Electrochromic devices, assemblies incorporating electrochromic devices, and/or methods of making the same

• US 8,638,487 B2
• Filed: 09/17/2012
• Issued: 01/28/2014
• Est. Priority Date: 08/27/2009
• Status: Active Grant

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Guardian Industries Corporation (KOCH Industries Incorporated)
• Inventors: Veerasamy, Vijayen S.
• Primary Examiner(s): Spector, David N
• Application Number:
  US13/621,310
• Publication Number:
  US 20130016417A1
• Time in Patent Office: 498 Days
• Field of Search: 359/265, 359/273, 359/274, 359/275
• 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 17/10055 with at least one intermediate air space
• 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 17/10761 containing vinyl acetal
• CPC Class Codes: B32B 17/10981 Pre-treatment of the layers
• CPC Class Codes: E06B 2009/2464 featuring transparency control by applying voltage, e.g. LCD, electrochromic panels
• CPC Class Codes: E06B 3/6722 with adjustable passage of light
• CPC Class Codes: E06B 9/24 Screens or other constructions affording protection against light, especially against sunshine; Similar screens for privacy or appearance; Slat blindsoperating, guiding or securing devices or arrangements for roll-type closures E06B9/56; free-hanging flexible screens A47H23/00
• CPC Class Codes: G02F 1/1508 using a solid electrolyte
• CPC Class Codes: G02F 1/1524 Transition metal compounds
• CPC Class Codes: G02F 1/1525 characterised by a particular ion transporting layer, e.g. electrolyte
• CPC Class Codes: G02F 1/1533 structural features not otherwise provided for
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1062 Prior to assembly

Abstract

Certain example embodiments of this invention relate to electrochromic (EC) devices, assemblies incorporating electrochromic devices, and/or methods of making the same. More particularly, certain example embodiments of this invention relate to improved EC materials, EC device stacks, high-volume manufacturing (HVM) compatible process integration schemes, and/or high-throughput low cost deposition sources, equipment, and factories.

Claims

1. An electrochromic assembly, comprising:

at least first and second glass substrates, the first and second substrates being substantially parallel to and spaced apart from one another; and

a plurality of sputter deposited device layers supported by the first substrate, the plurality of device layers comprising, in order moving away from the first substrate, a first transparent conductive coating, a doped and anodically coloring counter electrode layer, an ion conductor layer, a doped electrochromic layer comprising WOx, and a second transparent conductive coating,

wherein the first and second substrates are laminated to one another, and

wherein the second substrate is heat treated and the first substrate is not heat treated.

2. The assembly of claim 1, wherein the counter electrode and electrochromic layers are doped with Mg.

3. The assembly of claim 1, wherein the WOx is substoichiometric.

4. The assembly of claim 1, wherein the counter electrode and electrochromic layers are both color changeable when the electrochromic assembly is in operation.

5. The assembly of claim 1, wherein the device layers face away from the second substrate.

6. The assembly of claim 1, wherein the device layers face the second substrate.

7. The assembly of claim 1, wherein each said transparent conductive coating includes a layer comprising silver sandwiched between layers comprising indium tin oxide, and further wherein layers including Ni, Cr, and/or Cu are provided between each said layer comprising silver and each said layer comprising indium tin oxide.

8. The assembly of claim 1, wherein the first substrate is cut from a stock sheet of coated non-tempered glass.

9. The assembly of claim 1, wherein the counter electrode and electrochromic layers are both electrochromic color changing layers such that, in operation, the counter electrode layer becomes transparent upon insertion of ions therein and changes to a first desired color upon the loss of ions therefrom, the counter electrode layer becomes transparent upon the loss of ions therefrom and changes to a second desired color upon insertion of ions therein.

10. The assembly of claim 1, wherein the counter electrode and electrochromic layers each are doped with Mg, and the WOx is sub-stoichiometric.

11. The assembly of claim 1, wherein:

the counter electrode and electrochromic layers are both electrochromic color changing layers such that, in operation, the counter electrode layer becomes transparent upon insertion of ions therein and changes to a first desired color upon the loss of ions therefrom, the counter electrode layer becomes transparent upon the loss of ions therefrom and changes to a second desired color upon insertion of ions therein,

the first substrate is cut from a stock sheet of coated non-tempered glass,

the first and second substrates are laminated to one another via a polymer-based interlayer, and

the device layers face away from the second substrate.

12. The assembly of claim 1, wherein the ion conductor layer comprises LiNiO.

13. The assembly of claim 12, wherein the ion conductor layer has a nanocrystalline morphology.

14. The assembly of claim 1, wherein the ion conductor layer includes Li.

15. The assembly of claim 14, wherein the ion conductor layer includes LiPON.

16. The assembly of claim 15, wherein the ion conductor layer is deposited using a using a multi-frequency radio frequency-high frequency based plasma deposition source in which higher frequency plasma is superimposed on radio frequency power.

17. The assembly of claim 15, wherein the ion conductor layer is about 1-3 microns thick.

18. The assembly of claim 15, wherein the WOx is sub-stoichiometric, where 2.6<

x<

3.

19. The assembly of claim 18, wherein at least of the counter electrode, ion conductor, and electrochromic layers is doped with Mg.

20. The assembly of claim 19, wherein at least the ion conductor layer is doped with Mg.