Lamination of electrochromic device to glass substrates

• US 9,182,644 B2
• Filed: 05/31/2013
• Issued: 11/10/2015
• 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:
  US13/906,487
• Publication Number:
  US 20130258438A1
• Time in Patent Office: 893 Days
• Field of Search: 359265-275, 359/320, 359/894, 359/900, 345/105, 521/713, 522/045.4, 522/08, 527/861.1, 348/834, 348/835, 348/842
• US Class Current: 1/1
• 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:

providing an electrochromic glass substrate;

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

fabricating a plurality of electrochromic device precursors on each of said one or more substrate daughter panes, wherein a layout for said plurality of electrochromic device precursors has a space between electrochromic device precursors within said plurality of electrochromic device precursors;

cutting said one or more substrate daughter panes to form individual electrochromic devices, wherein cutting includes cutting said one or more substrate daughter panes along said space between said electrochromic device precursors, and each of said individual electrochromic devices includes a portion of said one or more substrate daughter panes and at least one of said plurality of electrochromic device precursors; and

laminating each of said individual electrochromic devices to a separate outer laminate glass pane.

2. The process of claim 1, wherein said one or more substrate daughter panes is mechanically cut.

3. The process of claim 1, wherein each of said individual electrochromic devices has an edge strength of at least 60 MPa.

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

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

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

7. The process of claim 1, wherein said individual electrochromic devices are about the same size as said outer laminate glass pane.

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

9. The process of claim 8, 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.

10. The process of claim 8, wherein said individual electrochromic devices are indented about 1 mm to about 2 mm relative to said outer laminate glass pane in at least one dimension.

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

12. The laminate of claim 11, wherein said laminate has an edge strength of at least about 60 MPa.

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

providing an electrochromic glass substrate;

fabricating a plurality of electrochromic device precursors on said electrochromic substrate, wherein a layout for said plurality of electrochromic device precursors has a space between electrochromic device precursors within said plurality of electrochromic device precursors;

cutting electrochromic glass substrate to form individual electrochromic devices, wherein cutting includes cutting the electrochromic glass substrate along said space between said electrochromic device precursors, and each of said individual electrochromic devices includes a portion of said electrochromic glass substrate and at least one of said plurality of electrochromic device precursors; and

laminating each of said individual electrochromic devices to a separate outer laminate glass pane, wherein said outer laminate glass pane comprises annealed glass, and

wherein said laminate withstands stresses of at least 17 MPa.

14. The process of claim 13, wherein said electrochromic glass substrate is mechanically cut.

15. The process of claim 13, wherein each of said individual electrochromic devices has an edge strength of at least 60 MPa.

16. The process of claim 13, wherein each of said individual electrochromic devices has an edge strength is at least 69 MPa.

17. The process of claim 13, wherein each of said individual electrochromic devices have has an edge strength is at least 75 MPa.

18. The process of claim 13, wherein each of said individual electrochromic devices have has an edge strength of at least 100 MPa.

19. The process of claim 13, wherein said individual electrochromic device is about the same size as its separate outer laminate glass pane.

20. The process of claim 13, wherein said individual electrochromic device is smaller than said its separate outer laminate glass pane in at least one dimension.

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

22. The process of claim 20, wherein said individual electrochromic device is indented about 1 mm to about 2 mm relative to its separate outer laminate glass pane in at least one dimension.

23. The process of claim 13, wherein said electrochromic glass substrate and said outer laminate glass pane comprise the same material.

24. The process of claim 13, wherein said electrochromic glass substrate is a different material than said outer laminate glass pane.

25. The process of claim 13, 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, low sodium-containing glass, or a polymer.

26. The process of claim 13, wherein said electrochromic glass substrate has a coefficient of thermal expansion ranging from about 2 ppm/K to about 10 ppm/K.

27. The process of claim 13, wherein said electrochromic glass substrate has a thickness ranging from about 0.7 mm to about 6 mm.

28. The process of claim 13, wherein said electrochromic glass substrate has a thickness ranging from about 10 μ

m to about 300 μ

m.

29. The process of claim 13, wherein said electrochromic glass substrate has a thickness ranging from about 40 μ

m to about 120 μ

m.

30. The process of claim 13, wherein said outer laminate glass pane has a thickness ranging from about 2.3 mm to about 12 mm.

31. The process of claim 13, 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.

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

33. The laminate of claim 32, wherein said laminate has an edge strength of at least 21 MPa.