Electro-optic device with ultrasonic solder bus

• US 9,550,457 B2
• Filed: 09/10/2015
• Issued: 01/24/2017
• Est. Priority Date: 09/11/2014
• Status: Active Grant

• Current Assignee: Gentex Corporation
• Original Assignee: Gentex Corporation
• Inventors: Green, Kristopher R., Stray, Joel A., Tonar, William L.
• Primary Examiner(s): Ben, Loha
• Application Number:
  US14/849,948
• Publication Number:
  US 20160075284A1
• Time in Patent Office: 502 Days
• Field of Search: 359/245, 359/247, 359/252, 359/253, 359265-274, 359/315, 359/318, 349/73, 349/74, 349/84, 349/113, 349/153, 349/158
• US Class Current: 1/1
• CPC Class Codes: B60R 1/088 using a cell of electrically changeable optical characteristic, e.g. liquid-crystal or electrochromic mirrors
• CPC Class Codes: G02F 1/0107 Gaskets, spacers or sealing of cells; Filling and closing of cells
• CPC Class Codes: G02F 1/1339 Gaskets; Spacers; Sealing of cells
• CPC Class Codes: G02F 1/153 Constructional details
• 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 1/161 Gaskets; Spacers; Sealing of cells; Filling or closing of cells

Abstract

An electro-optic assembly is provided that includes a first substantially transparent substrate comprising: a first surface, a second surface, and a first peripheral edge, the second surface comprises a first electrically conductive layer and a first isolation area. The assembly further includes a second substrate comprising: a third surface, a fourth surface, and a second peripheral edge, the third surface comprises a second electrically conductive layer. The assembly also includes a primary seal between the second and third surfaces, wherein the seal and the second and third surfaces define a substantially hermetic cavity; an electro-optic medium at least partially disposed in the cavity; and an electrically conductive solder that is disposed on at least portions of at least one of the first and second peripheral edges in electrical contact with one of the first and second electrically conductive layers.

Claims

1. An electro-optic assembly, comprising:

a first substantially transparent substrate comprising;

a first surface,

a second surface,

a first peripheral edge, and

wherein the second surface comprises a first electrically conductive layer and a first isolation area separating portions of the first electrically conductive layer;

a second substrate comprising;

a third surface,

a fourth surface,

a second peripheral edge, and

wherein the third surface comprises a second electrically conductive layer;

a primary seal between the second and third surfaces, wherein the seal and the second and third surfaces define a substantially hermetic cavity;

an electro-optic medium at least partially disposed in the cavity; and

an electrically conductive solder that is disposed on at least portions of at least one of the first and second peripheral edges in electrical contact with one of the first and second electrically conductive layers

wherein the electrically conductive solder has a composition suitable for bonding the solder with an ultrasonic solder bonding process to the at least portions of the first and second peripheral edges in electrical contact with one of the first and second electrically conductive layers.

2. The electro-optic assembly of claim 1, wherein a portion of the electrically conductive solder is disposed between the second and third surfaces to define at least a portion of the substantially hermetic cavity.

3. The electro-optic assembly of claim 1, wherein an electrically conductive foil is disposed on at least a portion of the electrically conductive solder.

4. The electro-optic assembly of claim 1, wherein the composition comprises at least 90% tin, 1% zinc and 1% antimony by weight.

5. The electro-optic assembly of claim 1, wherein the primary seal has an average width along the second and third surfaces of about 2.0 mm or less.

6. An electro-optic assembly, comprising:

a front substrate having a front substrate peripheral edge, a first surface and a second surface substantially parallel to the first surface, wherein the second surface comprises a first electrically conductive layer and a first isolation area separating portions of the first electrically conductive layer;

a rear substrate spaced from and arranged substantially parallel to the front substrate, the rear substrate having a rear substrate peripheral edge, a third surface, and a fourth surface substantially parallel to the third surface, wherein the third surface comprises a second electrically conductive layer;

a primary seal between the second and third surfaces, wherein the seal and the second and third surfaces define a substantially hermetic cavity;

an electro-optic medium at least partially disposed in the cavity; and

an electrically conductive solder that is disposed on at least portions of at least one of the front and rear substrate peripheral edges in electrical contact with one of the first and second electrically conductive layers,

wherein the substrates are arranged such that at least a portion of one of the second and third surfaces comprises an offset region, and

wherein the electrically conductive solder has a composition suitable for bonding the solder with an ultrasonic bonding process to the at least portions of the first and second peripheral edges in electrical contact with one of the first and second electrically conductive layers.

