Lamination of electrochromic device to glass substrates

• US 8,482,838 B2
• Filed: 07/07/2011
• Issued: 07/09/2013
• Est. Priority Date: 03/05/2010
• Status: Active Grant

• Current Assignee: Sage Electrochromics, Inc (Compagnie de Saint-Gobain SA)
• Original Assignee: Sage Electrochromics, Inc (Compagnie de Saint-Gobain SA)
• Inventors: Sbar, Neil L., Van Dine, John E., McCoy, Michael A.
• Primary Examiner(s): TRA, TUYEN Q
• Application Number:
  US13/178,065
• Publication Number:
  US 20110267672A1
• Time in Patent Office: 733 Days
• Field of Search: 359265-275, 345/105
• US Class Current: 359/265
• CPC Class Codes: B32B 17/10045 with at least one intermediate layer consisting of a glass sheet
• CPC Class Codes: B32B 17/10174 Coatings of a metallic or dielectric material on a constituent layer of glass or polymer
• CPC Class Codes: B32B 17/10513 Electrochromic layer
• CPC Class Codes: B32B 17/10743 containing acrylate (co)polymers or salts thereof
• CPC Class Codes: B32B 17/10761 containing vinyl acetal
• CPC Class Codes: B32B 17/10981 Pre-treatment of the layers
• CPC Class Codes: B32B 38/0004 Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• CPC Class Codes: C03B 33/0222 Scoring using a focussed radiation beam, e.g. laser
• CPC Class Codes: C03B 33/027 Scoring tool holders; Driving mechanisms therefor
• CPC Class Codes: C03B 33/076 Laminated glass comprising interlayers
• CPC Class Codes: C03B 33/091 using at least one focussed radiation beam, e.g. laser beam C03B33/0955 takes precedence
• CPC Class Codes: G02F 1/133351 Manufacturing of individual cells out of a plurality of cells, e.g. by dicing
• CPC Class Codes: G02F 1/15 based on an electrochromic effect
• CPC Class Codes: G02F 1/153 Constructional details
• CPC Class Codes: G02F 1/1533 structural features not otherwise provided for
• CPC Class Codes: Y10T 156/1052 with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 156/1062 Prior to assembly
• CPC Class Codes: Y10T 156/1064 Partial cutting [e.g., grooving or incising]
• CPC Class Codes: Y10T 156/1075 of plural laminae from single stock and assembling to each other or to additional lamina
• CPC Class Codes: Y10T 156/1089 of discrete laminae to single face of additional lamina

Abstract

Electrochromic device laminates and their method of manufacture are disclosed.

Claims

1. A process of manufacturing an electrochromic device laminate comprising:

(a) providing an electrochromic glass substrate;

(b) cutting said electrochromic glass substrate into one or more glass substrate daughter panes;

(c) fabricating a plurality of electrochromic device precursors on each of said one or more glass substrate daughter panes;

(d) cutting each of said plurality of electrochromic device precursors into individual electrochromic devices; and

(e) laminating each of said individual electrochromic devices to a separate outer laminate glass pane,

wherein each of said plurality of electrochromic device precursors are laser cut, and wherein each of said individual electrochromic devices have an edge strength of at least about 60 MPa.

2. The process of claim 1, wherein each of said individual electrochromic devices have an edge strength of at least about 69 MPa.

3. The process of claim 1, wherein each of said individual electrochromic devices have an edge strength of at least about 75 MPa.

4. The process of claim 1, wherein each of said individual electrochromic devices have an edge strength of at least about 100 MPa.

5. The process of claim 1, wherein said individual electrochromic devices are smaller than said outer laminate glass pane in at least one dimension.

6. The process of claim 5, wherein said individual electrochromic devices are indented about 0.5 mm to about 3 mm relative to said outer laminate glass pane in at least one dimension.

7. The process of claim 1, wherein said electrochromic glass substrate is a different material than said outer laminate glass pane.

8. The process of claim 1, wherein a material for said electrochromic glass substrate is selected from the group consisting of low coefficient of thermal expansion glass, soda-lime float glass, aluminosilicate glass, borofloat glass, boroaluminosilicate glass, or low sodium-containing glass.

9. The process of claim 1, wherein said electrochromic glass substrate has a coefficient of thermal expansion ranging from about 2 ppm/K to about 10 ppm/K.

