CN104842605A - 层迭电子式变色窗口 - Google Patents

层迭电子式变色窗口 Download PDF

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CN104842605A
CN104842605A CN201510248886.6A CN201510248886A CN104842605A CN 104842605 A CN104842605 A CN 104842605A CN 201510248886 A CN201510248886 A CN 201510248886A CN 104842605 A CN104842605 A CN 104842605A
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glass
window glass
variable color
glass substrate
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B·L·克瓦克
D·哈斯
S·邦格特
N·M·克里希纳
W·霍夫曼
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Applied Materials Inc
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    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10807—Making laminated safety glass or glazing; Apparatus therefor
    • B32B17/10981—Pre-treatment of the layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
    • B32B17/10036—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising two outer glass sheets
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/10788—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing ethylene vinylacetate
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/66—Units comprising two or more parallel glass or like panes permanently secured together
    • E06B3/67—Units comprising two or more parallel glass or like panes permanently secured together characterised by additional arrangements or devices for heat or sound insulation or for controlled passage of light
    • E06B3/6715—Units comprising two or more parallel glass or like panes permanently secured together characterised by additional arrangements or devices for heat or sound insulation or for controlled passage of light specially adapted for increased thermal insulation or for controlled passage of light
    • E06B3/6722—Units comprising two or more parallel glass or like panes permanently secured together characterised by additional arrangements or devices for heat or sound insulation or for controlled passage of light specially adapted for increased thermal insulation or for controlled passage of light with adjustable passage of light
