Thin-film coatings, electro-optic elements and assemblies incorporating these elements

• US 7,746,534 B2
• Filed: 08/03/2007
• Issued: 06/29/2010
• Est. Priority Date: 12/07/2006
• Status: Active Grant

• Current Assignee: Gentex Corporation
• Original Assignee: Gentex Corporation
• Inventors: Neuman, George A., Cammenga, David J., Tonar, William L., Anderson, John S., Luten, Henry A., Dozeman, Gary J., Forgette, Jeffrey A., Perron, Lansen M., Brummel, Nelson F., Poe, G. Bruce
• Primary Examiner(s): Thompson; Timothy J
• Application Number:
  US11/833,701
• Publication Number:
  US 20080310005A1
• Time in Patent Office: 1,061 Days
• Field of Search: 359265-275
• US Class Current: 359/265
• CPC Class Codes: B60R 1/00 Optical viewing arrangements; Real-time viewing arrangements for drivers or passengers using optical image capturing systems, e.g. cameras or video systems specially adapted for use in or on vehicles
• CPC Class Codes: B60R 1/04 mounted inside vehicle B60R1/025, B60R1/08 take precedence
• CPC Class Codes: B60R 1/06 mounted on vehicle exterior B60R1/025, B60R1/08 take precedence
• CPC Class Codes: B60R 1/083 Anti-glare mirrors, e.g. "day-night" mirrors
• CPC Class Codes: B60R 1/085 using a combination of interchangeable reflecting surfaces, e.g. reversible mirrors
• CPC Class Codes: B60R 2001/1215 with information displays
• CPC Class Codes: B60R 2001/1223 with sensors or transducers
• CPC Class Codes: B60R 2001/1253 with cameras, video cameras or video screens
• CPC Class Codes: B60R 2300/108 using 'non-standard' camera systems, e.g. camera sensor used for additional purposes i.a. rain sensor, camera sensor split in multiple image areas
• CPC Class Codes: C03C 17/36 at least one coating being a metal
• CPC Class Codes: C03C 17/3647 in combination with other metals, silver being more than 50%
• CPC Class Codes: C03C 17/3649 made of metals other than silver
• CPC Class Codes: C03C 17/3663 specially adapted for use as mirrors
• CPC Class Codes: E06B 3/6722 with adjustable passage of light
• CPC Class Codes: G02F 1/13439 characterised by their electrical, optical, physical properties; materials therefor; method of making
• 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 2201/34 reflector

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 optical element comprising:

a first substrate;

at least one thin-film layer deposited on the first substrate, and

a boundary-modifying material adjoining a boundary formed by any two of the substrate and the at least one thin-film layer,

wherein the boundary-modifying material differs from materials forming the substrate and the at least one thin-film layer, wherein an accumulation of the boundary-modifying material does not exceed ten atomic layers, and wherein the boundary-modifying material includes an element from a group consisting of chalcogenides and pnictogens.

2. The optical element of claim 1, wherein the boundary-modifying material includes at least one of sulfur and selenium.

3. The optical element of claim 1, wherein an accumulation of the boundary-modifying material does not exceed an atomic monolayer.

4. The optical element of claim 1, wherein an accumulation of the boundary-modifying material does not exceed five atomic layers.

5. The optical element of claim 1, wherein an accumulation of the boundary-modifying material does not exceed two atomic layers.

6. The optical element of claim 1, wherein the first substrate comprises glass.

7. The optical element of claim 1, wherein the at least one thin-film layer comprises one of ITO, IZO, zinc oxide, AZO, TiO₂, W, Mo, Fe, Ni, Co, Rh, Ir, Cu, Ag, Au, Zn, Cd, Hg, Ga, In, Tl, Ge, Sn, Pb, As, Sb, Cr and Bi.

16. The optical element of claim 1, wherein the first substrate is made of glass and the at least one thin-film layer includes a layer of Chromium deposited on the first substrate and a layer of silver-gold alloy deposited over the layer of Chromium, and wherein the boundary-modifying material is accumulated at the boundary between the layer of Chromium and the layer of silver-gold alloy.

17. The optical element of claim 1, wherein the first substrate is made of glass and the at least one thin-film layer includes a layer of TiO₂ deposited on the first substrate, a layer of ITO deposited on top of the TiO₂ layer, and a layer of silver-gold alloy deposited over the layer of ITO, and wherein the boundary-modifying material is accumulated at the boundary between the layer of ITO and the layer of silver-gold alloy.

18. The optical element of claim 1, wherein the boundary-modifying material enhances at least one of adhesion, environmental stability, conductivity, and nucleation characteristics of the at least one thin-film layer.

19. The optical element of claim 1, further comprising:

a second substrate, wherein the first and second substrates cooperate to form a cavity therebetween; and

an electrochromic medium located within the cavity.

22. The optical element of claim 16, wherein the boundary-modifying material is sulfur.

23. The optical element of claim 17, wherein the boundary-modifying material is sulfur.

24. The optical element of claim 1, wherein an accumulation of the boundary-modifying material occurs in a material substantially under the boundary.

8. A method for manufacturing an optical element, the method comprising:

providing a first base having a surface;

disposing a modifying material below the surface; and

overcoating the surface with a thin-film overlayer;

wherein the modifying material differs from materials forming the base and the thin-film overlayer, the modifying material includes an element from a group consisting of chalcogenides and pnistogens, and an accumulation of the modifying material does not exceed ten atomic layers.

9. The method of claim 8, wherein the disposing a modifying material includes disposing at least one of sulfur and selenium.

10. The method of claim 8, wherein the in the accumulation of the modifying material does not exceed an atomic monolayer.

11. The method of claim 8, wherein the in the accumulation of the modifying material does not exceed five atomic layers.

12. The method of claim 8, wherein the in the accumulation of the modifying material does not exceed two atomic layers.

13. The method of claim 8, wherein the first base comprises a first substrate and a first thin-film layer deposited thereon and the surface of the first base is defined by an outer surface of the first thin-film layer.

14. The method of claim 13, wherein the first substrate is made of glass and wherein at least one of the first thin-film layer and the thin-film overlayer contains at least one of ITO, IZO, zinc oxide, AZO, TiO₂, W, Mo, Fe, Ni, Co, Rh, Ir, Cu, Ag, Au, Zn, Cd, Hg, Ga, In, Tl, Ge, Sn, Pb, As, Sb, and Bi.

15. The method of claim 8, wherein the first base is made of glass and the thin-film overlayer contains at least one of ITO, IZO, zinc oxide, AZO, TiO₂, W, Mo, Fe, Ni, Go, Rh, Ir, Cu, Ag, Au, Zn, Cd, Hg, Ga, In, Tl, Ge, Sn, Pb, As, Sb, and Bi.

20. The method of claim 8, wherein the disposing comprises at least one of ion treatment, plasma treatment, chemical treatment, and physical vapor deposition.

21. The method of claim 8, further comprising:

placing a second base so as to form a cavity between the first and second bases; and

situating an electrochromic medium within the cavity.