10. The process of claim 1, wherein said electrochromic glass substrate has a thickness ranging from about 0.7 mm to about 6 mm.

11. The process of claim 1, wherein a material for said outer laminate glass pane is selected from the group consisting of low coefficient of thermal expansion glass, soda-lime float glass, aluminosilicate glass, borofloat glass, boroaluminosilicate glass, heat-strengthened glass, tempered glass, or a polymer.

12. The process of claim 1, wherein said outer laminate glass pane has a coefficient of thermal expansion ranging from about 2 ppm/K to about 10 ppm/K.

13. A laminate prepared according to the process of claim 1.

14. The laminate of claim 13, comprising a substrate having an edge strength of at least about 60 MPa.

15. A process of manufacturing an electrochromic device laminate comprising:

(a) providing an electrochromic glass substrate;

(b) cutting said electrochromic glass substrate into one or more glass substrate daughter panes;

(c) fabricating a plurality of electrochromic device precursors on each of said one or more glass substrate daughter panes;

(d) cutting each of said plurality of electrochromic device precursors into individual electrochromic devices; and

(e) laminating each of said individual electrochromic devices to a separate outer laminate glass pane,

wherein each of said plurality of electrochromic device precursors are cut by electrothermal cutting, and wherein each of said individual electrochromic devices have an edge strength of at least about 60 MPa.

16. The process of claim 15, wherein each of said individual electrochromic devices have an edge strength of at least about 69 MPa.

17. The process of claim 15, wherein each of said individual electrochromic devices have an edge strength of at least about 75 MPa.

18. The process of claim 15, wherein each of said individual electrochromic devices have an edge strength of at least about 100 MPa.

19. The process of claim 15, wherein said individual electrochromic devices are smaller than said outer laminate glass pane in at least one dimension.

20. The process of claim 19, wherein said individual electrochromic devices are indented about 0.5 mm to about 3 mm relative to said outer laminate glass pane in at least one dimension.

21. The process of claim 15, wherein said electrochromic glass substrate is a different material than said outer laminate glass pane.

22. The process of claim 15, wherein a material for said electrochromic glass substrate is selected from the group consisting of low coefficient of thermal expansion glass, soda-lime float glass, aluminosilicate glass, borofloat glass, boroaluminosilicate glass, or low sodium-containing glass.

23. A laminate prepared according to the process of claim 15.

24. The laminate of claim 23, comprising a substrate having an edge strength of at least about 60 MPa.

25. A process of manufacturing an electrochromic device laminate comprising:

(a) providing an electrochromic glass substrate;

(b) fabricating a plurality of electrochromic device precursors on said electrochromic glass substrate;

(c) cutting each of said plurality of electrochromic device precursors into individual electrochromic devices; and

(d) laminating each of said individual electrochromic devices to a separate outer laminate glass pane,

wherein each of said plurality of electrochromic device precursors are laser cut, and wherein each of said individual electrochromic devices have an edge strength of at least about 60 MPa.

26. The process of claim 25, wherein said individual electrochromic device is about the same size as said outer laminate glass pane.

27. The process of claim 25, wherein said individual electrochromic device is smaller than said outer laminate glass pane in at least one dimension.

28. The process of claim 27, wherein said individual electrochromic device is indented about 0.5 mm to about 3 mm relative to said outer laminate glass pane in at least one dimension.

29. The process of claim 27, wherein said individual electrochromic device is indented about 1 mm to about 2 mm relative to said outer laminate glass pane in at least one dimension.

30. The process of claim 25, wherein said electrochromic glass substrate is a different material than said outer laminate glass pane.

31. The process of claim 25, wherein a material for said electrochromic glass substrate is selected from the group consisting of low coefficient of thermal expansion glass, soda-lime float glass, aluminosilicate glass, borofloat glass, boroaluminosilicate glass, or low sodium-containing glass.

32. The process of claim 25, wherein said electrochromic glass substrate has a coefficient of thermal expansion ranging from about 2 ppm/K to about 10 ppm/K.

33. The process of claim 25, wherein said electrochromic glass substrate has a thickness ranging from about 0.7 mm to about 6 mm.