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B9/00—Screening or protective devices for wall or similar openings, with or without operating or securing mechanisms; Closures of similar construction
    • E06B9/24—Screens or other constructions affording protection against light, especially against sunshine; Similar screens for privacy or appearance; Slat blinds
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/15—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on an electrochromic effect
    • G02F1/153—Constructional details
    • G02F1/1533—Constructional details structural features not otherwise provided for
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B9/00—Screening or protective devices for wall or similar openings, with or without operating or securing mechanisms; Closures of similar construction
    • E06B9/24—Screens or other constructions affording protection against light, especially against sunshine; Similar screens for privacy or appearance; Slat blinds
    • E06B2009/2464—Screens or other constructions affording protection against light, especially against sunshine; Similar screens for privacy or appearance; Slat blinds featuring transparency control by applying voltage, e.g. LCD, electrochromic panels
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10S359/90—Methods
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1062—Prior to assembly
    • Y10T156/1075—Prior to assembly of plural laminae from single stock and assembling to each other or to additional lamina
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T156/12—Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing

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  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Joining Of Glass To Other Materials (AREA)
  • Electrochromic Elements, Electrophoresis, Or Variable Reflection Or Absorption Elements (AREA)
  • Laminated Bodies (AREA)

Abstract

描述一种制造具有多种尺寸及功能的电子式变色窗口玻璃的方法。该方法包含：(a)提供一大规格玻璃基板；(b)在大规格玻璃基板上制造多个电子式变色薄膜元件；(c)将大规模玻璃基板切割成多个电子式变色零件，每个电子式变色零件包括多个电子式变色薄膜元件中的一个；(d)提供多个窗口玻璃零件；(e)将多个电子式变色零件中的每一个与多个窗口玻璃零件中对应的一个匹配；及(f)层迭每个匹配的电子式变色元件及窗口玻璃零件。层迭可导致电子式变色元件夹在玻璃基板及窗口玻璃零件之间或在层迭零件的表面上。电子式变色元件可以是电致变色元件。

