Thin-film devices and fabrication

Patent metadata

Field	Value
Publication number	US-2016334688-A1
Application number	US-201415109624-A
Country	US
Kind code	A1
Filing date	Dec 31, 2014
Priority date	Dec 12, 2011
Publication date	Nov 17, 2016
Grant date	—

Abstract

Thin-film devices, for example electrochromic devices for windows, and methods of manufacturing are described. Particular focus is given to methods of patterning optical devices. Various edge deletion and isolation scribes are performed, for example, to ensure the optical device has appropriate isolation from any edge defects. Methods described herein apply to any thin-film device having one or more material layers sandwiched between two thin film electrical conductor layers. The described methods create novel optical device configurations.

First claim

We claim:

1 . A method of fabricating an optical device, the method comprising:
a) receiving a first substrate, said first substrate comprising a material selected from the group consisting of tempered glass, heat strengthened glass, chemically strengthened glass and a polymer; b) laminating a second substrate to the first substrate to form a laminate, wherein the second substrate is a thin flexible low-sodium annealed glass; and c) fabricating the optical device on the outer surface of the thin flexible low-sodium annealed glass of the laminate.

2 . The method of claim 1 , wherein the optical device is a solid state and inorganic electrochromic device.

3 . The method of claim 2 , wherein the first substrate is a tempered glass lite.

4 . The method of claim 3 , wherein the tempered glass lite is between about 2 mm and about 25 mm thick.

5 . The method of claim 4 , wherein b) comprises using a silicone based lamination adhesive capable of withstanding temperatures of between about 300° C. and 450° C.

6 . The method of claim 5 , wherein the second substrate is larger than the first substrate and b) further comprises registering the first and second substrates so they are centered with each other on both X and Y axes, so that after b) there is an overhang of the second substrate about the perimeter of the first substrate.

7 . The method of claim 6 , wherein the first substrate is between about 30 cm and about 300 cm on its largest dimension, and the second substrate is a ribbon between about ½ m and about 3 m wide and between about 10 m and about 300 m long.

8 . The method of claim 7 , wherein a plurality of the first substrate are laminated to the second substrate in b).

9 . The method of claim 7 , further comprising cutting the excess of the second substrate from about the perimeter of the laminate.

10 . The method of claim 1 or 9 , wherein the first and second substrate's lamination surfaces are coextensive.

11 . The method of claim 1 or 9 , wherein the second substrate is set back from the first substrate about the perimeter of the laminate.

12 . The method of claim 7 , wherein cutting the excess of the second substrate from the perimeter of the laminate comprises using at least one of laser cutting, electrothermal cutting and mechanical cutting.

13 . The method of claim 9 , further comprising applying an edge treatment to the perimeter of the second substrate of the laminate so as to strengthen or protect the edge.

14 . The method of claim 13 , wherein the edge treatment comprises application of an edge adhesive.

15 . The method of claim 13 , wherein the edge treatment comprises an edge grind and/or polish.

16 . The method of claim 13 , wherein the edge treatment comprises both an edge grind and application of an edge adhesive.

17 . The method of claim 14 or 16 , wherein the edge adhesive is an epoxy or a silicone based adhesive.

18 . The method of claim 17 , wherein the edge adhesive comprises a low viscosity so as to penetrate and seal microcracks and defects in the glass edge.

19 . The method of claim 17 , wherein application of an edge adhesive is a two-part application of the low viscosity portion, and application of a more viscous portion thereafter.

20 . The method of claim 13 , wherein the edge treatment comprises heating the edge to melt and outer portion so as to reduce or eliminate microcracks and defects in the edge.

21 . The method of claim 13 , wherein the edge treatment comprises application of a laser to remove defect portions of the edge and/or bevel the edge.

22 . The method of any of claims 1 - 21 , further comprising cleaning the laminate between b) and c).

23 . The method of claim 2 , further comprising applying a top coat to the solid state and inorganic electrochromic device of the laminate after c).

24 . The method of any of claims 1 - 23 , further comprising fabricating an IGU from the laminate, wherein the optical device is within the sealed volume of the IGU.

25 . A method of forming a plurality of EC laminates, the method comprising:
a) laminating a plurality of support substrates to a single sheet of thin flexible low-sodium annealed glass; said plurality of support substrates comprising one or more of at least one of a tempered glass lite, a heat strengthened glass lite, a chemically strengthened glass lite and a polymeric lite; b) cutting the plurality of laminates from the single sheet of thin flexible low-sodium annealed glass; and c) coating each of the plurality of laminates with an EC device.

26 . The method of claim 25 , wherein a) comprises using a silicone based lamination adhesive capable of withstanding temperatures of between about 300° C. and 450° C.

27 . The method of claim 26 , wherein the EC device is a solid state and inorganic electrochromic device.

28 . The method of claim 27 , wherein each of the plurality of support substrates is a tempered glass lite.

29 . The method of any of claims 25 - 28 , wherein the plurality of laminates are cleaned after b) and before c).

30 . The method of claim 29 , wherein the plurality of laminates are top coated on the EC device side after c).

31 . A method of forming a plurality of IGUs, the method comprising:
a) laminating a plurality of support substrates to a single sheet of thin flexible low-sodium annealed glass to make a plurality of laminates; said plurality of support substrates comprising one or more of at least one of a tempered glass lite, a heat strengthened glass lite, a chemically strengthened glass lite and a polymeric lite; b) coating each of the plurality of laminates with an EC device; c) applying bus bars to each EC device; d) applying a spacer to each EC device; e) applying a mate lite to each spacer; and f) pressing the constructs to form the plurality of IGUs; wherein the IGUs are cut from the single sheet of thin flexible low-sodium annealed glass.

32 . The method of claim 31 , wherein a) comprises using a silicone based lamination adhesive capable of withstanding temperatures of between about 300° C. and 450° C.

33 . The method of claim 31 , wherein the EC device is a solid state and inorganic electrochromic device.

34 . The method of claim 31 , wherein each of the plurality of support substrates is a tempered glass lite.

35 . The method of any of claims 31 - 34 , wherein the plurality of laminates are cleaned after a) and before b).

36 . The method of claim 31 , wherein the plurality of laminates top coated on the EC device side after b).

37 . The method of claim 31 , wherein the plurality of laminates top coated on the EC device side after c).

38 . The method of any of claims 31 - 37 , wherein c) and d) are done simultaneously, wherein the spacer is a pre-wired spacer.

39 . The method of claim 31 , wherein the spacer and/or the mate lite has a pre-applied primary sealant.

40 . An optical device laminate comprising:
i) a first substrate comprising a material selected from the group consisting of tempered glass, heat strengthened glass, chemically strengthened glass and a polymer; ii) a second substrate laminate

Assignees

• View Inc

Inventors

• Tran Tom Toan-Cong
• Griedel Brian D
• Rozbicki Robert T
• Martin Todd William

Classifications

• G02F1/153 Primary

  Constructional details · CPC title

• G02F1/1533 Primary

  structural features not otherwise provided for · CPC title

• G02F1/161

  Gaskets; Spacers; Sealing of cells; Filling or closing of cells · CPC title

• G02F1/155

  Electrodes · CPC title

• G02F1/1523

  comprising inorganic material · CPC title