a cycloaliphatic amine.

41. The electrochromic mirror of claim 40, wherein said bisphenol A epoxy resin has the following structural formula:

wherein n has an average value less than about 3.

42. The electrochromic mirror of claim 41, wherein n has an average value between about 0.15 and about 3.

43. The electrochromic mirror of claim 40, wherein said cycloaliphatic amine is a bis(cycloaliphatic) amine.

44. The electrochromic mirror of claim 40, wherein said cycloaliphatic amine is a bis(aminocyclohexyl) methane.

45. The electrochromic mirror of claim 40, wherein said reflector is disposed on a front surface of said rear element.

46. An electrochromic mirror comprising:

a front element;

a rear element;

a seal provided to form a sealed chamber, the sealed chamber being between said elements;

an electrochromic material disposed in said chamber; and

a reflector disposed on a surface of said rear element,

wherein said seal comprises an epoxy novolac resin at least partially cured with a cycloaliphatic amine.

47. The electrochromic mirror of claim 46, wherein said epoxy novolac resin has the following structural formula:

wherein n has an average value from about 0 to about 3.

48. The electrochromic mirror of claim 47, wherein said epoxy novolac resin is a bisphenol F epoxy resin.

49. The electrochromic mirror of claim 47, wherein X in said formula is hydrogen.

50. The electrochromic mirror of claim 49, wherein n has an average value from about 0 to about 1.8.

51. The electrochromic mirror of claim 50, wherein n has an average value of about 0.2.

52. The electrochromic mirror of claim 47, wherein said epoxy novolac resin is an epoxy phenolic novolac resin.

53. The electrochromic mirror of claim 46, wherein said cycloaliphatic amine is a bis(cycloaliphatic) amine.

54. The electrochromic device of claim 46, wherein said cycloaliphatic amine is a bis(aminocyclohexyl) methane.

55. A rearview mirror assembly for a vehicle comprising the electrochromic device of claim 46, and a reflector disposed on a surface of said rear element.

56. The electrochromic device of claim 47, wherein said epoxy novolac resin is an epoxy cresol novolac resin.

57. The electrochromic device of claim 56, wherein X in said formula is CH₃.

58. The electrochromic device of claim 57, wherein n is between about 0.8 and about 3.

59. An electrochromic device comprising:

a front element;

a rear element;

a seal provided to form a sealed chamber, the sealed chamber being between said elements; and

an electrochromic material disposed in said chamber,

wherein said seal comprises an epoxy phenolic novolac resin at least partially cured with a bis(aminocyclohexyl) methane, wherein said epoxy phenolic novolac resin has the following structural formula;

wherein n has an average value from about 0.2 to about 1.6.

60. A rearview mirror assembly for a vehicle comprising the electrochromic device of claim 59, and a reflector disposed on a surface of said rear element.

61. An electrochromic mirror comprising:

a front element including a transparent electrically conductive first electrode disposed on a rear surface thereof;

a rear element having a front surface and a rear surface;

a seal provided to form a sealed chamber, the sealed chamber being between said front and rear elements;

an electrochromic material disposed in said chamber; and

a reflector disposed on a surface of said rear element,

wherein said seal comprises an epoxy phenolic novolac resin at least partially cured with a bis(aminocyclohexyl) methane, wherein said epoxy phenolic novolac resin has the following structural formula;

wherein X is hydrogen and n has an average value of about 0.2.

62. The electrochromic mirror of claim 61, wherein said reflector is disposed on the front surface of said rear element.

63. The electrochromic mirror of claim 61, wherein said reflector covers less than all of the front surface of said rear element.

64. The electrochromic mirror of claim 61, wherein at least a portion of said reflector functions as a second electrode, wherein both said first and second electrodes are electrically coupled to said electrochromic material.

65. The electrochromic mirror of claim 61, and further comprising a coating disposed on one of the surfaces of said elements, said coating comprising a first layer of indium tin oxide, a layer comprising a metal, and a second layer of indium tin oxide.

66. The electrochromic mirror of claim 61, wherein said elements are made of glass.

67. The electrochromic mirror of claim 61 and further comprising a display positioned behind said rear element.

68. The electrochromic mirror of claim 67, wherein said display is a compass display for displaying vehicle heading.

69. The electrochromic mirror of claim 61, wherein said front and rear elements are shaped and positioned relative to one another such that there is no offset of the edges of said elements.

70. The electrochromic mirror of claim 61, wherein said chamber further contains a cross-linked polymer matrix.

71. The electrochromic mirror of claim 70, wherein said cross-linked polymer matrix cooperatively interacts with said front and rear elements.

72. The electrochromic mirror of claim 70, wherein said electrochromic material is in a solution that is interspersed in said cross-linked polymer matrix.

73. The electrochromic mirror of claim 70, wherein said electrochromic material is a solution-phase electrochromic material.

74. The electrochromic mirror of claim 61 and further comprising a layer of transparent conductive material disposed on a front surface of said rear element.

75. The electrochromic mirror of claim 61, wherein said transparent electrically conductive first electrode has a sheet resistance ranging from about 0.1 ohms per square to about 20 ohms per square.

76. The electrochromic mirror of claim 75, wherein said transparent electrically conductive first electrode has a sheet resistance ranging from about 0.2 ohms per square to about 6 ohms per square.

77. The electrochromic mirror of claim 61, wherein said reflector is disposed on the front surface of said rear element, said reflector having at least one layer of a reflector/electrode comprising a reflective material covering an inner portion of said front surface of said rear element and extending to a small area of an edge thereof.

78. The electrochromic mirror of claim 61, wherein said mirror is an outside mirror adapted to be mounted to a vehicle exterior.

79. The electrochromic mirror of claim 78, wherein said mirror has a reflectance of at least about 50 percent.

80. The electrochromic mirror of claim 61, wherein said mirror is an inside mirror adapted to be mounted to a vehicle interior.

81. The electrochromic mirror of claim 80, wherein said mirror has a reflectance of at least about 70 percent.

82. The electrochromic mirror of claim 61, wherein said electrochromic material is a solution-phase electrochromic material contained within said chamber in contact with said reflector.

83. The electrochromic mirror of claim 61, wherein said cycloaliphatic amine is a bis(cycloaliphatic) amine.

84. The electrochromic mirror of claim 61, wherein said cycloaliphatic amine is a bis(aminocyclohexyl) methane.

85. The electrochromic mirror of claim 61, wherein said electrochromic material is a solution-phase electrochromic material.

86. The electrochromic mirror of claim 61, wherein said reflector is disposed on the front surface of said rear element, said reflector having a reflector/electrode including at least a layer of reflective material.

87. The electrochromic mirror of claim 86, wherein said reflector/electrode has a sheet resistance below 2 ohms per square.