Thin-Film Coatings, Electro-Optic Elements and Assemblies Incorporating These Elements

• US 20080310005A1
• Filed: 08/03/2007
• Published: 12/18/2008
• 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
• Granted Patent: US 7,746,534 B2
• Time in Patent Office: Days
• 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 comprising a first and second surface, the first substrate comprising at least first one layer of material on at least one of the first and second surfaces, wherein the at least one first layer comprises an outer surface that has been modified such that the outer surface comprises an atom type not present in a bulk of the at least one first layer and an atom type present in the bulk of the at least one first layer, and that advances at least a select one of adhesion, stability, nucleation and conductivity of a second layer that is adjacent to the outer surface of the at least one first layer.

2. The optical element of claim 1, wherein the optical element comprises an electro-optic element.

3. The optical element of claim 2, further comprising:

a second substrate comprising a third and fourth surface, wherein the first and second substrate cooperate to form a cavity therebetween; and

an electrochromic medium located within the cavity.

4. The optical element of claim 1, wherein the outer surface of the at least one first layer is modified with a member of the chalcogenide group of elements.

5. The optical element of claim 4, wherein the outer surface of the at least one first layer is modified with at least one of sulfur and selenium.

6. The optical element of claim 1, wherein a majority of the atom type not present in the bulk of the at least one first layer is located at a depth of between 1 and 10 atomic layers of the outer surface.

7. The optical element of claim 6, wherein a majority of the atom type not present in the bulk of the at least one first layer is located at a depth of between 1 and 5 atomic layers of the outer surface.

8. The optical element of claim 7, wherein a majority of the atom type not present in the bulk of the at least one first layer is located at a depth of between 1 and 2 atomic layers of the outer surface.

9. The optical element of claim 1, wherein the at least one first layer comprises at least one of a non-metal, a metal, and a metal oxide.

10. The optical element of claim 9, wherein the at least one first layer comprises at least a select one of ITO, IZO, zinc oxide, AZO, TiO2, w, Mo, Fe, Tu, Ox, Co, Rh, Ir, Cu, Ag, Au, Zn, Cd, Hg, Ga, In, TI, Ge, Sn, Pb, As, Sb, and Bi.

11. A method for manufacturing an optical element, comprising:

providing a first substrate comprising a first and second surface, the first substrate comprising at least one first layer of material on at least one of the first and second surfaces; and

modifying an outer surface of the at least one layer such that the outer surface includes an atom type not present in a bulk of the at least one first layer and an atom type present in the bulk of the at least one first layer, and that advances at least a select one of a of adhesion, stability, nucleation and conductivity of a second layer that is adjacent to the surface of the at least one first layer.

12. The method of claim 11, wherein the modifying step comprises at least one of ion implantation, plasma treatment, chemical treatment, and physical vapor deposition.

13. The method of claim 11, further comprising:

providing a second substrate comprising a third and fourth surface, wherein the first and second substrate cooperate to form a cavity therebetween; and

providing an electrochromic medium located within the cavity.

14. The method of claim 11, wherein the modifying step includes modifying the outer surface of the at least one layer with a member of the chalcogenide group of elements.

15. The method of claim 14, wherein the modifying step includes modifying the outer surface of the at least one first layer with at least one of sulfur and selenium.

16. The method of claim 11, wherein the modifying step results in a majority of the atom type not present in the bulk of the at least one layer being located at a depth of between 1 and 10 atomic layers of the outer surface.

17. The method of claim 16, wherein the modifying step results in a majority of the atom type not present in the bulk of the at least one layer being located at a depth of between 1 and 5 atomic layers of the outer surface.

18. The method of claim 17, wherein the modifying step results in a majority of the atom type not present in the bulk of the at least one layer being located at a depth of between 1 and 2 atomic layers of the outer surface.

19. The method of claim 11, wherein the step of providing the first substrate comprises providing the at least one first layer as comprising at least one of a non-metal, a metal, and a metal oxide.

20. The method of claim 19, wherein the step of providing the first substrate comprises providing the at least one first layer as comprising at least a select one of ITO, IZO, zinc oxide, AZO, TiO2, w, Mo, Fe, Tu, Ox, Co, Rh, Ir, Cu, Ag, Au, Zn, Cd, Hg, Ga, In, TI, Ge, Sn, Pb, As, Sb, and Bi.