Description

层迭电子式变色窗口
本申请是申请日为2009年12月1日，申请号为200980156688.X的专利申请的分案申请。
技术领域
本发明一般关于电子式变色窗口，且特别是用于适应多种窗口尺寸及功能并同时维持高良率、高产量及低成本的电子式变色窗口的改良制造方法。
背景技术
智能型窗口是结合具有可控制光及热穿透性质的元件的玻璃单元(glazing unit)。该元件一般为直接沉积于玻璃表面上或层迭于玻璃表面上的层的形式。整合此智能型窗口至建筑物中可通过调整窗口的光与热性质而提供控制内部亮度及温度的机会。电致变色元件、悬浮粒子元件(SPD)及高分子分散液晶(PDLC)元件皆为可结合至智能型窗口的实例；在这些特定元件中的透光率皆可以电子式控制，且结合这些元件的智能型窗口亦如所知是电子式变色窗口。
电致变色元件目前广泛结合于各种产品当中，包括智能型窗口、后视镜、及用于博物馆展示的保护玻璃。电致变色元件是响应横跨该元件所施加的电压而可改变光(及热)穿透率性质的元件。电致变色元件可制造为在透明及半透明态(其中穿透光为有色的)之间电切换的元件。进一步的说，可制造一些过渡金属氢化物电致变色元件为介于透明与反射态之间切换的元件。电致变色元件的功能的更详细讨论在Granqvist,C.-G.的“Nature Materials”(v5,n2,2006年2月)中第89-90页可找到。电致变色元件是目前在智能型窗口使用中最具希望的电子式变色元件。
SPD及PDLC元件已结合于智能型窗口中。SPD是具有一含有一些微观粒子悬浮液的薄膜且于薄膜两侧含有透明电极的元件。粒子是随机定向的且降低了膜的穿透率。然而，当横跨该膜施加电场时，粒子会与电场对齐，而增加膜的透光率。PDLC包含夹在薄塑料膜上的透明导体液晶层之间的液晶层。液晶粒子随机定向于层中且散射光(层为半透明)。然而，当横跨液晶层施加电场时，晶体经对齐以提供光学透明薄膜。通过施加横跨液晶层的电压以控制透明度。
当电致变色元件结合至智能型窗口中时，需要确保电致变色元件具有至少十年的使用寿命，较佳为三十年或更多。然而，电致变色元件暴露至大气中的氧及水可降级装置的效能及降低装置的使用寿命。在绝缘玻璃单元(IGU)的内表面并入电致变色元件可在30年或更多年间提供对满意效能所需的保护环境。SPD及PDLC元件也从通过IGU提供的环境保护而得到益处。
智能型窗口一般为IGU形式。包括电子式变色元件220的IGU100被显示在图1至3中。控制器及电源190通过电引线195附加至电子式变色元件220。图3示出IGU的截面图(非按原尺寸)，IGU包含两片玻璃210及330，玻璃210及330通过框架340沿着四个边缘分隔开及通过密封层350沿着四个边缘密封在一起。内部体积380填充例如氩这样的惰性气体，以提供热隔离及非氧化环境。当一电子式变色元件220结合至IGU中，电子式变色元件220在玻璃210(朝向户外的零件)的外部零件上制造及定位于玻璃210的朝内表面上。参看图2，图2为该玻璃210的外部零件的内表面的俯视图。在IGU内的惰性环境不会影响电子式变色元件220的效能。
在IGU中的玻璃210的外部零件可以是变色、迭层、强化(tempered)、热硬化(heat-strengthened)等的玻璃。当电致变色元件220以上述方式结合至IGU中时，玻璃210的外部零件将经受热应力。进一步来说，若玻璃210的外部零件也变色，此举将增加玻璃中的热应力。因而时常指定并且需要强化或热硬化玻璃。
目前制造包括电子式变色元件的智能型窗口的基本原理是将所有玻璃功能-可变色元件、色彩/变色、厚度、强度、尺寸等结合至单片玻璃里。然而，此原理导向了不灵活且昂贵的制造程序(可整合的功能具有很有限的范围)，这些是不同功能的相互矛盾的制造需求的结果。例如，考虑对于具有强化玻璃及电子式变色电致变色元件的智能型窗口的制造程序所具有的问题，其中某一窗口尺寸范围是想要的。(强化玻璃及电致变色元件)此两种特征结构的处理需求是与包括玻璃裁切的整合处理不兼容的。这是因为在玻璃已强化后无法将玻璃切割而产生不同尺寸的零件，且若电致变色元件在强化前已沉积于玻璃上，随后电致变色元件无法承受强化玻璃所需的处理。因此，须在沉积电致变色元件层之前切割及强化玻璃。这就要求制造设备应对多种玻璃片尺寸，这会导致昂贵的制造设备及处理。进一步的说，控制多种不同基板尺寸在产率上可具有不良影响。例如，玻璃片的不同尺寸在沉积腔室中将呈现不同电场分布，不同电场分布可不良地影响沉积层的均匀性。(这在涉及离子物质(例如，等离子体增强处理)的沉积处理中是显著的)。另一实例是结合不同玻璃厚度的电致变色元件的沉积。对大多数典型薄膜沉积处理而言，当沉积电致变色元件的层时，想要控制基板温度；然而不同厚度的玻璃将以不同速率加热及冷却，从而导致较厚玻璃的产量较低并且很难控制处理均匀性。明确地说，存有一种对于智能型窗口的制造程序的需要，其中该制造程序具有灵活性且与低成本、高产率及高产量制造兼容。
