Electrochromic window fabrication methods

• US 9,102,124 B2
• Filed: 03/27/2012
• Issued: 08/11/2015
• Est. Priority Date: 11/08/2010
• Status: Active Grant

• Current Assignee: View Incorporated
• Original Assignee: View Incorporated
• Inventors: Collins, Mark A., Parker, Ronald M., Rozbicki, Robert T., Shrivastava, Dhairya
• Primary Examiner(s): PINKNEY, DAWAYNE
• Application Number:
  US13/431,729
• Publication Number:
  US 20120182593A1
• Time in Patent Office: 1,232 Days
• Field of Search: 359265-275, 359/277, 359245-247, 359/254, 359/242, 345/49, 345/105, 250/70, 348/817, 438/929
• US Class Current: 1/1
• CPC Class Codes: B32B 17/10055 with at least one intermediate air space
• CPC Class Codes: B32B 17/10128 Treatment of at least one glass sheet
• CPC Class Codes: B32B 17/10183 being not continuous, e.g. in edge regions
• CPC Class Codes: B32B 17/10513 Electrochromic layer
• CPC Class Codes: B32B 17/10697 being cross-linked
• CPC Class Codes: B32B 17/10908 in liquid form
• CPC Class Codes: B32B 17/1099 After-treatment of the layered product, e.g. cooling
• CPC Class Codes: B32B 2333/12 Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
• 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 3/673 Assembling the units E06B3/677 takes precedence ; making hollow glass sheets or bricks C03B23/24
• 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: G02B 1/14 Protective coatings, e.g. hard coatings
• CPC Class Codes: G02F 1/133308 Support structures for LCD panels, e.g. frames or bezels
• CPC Class Codes: G02F 1/133311 Environmental protection, e.g. against dust or humidity
• CPC Class Codes: G02F 1/153 Constructional details
• CPC Class Codes: G02F 1/1533 structural features not otherwise provided for
• CPC Class Codes: G02F 1/155 Electrodes
• CPC Class Codes: G02F 1/161 Gaskets; Spacers; Sealing of cells; Filling or closing of cells
• 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 29/49004 : including measuring or testing of device or component part
• CPC Class Codes: Y10T 29/49124 : On flat or curved insulated base, e.g., printed circuit, etc.

Abstract

Methods of manufacturing electrochromic windows are described. An electrochromic device is fabricated to substantially cover a glass sheet, for example float glass, and a cutting pattern is defined based on one or more low-defectivity areas in the device from which one or more electrochromic panes are cut. Laser scribes and/or bus bars may be added prior to cutting the panes or after. Edge deletion can also be performed prior to or after cutting the electrochromic panes from the glass sheet. Insulated glass units (IGUs) are fabricated from the electrochromic panes and optionally one or more of the panes of the IGU are strengthened.

Claims

1. A method of manufacturing an insulated glass unit (IGU), the method comprising, in the following order:

(1) fabricating a solid-state and inorganic electrochromic device film on a glass sheet;

(2) fabricating the IGU using the glass sheet; and

then

(3) strengthening the glass sheet while in the IGU fabricated in (2);

wherein the solid-state and inorganic electrochromic device film faces the interior volume of the IGU, and

wherein strengthening the glass sheet comprises laminating the glass sheet with a reinforcing substrate or applying a polymeric coating to the glass sheet.

2. The method of claim 1, wherein (1) comprises defining a cutting pattern for cutting the glass sheet from a larger glass sheet coated with the solid-state and inorganic electrochromic device film and cutting the larger glass sheet according to the cutting pattern to create the glass sheet.

3. The method of claim 2, wherein the cutting pattern is defined, at least in part, by identifying one or more low-defectivity areas on the solid-state and inorganic electrochromic device film.

4. The method of claim 1, wherein the glass sheet is heat strengthened glass.

5. The method of claim 1, wherein the polymeric coating is a safety glazing.

6. The method of claim 5, wherein the coating is selected from the group consisting of an ormosil coating, a sol-gel coating and an acrylic glaze.

7. The method of claim 1, further comprising defining a cutting pattern for cutting two or more electrochromic panes from the glass sheet and cutting the glass sheet according to the cutting pattern, configured to create the two or more electrochromic panes, and wherein the IGU is fabricated in with at least two of the two or more electrochromic panes cut from the glass sheet.

8. The method of claim 7, wherein (3) comprises strengthening both of the electrochromic panes by laminating the electrochromic panes.

9. The method of claim 8, wherein the electrochromic panes are laminated using a liquid resin.

10. The method of claim 9, wherein the liquid resin comprises a compensating optical property.

11. The method of claim 2, wherein cutting is laser cutting.

12. The method of claim 2, wherein cutting the glass sheet is by mechanical cutting.

13. The method of claim 1,

further comprising cutting an electrochromic device pane from the glass sheet after (1) and before (2);

and

wherein (2) comprises fabricating the IGU using the electrochromic device pane cut from the glass sheet.

14. The method of claim 1, wherein laminating the glass sheet comprises at least one of lamination with float glass, tempered glass, plexiglass or thin flexible glass.

15. The method of claim 14, wherein the float glass, tempered glass or plexiglass is thicker than the glass sheet.

16. The method of claim 1, wherein strengthening the glass sheet comprises application of a reinforcing pane to form a triple pane structure having a volume between the glass sheet and the reinforcing pane.

17. The method of claim 16, further comprising introducing a resin into the volume and curing the resin.

18. The method of claim 17, wherein the resin is cured using a catalyst or ultraviolet irradiation.

19. The method of claim 18, wherein the resin imparts a color to the resulting laminate.

20. The method of claim 19, wherein the color is blue.

21. The method of claim 19, wherein the resin comprises a compensating optical property.