Electrochromic window fabrication methods

• US 9,513,525 B2
• Filed: 06/15/2015
• Issued: 12/06/2016
• 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:
  US14/740,114
• Publication Number:
  US 20150346574A1
• Time in Patent Office: 540 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 one or more electrochromic panes, the method comprising:

(a) depositing an electrochromic device on a glass sheet;

(b) detecting one or more defects in the electrochromic device using lock-in infrared thermography while applying electrical energy to the electrochromic device and defining a cutting pattern based on the locations of the one or more defects, the cutting pattern for cutting the glass sheet with the electrochromic device previously deposited thereon in (a); and

(c) cutting the glass sheet according to the cutting pattern to create the one or more electrochromic panes.

2. The method of claim 1, wherein the one or more defects are detected by measuring temperature variations while electrical energy is applied to the electrochromic device.

3. The method of claim 1, wherein the cutting pattern is defined based on the one or more identified regions of low defectivity;

the glass sheet being cut from a region of low defectivity.

4. The method of claim 1, wherein applying electrical energy to the electrochromic device is used to change one or more optical properties to cause the one or more defects to be detectable.

5. The method of claim 1, wherein (b) comprises at least one of:

identifying one or more areas of non-uniformity in the electrochromic device,

identifying one or more areas where materials used to make the electrochromic device were deposited on the back side of the glass sheet, and

identifying one or more performance characteristics of the electrochromic device.

6. A method comprising:

(a) applying electrical energy to an electrochromic device to change one or more optical properties;

(b) detecting one or more electrical short defects in the electrochromic device using lock-in infrared thermography; and

(c) mitigating the one or more electrical short defects detected in (b) , wherein mitigating comprises detecting the one or more electrical short defects by measuring temperature variations while electrical energy is applied to the electrochromic device, wherein the temperature variations are induced by leakage current from the electrical short defects.

7. The method of claim 6, wherein (c) is performed after an electrochromic device pane is cut from a larger sheet of glass coated with the electrochromic device.

8. The method of claim 6, wherein mitigating in (c) further comprises circumscribing the one or more electrical short defects using laser ablation.

9. The method of claim 6, wherein mitigating in (c) further comprises mitigating the one more electrical short defects by localized laser heating.

15. The method of claim 6, wherein the electrochromic device is an all solid state and inorganic electrochromic device.

10. A method of processing an electrochromic window, the method comprising:

(i) identifying one or more electrical short defects in an electrochromic device on a pane of the electrochromic window, wherein the one or more electrical short defects are identified by measuring temperature variations using lock-in infrared thermography while electrical energy is applied to the electrochromic device coating; and

(ii) mitigating the one or more electrical short defects detected in (i).

11. The method of claim 10, wherein (i) and (ii) are performed after the pane is cut from a larger sheet of glass with the electrochromic device.

12. The method of claim 10, wherein (i) and (ii) are performed before the pane is cut from a larger sheet of glass with the electrochromic device.

13. The method of claim 10, wherein (ii) comprises circumscribing the one or more electrical short defects using laser ablation.

14. The method of claim 10, wherein (ii) comprises mitigating the one more electrical short defects by localized laser heating.