发明内容
本发明实施例基于下列概念：(1)将不同玻璃功能分离至一些玻璃零件中，及(2)利用玻璃层迭技术以结合玻璃零件而提供具有增强功能的整合玻璃产品。当想要不同功能而导向不兼容的处理需求及/或折衷的效能时，此方法特别有价值。提供一种制造电子式变色窗口玻璃的方法，该方法轻易地容许广泛种类的窗口尺寸及功能。此方法包括单独地制造电子式变色元件和窗口玻璃，且最终将电子式变色元件层迭至窗口玻璃。当制造电子式变色元件时，此方法允许更大得多的处理灵活性，并提供窗口玻璃的规格的更大灵活性。这些概念及方法允许成本效益、高产率及高产量的电子式变色窗口的制造。用此文所叙述的方法制造的电子式变色窗口玻璃可结合入IGU中，及其它类型建筑玻璃中。
本发明的实施例的方法允许在标准尺寸及厚度的基板上制造的电子式变色元件(所有薄膜处理在单一尺寸玻璃基板上完成)。此举提供稳定生产环境，稳定生产环境适于具有良好处理控制、高产量及高效能的大量制造。只有在从基板中切割出单独的电子式变色元件之后，才需要控制不同尺寸的基板。
根据本发明的多个方面，制造具有多种尺寸及功能的电子式变色窗口玻璃的方法包含：(a)提供一大规格玻璃基板；(b)在大规格玻璃基板上制造多个电子式变色薄膜元件；(c)将大规格玻璃基板切割成多个电子式变色零件，每个电子式变色零件包括多个电子式变色薄膜元件中的一个；(d)提供多个窗口玻璃零件；(e)将多个电子式变色零件中的每一个与多个窗口玻璃零件中对应的一个匹配；及(f)层迭匹配的电子式变色元件及窗口玻璃零件。层迭可导致电子式变色元件夹在玻璃基板及窗口玻璃零件中或在层迭零件的表面上。电子式变色元件可以是电致变色元件；然而，电子式变色元件可以是SPD、PDLC元件或气致变色(gasochromic)元件。电子式变色元件通常为薄膜元件且可使用所需的以下处理来进行制造：机器人控制基板；在真空中处理；等离子体处理；及/或加热基板。玻璃零件可经由热处理、强化、变色、层迭、高强度等且可自多种不同尺寸及厚度中选择。
进一步而言，本发明实施例的制造方法包含在生产线(其中使用标准大规格玻璃基板)上制造电子式变色元件的概念，而不论最终电子式变色元件的尺寸。因此，本发明的其它方面包括制造具有多种尺寸及功能的电子式变色窗口的方法，该方法包含：(a)提供多个相同的大规格玻璃基板；(b)在多个大规格玻璃基板上制造多个电子式变色薄膜元件；(c)将多个大规格玻璃基板切割成多个电子式变色零件，每个电子式变色零件包括多个电子式变色薄膜元件中的一个；(d)提供多个窗口玻璃零件；(e)将多个电子式变色零件中的每一个与多个窗口玻璃零件中对应的一个匹配；及(f)层迭匹配的电子式变色零件及窗口玻璃零件。
根据本发明又另一方面，电子式变色窗口包含：一片窗口玻璃；玻璃基板；形成于该玻璃基板上的电致变色薄膜元件；及介于电致变色薄膜与窗口玻璃之间的层迭层，该层迭层将该电致变色薄膜元件附着至该窗口玻璃。该层迭层可包括诸如聚乙烯丁醛(PVB)及乙烯乙酸乙烯酯(EVA)的接合剂。
根据本发明的其它方面，一种用于形成具有多种尺寸及功能的电子式变色窗口玻璃的装置，该装置包含：第一系统，用以在大规格玻璃基板上制造多个电子式变色薄膜元件；第二系统，用以将大规格玻璃基板切割成多个电子式变色零件，每个电子式变色元件包括多个电子式变色薄膜元件中的一个；及第三系统，用以层迭匹配的电子式变色零件及窗口玻璃零件，其中多个电子式变色零件中的每一个与多个窗口玻璃零件中对应的一个匹配。此装置可进一步包含第四系统，用以从每个层迭零件中构建出IGU。
附图说明
本发明的这些及其它方面及特征结构通过本发明的以上描述及伴随的附图对那些本领域技术人员将变得显而易见。
图1示出了结合一电子式变色元件的一绝缘玻璃单元的透视图。
图2是图1的绝缘玻璃单元的外玻璃片的内表面的俯视图，图2示出了电子式变色元件。
图3是图1的绝缘玻璃单元的横截面图。
图4示出了图1的绝缘玻璃单元具有根据本发明第一实施例的配置的横截面图。
图5示出了图1的绝缘玻璃单元具有根据本发明第二实施例的配置的横截面图。
图6示出了根据本发明实施例的用于制造具有电子式变色元件的绝缘玻璃单元的流程图。
图7示出了根据本发明实施例的用于制造具有电子式变色元件的绝缘玻璃单元的装置。
具体实施方式
本发明现参照附图详细地描述，附图提供本发明的范例实施例以使那些熟悉此技术领域者可实施本发明。须注意的是，以下的附图及范例并非将本发明的范畴限制为单一实施例，但可通过交换一些或全部所描述或示例的元件的方式使其它实施例为可能。再者，本发明的特定实施例可部分或完全地实施于已知部件中，这些已知部件的那些部分只有对本发明的理解为必须者将被描述，这些已知部件的其它部分的详细描述将被省略以免混淆本发明。在本发明说明书中，示出单一部件的一实施例不应视为限制；更确切地说，本发明意欲涵盖包括多个相同部件的其它实施例，且反之亦然，除非此文中另有明确说明。再者，申请人不意欲将本说明书中的任何术语认为是不一般的或特别意义，除非此文中另有明确阐述。进一步而言，本发明通过参照本文所述的示例方法的已知部件而涵盖现今及未来的已知等效物。