7. The electro-optic assembly of claim 6, wherein a portion of the electrically conductive solder is disposed between the second and third surfaces to define at least a portion of the substantially hermetic cavity.

8. The electro-optic assembly of claim 6, wherein an electrically conductive foil is disposed on at least a portion of the electrically conductive solder.

9. The electro-optic assembly of claim 6, wherein the composition comprises at least 90% tin, 1% zinc and 1% antimony by weight.

10. The electro-optic assembly of claim 6, wherein a portion of the third surface comprises the offset region and the electrically conductive solder is further disposed on the offset region.

11. The electro-optic assembly of claim 6, wherein a portion of the second surface comprises the offset region and the electrically conductive solder is further disposed on the offset region.

12. The electro-optic assembly of claim 6, wherein portions of the second and third surfaces comprise respective offset regions and the electrically conductive solder is further disposed on the offset regions.

13. The electro-optic assembly of claim 6, wherein the primary seal has an average width along the second and third surfaces of about 2.0 mm or less.

14. A vehicular rearview assembly having a front portion, comprising:

a front substrate having a front substrate peripheral edge, a first surface and a second surface substantially parallel to the first surface, wherein the second surface comprises a first electrically conductive layer and a first isolation area separating portions of the first electrically conductive layer;

a rear substrate spaced from and arranged substantially parallel to the front substrate, the rear substrate having a rear substrate peripheral edge, a third surface, and a fourth surface substantially parallel to the third surface, wherein the third surface comprises a second electrically conductive layer;

a primary seal between the second and third surfaces, wherein the seal and the second and third surfaces define a substantially hermetic cavity;

an electro-optic medium at least partially disposed in the cavity;

a housing structure having an aperture corresponding to the front portion of the vehicular rearview assembly, wherein at least a portion of the housing structure is configured to support at least one of the substrates; and

an electrically conductive solder that is disposed on at least portions of at least one of the front and rear substrate peripheral edges in electrical contact with one of the first and second electrically conductive layers,

wherein the substrates are arranged such that at least a portion of one of the second and third surfaces comprises an offset region, and

wherein the electrically conductive solder has a composition suitable for bonding the solder with an ultrasonic bonding process to the at least portions of the first and second peripheral edges in electrical contact with one of the first and second electrically conductive layers.

15. The vehicular rearview assembly of claim 14, wherein a portion of the electrically conductive solder is disposed between the second and third surfaces to define at least a portion of the substantially hermetic cavity.

16. The vehicular rearview assembly of claim 14, wherein an electrically conductive foil is disposed on at least a portion of the electrically conductive solder.

17. The vehicular rearview assembly of claim 14, wherein the composition comprises at least 90% tin, 1% zinc and 1% antimony by weight.

18. The vehicular rearview assembly of claim 14, wherein a portion of the third surface comprises the offset region and the electrically conductive solder is further disposed on the offset region.

19. The vehicular rearview assembly of claim 14, wherein a portion of the second surface comprises the offset region and the electrically conductive solder is further disposed on the offset region.

20. The vehicular rearview assembly of claim 14, wherein portions of the second and third surfaces comprise respective offset regions and the electrically conductive solder is further disposed on the offset regions.

21. The vehicular rearview assembly of claim 14, wherein the primary seal has an average width along the second and third surfaces of about 2.0 mm or less.

22. The vehicular rearview assembly of claim 14, wherein the substrates are arranged according to their respective dimensions such that at least a portion of one of the second and third surfaces comprises an offset region.