Electrochemical devices with plastic substrates

• US 9,766,528 B2
• Filed: 03/09/2016
• Issued: 09/19/2017
• Est. Priority Date: 03/09/2015
• Status: Active Grant

• Current Assignee: Gentex Corporation
• Original Assignee: Gentex Corporation
• Inventors: Kloeppner, Leroy J., Tonar, William L., Dozeman, Gary J., Baumann, Kelvin L., Saenger Nayver, Mario F., Petroelje, Zachary J., DeNolf, Garret
• Primary Examiner(s): TRA, TUYEN Q
• Application Number:
  US15/065,788
• Publication Number:
  US 20160266460A1
• Time in Patent Office: 559 Days
• Field of Search: 359265-275, 345105
• CPC Class Codes: G02F 1/15165 Polymers
• CPC Class Codes: G02F 1/1533 structural features not otherwise provided for
• CPC Class Codes: G02F 2001/1536 additional, e.g. protective, layer inside the cell
• CPC Class Codes: G02F 2201/086 UV absorbing
• CPC Class Codes: G02F 2201/501 Blocking layers, e.g. against migration of ions

Abstract

An electrochromic device includes a first flexible or rigid plastic substrate including a front surface, and a rear surface, wherein the rear surface comprises a first conductive material; and the front surface, the rear surface, or both the front surface and the rear surface of the first substrate comprises a gas diffusion barrier; and a second flexible or rigid plastic substrate including a front surface, and a rear surface, wherein the front surface comprises a second conductive material, wherein the first substrate is joined to the second substrate by a sealing member, where the rear surface of the first substrate and the front surface of the second substrate with the sealing member define a chamber therebetween.

Claims

1. An electrochromic device comprising:

a first flexible or rigid plastic substrate comprising;

a front surface; and

a rear surface;

wherein;

the rear surface comprises a first conductive material; and

the front surface, the rear surface, or both the front surface and the rear surface of the first substrate comprises a gas diffusion barrier;

a second flexible or rigid plastic substrate comprising;

a front surface; and

a rear surface;

wherein;

the front surface comprises a second conductive material;

wherein;

the first substrate is joined to the second substrate by a sealing member, where the rear surface of the first substrate and the front surface of the second substrate with the sealing member define a chamber therebetween;

the chamber comprising an electrochromic medium comprising a cathodic material and an anodic material; and

the first conductive material comprises a conductive nanowire coating, a conductive metal mesh, or an insulator/metal/insulator stack (IMI stack).

2. The electrochromic device of claim 1, wherein the front surface, the rear surface, or both the front surface and the rear surface of the second substrate comprises a gas diffusion barrier.

3. The electrochromic device of claim 2, wherein the gas diffusion barrier(s) comprises a layer applied by plasma-enhanced chemical vapor deposition (PECVD), a layer applied by neutral beam assisted sputtering (NBAS), a layer applied by atomic layer deposition (ALD), a co-polymer of ethylene vinyl alcohol, a polyvinyl alcohol, a polymeric film of self-assembled nanoparticles (SNAP), a multilayer barrier comprising alternating layers of organic and inorganic materials, or a multilayer barrier comprising alternating thin films of cationic and anionic polymers, or a flexible, thin glass film.

4. The electrochromic device of claim 1, wherein the front surface, the rear surface, or both the front surface and the rear surface of the first and second substrates comprises an adhesion promotion layer.

5. The electrochromic device of claims 1, wherein the first substrate, the second substrate, or both the first substrate and the second substrate comprise polyethylene naphthalate (PEN), polyacrylonitrile, polyethylene terephthalate (PET), polycarbonate, a cycloolefin polymer (COP), a cycloolefin co-polymer (COC), an acrylic, a polyamide, or an epoxy.

6. The electrochromic device of claim 1, wherein the first conductive material comprises a first conductive nanowire coating, a first conductive metal mesh, or a first IMI stack;

and the second conductive material comprises a second conductive nanowire coating, a second conductive metal mesh, or a second IMI stack.

7. The electrochromic device of claim 6, further comprising a conductive coating overlaying either or both of the first or second conductive material.

8. The electrochromic device of claim 7, wherein the conductive coating comprises a transparent conductive oxide, carbon nanotubes, graphene, or a conductive polymer.

9. The electrochromic device of claim 1, wherein the chamber comprises a first polymer-based electrochromic film.

10. The electrochromic device of claim 9, wherein the first polymer-based electrochromic film is a first thermoplastic electrochromic film.

11. The electrochromic device of claim 10, wherein the first thermoplastic electrochromic film comprises a first electroactive material and a first thermoplastic polymer.

12. The electrochromic device of claim 11, wherein the first electroactive material is a cathodic material, and anodic material, or a mixture of a cathodic material and an anodic material.

13. The electrochromic device of claim 12, wherein the cathodic material comprises a viologen.

14. The electrochromic device of claim 12, wherein the anodic material comprises a phenazine, a phenothiazine, a triphenodithiazine, a carbazole, an indolocarbazole, a biscarbazole, or a ferrocene.

15. The electrochromic device of claim 10, wherein the chamber comprises a second thermoplastic electrochromic film comprising a second electroactive material and a second thermoplastic polymer.

16. The electrochromic device of claim 15, wherein the first and second thermoplastic electrochromic films are separated by an ion-exchange or porous membrane.

17. The electrochromic device of claim 1, wherein the sealing member comprises a hot melt or an ultrasonic weld between the first substrate and the second substrate, or a heat seal film that covers an edge of the front surface of the first substrate and extends to an edge of the rear surface of the second substrate.

18. A process of forming a substrate for an electrochromic device, the process comprising coating a first surface of a first flexible or rigid plastic substrate with a first polymer-based film, the polymer-based electrochromic film comprising at least one first electroactive material and a first thermoplastic polymer, the first surface further comprising a conductive nanowire coating, a conductive metal mesh, or an insulator/metal/insulator stack (“

IMI stack”

), and a gas barrier coating on a second surface of the first flexible or rigid plastic substrate, the second surface being substantially parallel to and opposite from the first surface.