34. The process of claim 25, wherein a material for said outer laminate glass pane is selected from the group consisting of low coefficient of thermal expansion glass, soda-lime float glass, aluminosilicate glass, borofloat glass, boroaluminosilicate glass, heat-strengthened glass, tempered glass, or a polymer.

35. The process of claim 25, wherein said outer laminate glass pane has a coefficient of thermal expansion ranging from about 2 ppm/K to about 10 ppm/K.

36. The process of claim 25, wherein said outer laminate glass pane has a thickness ranging from about 2.3 mm to about 12 mm.

37. The process of claim 25, wherein an interlayer material for laminating said individual electrochromic devices to said separate outer laminate glass pane is selected from the group consisting of polyvinylbutyral, ionomeric materials, ethylenevinyl acetate, polyurethanes, or mixtures thereof.

38. A laminate prepared according to the process of claim 25.

39. The laminate of claim 38, comprising a substrate having an edge strength of at least about 60 MPa.

40. A process of manufacturing an electrochromic device laminate comprising:

(a) providing an electrochromic glass substrate;

(b) fabricating a plurality of electrochromic device precursors on said electrochromic glass substrate;

(c) cutting each of said plurality of electrochromic device precursors into individual electrochromic devices; and

(d) laminating each of said individual electrochromic devices to a separate outer laminate glass pane,

wherein each of said plurality of electrochromic device precursors are cut by electrothermal cutting, and wherein each of said individual electrochromic devices have an edge strength of at least about 60 MPa.

41. The process of claim 40, wherein each of said individual electrochromic devices have an edge strength is at least about 69 MPa.

42. The process of claim 40, wherein each of said individual electrochromic devices have an edge strength is at least about 75 MPa.

43. The process of claim 40, wherein each of said individual electrochromic devices have an edge strength of at least about 100 MPa.

44. The process of claim 40, wherein said individual electrochromic device is smaller than said outer laminate glass pane in at least one dimension.

45. The process of claim 44, wherein said individual electrochromic device is indented about 0.5 mm to about 3 mm relative to said outer laminate glass pane in at least one dimension.

46. The process of claim 40, wherein said electrochromic glass substrate is a different material than said outer laminate glass pane.

47. The process of claim 40, wherein a material for said electrochromic glass substrate is selected from the group consisting of low coefficient of thermal expansion glass, soda-lime float glass, aluminosilicate glass, borofloat glass, boroaluminosilicate glass, or low sodium-containing glass.

48. A laminate prepared according to the process of claim 40.

49. The laminate of claim 48, comprising a substrate having an edge strength of at least about 60 MPa.

50. A laminate comprising:

(a) an electrochromic device, said electrochromic device comprising an electrochromic stack on a glass substrate;

(b) an outer laminate glass pane; and

(c) an interlayer material sandwiched between said electrochromic device and said outer laminate glass pane,

wherein said electrochromic device has an edge strength of at least about 60 MPa.

51. The laminate of claim 50, wherein said electrochromic device is prepared by laser cutting.

52. The laminate of claim 50, wherein said laminate is part of an integrated glass unit.

53. The laminate of claim 50, wherein said glass substrate and said outer laminate glass pane comprise the same material.

54. The laminate of claim 50, wherein said glass substrate is a different material than said outer laminate glass pane.

55. The laminate of claim 50, wherein a material for said glass substrate is selected from the group consisting of low coefficient of thermal expansion glass, soda-lime float glass, aluminosilicate glass, borofloat glass, boroaluminosilicate glass, or low sodium-containing glass.

56. The laminate of claim 50, wherein said glass substrate has a coefficient of thermal expansion ranging from about 2 ppm/K to about 10 ppm/K.

57. The laminate of claim 50, wherein said glass pane has a thickness ranging from about 0.7 mm to about 6 mm.

58. The laminate of claim 50, wherein a material for said outer laminate glass pane is selected from the group consisting of low coefficient of thermal expansion glass, soda-lime float glass, aluminosilicate glass, borofloat glass, boroaluminosilicate glass, heat-strengthened glass, tempered glass, or a polymer.

59. The laminate of claim 50, wherein said outer laminate glass pane has a coefficient of thermal expansion ranging from about 2 ppm/K to about 10 ppm/K.

60. The laminate of claim 50, wherein said out laminate glass pane has a thickness ranging from about 2.3 mm to about 12 mm.