一般而言，本发明实施例基于以下概念：(1)将不同玻璃功能分离至一些玻璃零件中，及(2)利用玻璃层迭技术以结合玻璃零件而提供具有增强功能的整合玻璃产品。本文提供的范例关于具有不同功能的两个玻璃零件的层迭；然而，此概念可应用于具有不同功能的三个或多个玻璃零件的层迭。
本发明实施例设想了制造电子式变色窗口的替代方法，其中该电子式变色元件和窗口玻璃是单独制造的，且随后该窗口玻璃被层迭至该电子式变色元件上。此方法允许灵活选择制造电子式变色元件的处理条件，灵活选择窗口玻璃的功能，并且宽广地选择窗口尺寸。这些概念及方法允许在制造结合入建筑玻璃(如IGU)的电子式变色窗口时有效地控制成本。提供关于薄膜电致变色电子式变色元件的详细描述范例；然而，此概念可应用于其它电子式变色元件，包括SPD及PDLC元件。
图4示出了电子式变色窗口玻璃(非按照尺寸)，电子式变色窗口玻璃根据本发明实施例制造，被结合入一IGU(如图1的IGU)中。电子式变色元件420位于玻璃基板460上。具有电子式变色元件420的玻璃基板460被层迭至玻璃410(本文中称为窗口玻璃)的外部零件。电子式变色元件420在层迭结构中远离玻璃410的外部零件。层迭层470可包括像聚乙烯丁醛(PVB)及乙烯乙酸乙烯酯(EVA)这样的接合剂。层迭处理较佳地为真空层迭处理，其中玻璃410的外部零件及电子式变色元件420的堆栈(其间具有接合剂于其中)，被放置于一真空袋中，该真空袋被抽空以在堆栈上施加均匀压力，且随后此袋被放置于一高温及高压熔炉中或一压力锅中。处理温度及压力将取决于电子式变色元件的类型。对于电致变色元件，温度范围通常自125℃至175℃。尽管温度范围通常将仍居中于接近150℃处，温度范围可更广。压力可高达20巴(且可能更高)，如所需，典型压力可接近13巴。控制此压力以避免在层迭期间损害电子式变色元件。真空袋的使用仅为用于提供均匀压力而不损害电子式变色元件420的方法的一实例。可使用其它方法提供压力及温度，该压力及温度可被施加而不损害电子式变色元件420。
图5示出了图4的替代配置。图5中，电子式变色元件在层迭结构中朝向玻璃410的外部零件，即电子式变色元件420与层迭层470接触。在此实施例中，层迭处理可以是以上所述的真空层迭处理，或堆栈可在中间温度被卷起来且随后为了最终层迭而放置于一高温及高压熔炉或一压力锅中。(在中间温度卷起来而非在较高温度是预期在元件上提供一更均匀压力且因此在附着强度及实体外观方面有较好的层迭质量。)
当电子式变色元件为电致变色元件时，须考虑保护该元件使该原件免于外界氧化物的影响，如以上所述。此保护可通过结合至IGU中提供。另外，或此外，可如Kwak等人于美国专利申请号12/134,437中所述而提供一封装层(未示出)。对不想要的氧化物而言，此封装层扮演一扩散阻障层。
图6示出了根据本发明实施例的用于制造电子式变色窗口玻璃的流程图。此方法包含：提供一大规格玻璃基板(610)；在大规格玻璃基板上制造多个电子式变色薄膜元件(620)；将大规模玻璃基板切割成多个电子式变色零件，每个电子式变色零件包括多个电子式变色薄膜元件中的一个(630)；提供多个窗口玻璃零件，该多个窗口玻璃零件可具有不同尺寸并具有不同性质(640)；将多个电子式变色零件中的每一个与多个窗口玻璃零件中对应的一个匹配(650)；层迭每个匹配的电子式变色元件及窗口玻璃零件(660)；及(选择性)制造多个绝缘玻璃单元(IGU)，该多个绝缘玻璃单元(IGU)可具有不同尺寸及功能。
电子式变色元件是诸如电致变色元件这样的薄膜元件，且电子式变色元件可使用以下所需处理来制造：以机器人控制基板；在真空中处理；等离子体处理；及/或加热基板。更多薄膜电致变色元件的细节及用于这些元件的制造方法可在Kwak等人的美国专利申请号12/134,437中找到。相关薄膜沉积处理的一些实例包括如物理气相沉积(PVD)、化学气相沉积(CVD)及等离子体增强沉积技术的真空沉积技术。在薄膜沉积期间，希望加热基板。窗口玻璃零件可受热处理、强化、变色、层迭、高强度等且可自多种不同尺寸及厚度中选择。既然电子式变色元件的制造可在单独的基板上完成，在元件的制造上及窗口玻璃零件的规格上可有较大的灵活性。例如，在窗口玻璃零件的制备中，玻璃片可切割成想要的尺寸且随后经强化。多个电子式变色元件可在大玻璃基板上有效地制造且随后可自该片切割出单独的元件。可随后层迭强化零件及元件以形成电子式变色窗口，适于整合至IGU。
电子式变色零件可全为同一尺寸，或可以是不同尺寸。参看图6中的处理630。换言之，具有电子式变色元件的玻璃基板可切割成多个相同尺寸零件，或切割成多个不同尺寸零件，取决于在基板上已制造的电子式变色元件。可提供对应于电子式变色零件的尺寸的窗口玻璃零件的尺寸，所有皆根据电子式变色窗口玻璃的规格。参看图6中的处理640及650。一般而言，电子式变色零件将小于或等于窗口玻璃零件，如图2-5中所示。(在图4中示出的元件的替代实施例中，玻璃基板460是与窗口玻璃零件410相同的尺寸，且框架340位于玻璃基板460的表面上。虽然电子式变色元件420仍应较小于窗口玻璃零件410，以便嵌入框架340与密封剂350中。)
再者，根据本发明实施例，图6中的流程图可延伸用于电子式变色窗口的制造程序，其中处理多种相同大规格基板。因此，一种制造具有多种尺寸及功能的电子式变色窗口玻璃的方法包含：提供多个相同大规格玻璃基板；在多个大规格玻璃基板上制造多个电子式变色薄膜元件；将多个大规格玻璃基板切割成多个电子式变色零件，每个电子式变色零件包括多个电子式变色薄膜元件中的一个；提供多个窗口玻璃零件；将多个电子式变色零件中的每一个与多个窗口玻璃零件中对应的一个匹配；层迭每个匹配的电子式变色零件及窗口玻璃零件；及(选择性)制造多个绝缘玻璃单元(IGU)，该多个绝缘玻璃单元(IGU)可具有不同尺寸及功能。此制造程序同时包括多个相同基板的串行处理，及其中处理允许的多个相同基板的平行处理。
图7是根据本发明一些实施例的用于制造具有多种尺寸及功能的电子式变色窗口玻璃的装置及IGU的示意图。可使用图7的装置(例如)根据图6的流程图来制造IGU。图7的装置包含四个系统。第一系统720在大规格玻璃基板上制造多个电子式变色薄膜元件。第二系统730将大规格玻璃基板切割成多个电子式变色零件，各电子式变色零件包括多个电子式变色薄膜零件。第三系统730层迭经匹配的电子式变色零件及窗口玻璃零件，其中多个电子式变色零件中的每一个与多个窗口玻璃零件中对应的一个匹配。第四系统770从每个层迭零件中构建出IGU。图7中的虚线指示了(在线上方)控制大规格、标准尺寸的玻璃的装置，及(在线下方)控制具有多种不同尺寸的较小玻璃零件的装置。
本发明的制造方法亦可应用于使用悬浮粒子元件(SPD)、高分子分散液晶(PDLC)元件及气致变色元件来控制透光率的IGU。
虽然本发明已参照实施例详细地描述，在不背离此发明的精神及范畴下，形式及细节中的变化及修饰对那些本领域技术人员为显而易见。随附的权利要求书将涵盖此变化及修饰。本发明由以下权利要求书所界定。

Claims (11)

1.一种制造电子式变色窗口玻璃的方法，该电子式变色窗口玻璃具有多种尺寸及功能，该方法包含：
提供一大规格玻璃基板，其中该玻璃基板是与层迭层接触；
在该大规格玻璃基板上制造多个电子式变色薄膜元件；
将该大规格玻璃基板切割成多个电子式变色零件，每个电子式变色零件包括所述多个电子式变色薄膜元件中的一个；
提供多个窗口玻璃零件；
将所述多个电子式变色零件中的每一个与所述多个窗口玻璃零件中对应的一个匹配起来；及
层迭每个匹配的电子式变色零件与窗口玻璃零件，其中在该层迭期间，该电子式变色薄膜元件是远离所述多个窗口玻璃零件中对应的一个的表面。
2.如权利要求1所述的方法，其中，所述窗口玻璃零件包括热处理玻璃零件、变色玻璃零件、或层迭玻璃零件。
3.如权利要求1所述的方法，其中，该电子式变色薄膜元件是电致变色元件、悬浮粒子元件、或高分子分散液晶元件。
4.如权利要求1所述的方法，其中，该制造包括在该大规格玻璃基板上真空沉积一薄膜。
5.如权利要求4所述的方法，其中，该制造包括在该大规格玻璃基板上等离子体沉积一薄膜。
6.如权利要求1所述的方法，其中，该制造包括加热该大规格玻璃基板。
7.如权利要求1所述的方法，其中，所述多个电子式变色零件包括不同尺寸的零件。
8.一种制造电子式变色窗口玻璃的方法，该电子式变色窗口玻璃具有多种尺寸及功能，该方法包含：
提供多个相同的大规格玻璃基板，其中该玻璃基板是与层迭层接触；
在所述多个大规格玻璃基板上制造多个电子式变色薄膜元件；
将所述多个大规格玻璃基板切割成多个电子式变色零件，每个电子式变色零件包括所述多个电子式变色薄膜元件中的一个；
提供多个窗口玻璃零件；
将所述多个电子式变色零件中的每一个与所述多个窗口玻璃零件中对应的一个匹配起来；及
层迭每个匹配的电子式变色零件及窗口玻璃零件，其中在该层迭期间，该电子式变色薄膜元件是远离所述多个窗口玻璃零件中对应的一个的表面。
9.如权利要求1或8所述的方法，其中，所述窗口玻璃零件包括具有不同玻璃尺寸的零件。
10.如权利要求1或8所述的方法，其中，所述窗口玻璃零件包括具有不同玻璃厚度的零件。
11.一种用于形成电子式变色窗口玻璃的装置，该电子式变色窗口玻璃具有多种尺寸及功能，所述装置包含：
薄膜元件制造系统，用以在一大规格玻璃基板上制造多个电子式变色薄膜元件，其中该玻璃基板是与层迭层接触；
玻璃切割工具，用以将该具有多个电子式变色薄膜元件的大规格玻璃基板切割成多个电子式变色零件，每个电子式变色零件包括所述多个电子式变色薄膜元件中的一个；及
层迭工具，用以层迭经匹配的电子式变色零件及窗口玻璃零件，其中所述多个电子式变色零件中的每一个是与多个窗口玻璃零件中对应的一个相匹配的，其中在该层迭期间，该电子式变色薄膜元件是远离所述多个窗口玻璃零件中对应的一个的表面。
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