61. The laminate of claim 50, wherein said glass substrate is smaller than said outer laminate glass pane in at least one dimension.

62. The laminate of claim 61, wherein said glass substrate is indented about 0.5 mm to about 3 mm relative to said outer laminate glass pane in at least one dimension.

63. The laminate of claim 61, wherein said glass substrate is indented about 1 mm to about 2 mm relative to said outer laminate glass pane in at least one dimension.

64. The laminate of claim 61, wherein a perimeter of said smaller glass substrate is surrounded on at least one side by a material selected from the group consisting of interlayer material and protective materials.

65. The laminate of claim 50, wherein said interlayer material is selected from the group consisting of polyvinylbutyral, ionomeric materials, ethylenevinyl acetate, polyurethanes, or mixtures thereof.

66. The laminate of claim 50, wherein said anncalcd glass substrate is soda-lime float glass having a coefficient of thermal expansion of about 8.5 ppm/K, said outer laminate glass pane is tempered soda-lime float glass having a coefficient of thermal expansion of about 8.5 ppm/K, and said interlayer material is polyvinylbutyral.

67. The laminate of claim 50, wherein said glass substrate is prepared by laser cutting and has an edge strength of at least 69 MPa.

68. The laminate of claim 50, wherein said electrochromic stack is between said glass substrate and said interlayer material.

69. The laminate of claim 50, wherein said electrochromic stack is on a surface of said glass substrate opposite of said interlayer material.

70. A process of manufacturing an electrochromic device laminate comprising:

(a) providing an electrochromic glass substrate;

(b) fabricating a plurality of electrochromic device precursors on said electrochromic glass substrate;

(c) cutting each of said plurality of electrochromic device precursors into individual electrochromic devices; and

(d) laminating each of said individual electrochromic devices to a separate outer laminate glass pane,

wherein each of said plurality of electrochromic device precursors are laser cut, and wherein each of said individual electrochromic devices have an edge strength of at least about 69 MPa.

71. The process of claim 70, wherein said individual electrochromic device is smaller than said outer laminate glass pane in at least one dimension.

72. The process of claim 71, wherein said individual electrochromic device is indented about 0.5 mm to about 3 mm relative to said outer laminate glass pane in at least one dimension.

73. The process of claim 71, wherein said individual electrochromic device is indented about 1 mm to about 2 mm relative to said outer laminate glass pane in at least one dimension.

74. A process of manufacturing an electrochromic device laminate comprising:

(a) providing an electrochromic glass substrate;

(b) fabricating a plurality of electrochromic device precursors on said electrochromic glass substrate;

(c) cutting each of said plurality of electrochromic device precursors into individual electrochromic devices; and

(d) laminating each of said individual electrochromic devices to a separate outer laminate glass pane,

wherein each of said plurality of electrochromic device precursors are laser cut, and wherein each of said individual electrochromic devices have an edge strength of at least about 75 MPa.

75. The process of claim 74, wherein said individual electrochromic device is smaller than said outer laminate glass pane in at least one dimension.

76. The process of claim 75, wherein said individual electrochromic device is indented about 0.5 mm to about 3 mm relative to said outer laminate glass pane in at least one dimension.

77. The process of claim 75, wherein said individual electrochromic device is indented about 1 mm to about 2 mm relative to said outer laminate glass pane in at least one dimension.

78. A process of manufacturing an electrochromic device laminate comprising:

(a) providing an electrochromic glass substrate;

(b) fabricating a plurality of electrochromic device precursors on said electrochromic glass substrate;

(c) cutting each of said plurality of electrochromic device precursors into individual electrochromic devices; and

(d) laminating each of said individual electrochromic devices to a separate outer laminate glass pane,

wherein each of said plurality of electrochromic device precursors are laser cut, and wherein each of said individual electrochromic devices have an edge strength of at least about 100 MPa.

79. The process of claim 78, wherein said individual electrochromic device is smaller than said outer laminate glass pane in at least one dimension.

80. The process of claim 79, wherein said individual electrochromic device is indented about 0.5 mm to about 3 mm relative to said outer laminate glass pane in at least one dimension.

81. The process of claim 79, wherein said individual electrochromic device is indented about 1 mm to about 2 mm relative to said outer laminate glass pane in at least one dimension.