TW202142940A - 電致變色窗製造方法 - Google Patents
電致變色窗製造方法 Download PDFInfo
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- TW202142940A TW202142940A TW110128716A TW110128716A TW202142940A TW 202142940 A TW202142940 A TW 202142940A TW 110128716 A TW110128716 A TW 110128716A TW 110128716 A TW110128716 A TW 110128716A TW 202142940 A TW202142940 A TW 202142940A
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- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
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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
- B32B17/10009—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
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- B32B17/10174—Coatings of a metallic or dielectric material on a constituent layer of glass or polymer
- B32B17/10183—Coatings of a metallic or dielectric material on a constituent layer of glass or polymer being not continuous, e.g. in edge regions
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Abstract
本發明描述製造電致變色窗之方法。製造一電致變色器件以實質上覆蓋一玻璃薄片(舉例而言,浮法玻璃),且基於該器件中之一或多個低缺陷區域界定一切割圖案,自該區域切割一或多個電致變色窗板。可在切割該等窗板之前或之後加上雷射刻劃及/或匯流條。亦可在自該玻璃薄片切割該等電致變色窗板之前或之後執行邊緣刪除。絕緣玻璃單元(IGU)由該等電致變色窗板製造且視情況強化該IGU之該等窗板之一或多者。
Description
本發明一般係關於電致變色器件,更特定言之,本發明係關於電致變色窗。
本申請案主張2010年11月8日申請之題名為「電致變色窗製造方法」(「ELECTROCHROMIC WINDOW FABRICATION METHODS」)之美國專利申請案第12/941,882號之優先權。
電致變色係一種現象,其中一材料當放置在一不同電子狀態時展現光學性質之一可逆電化學媒介變化,通常經受一電壓變化。該光學性質通常係顏色、透射率、吸收率及反射率之一或多者。一熟知電致變色材料係氧化鎢(WO3
)。氧化鎢係一陰極電致變色材料,其中藉由電化學還原而發生一著色轉變(透明轉藍色)。
舉例而言,電致變色材料可併入於用於家庭、商業及其他使用之窗中。可藉由改變電致變色材料來改變此等窗之顏色、透射率、吸收率及/或反射率,即,電致變色窗係可電子變暗或變亮之窗。施加至窗之一電致變色器件之一小電壓將造成窗變暗;逆轉該電壓造成窗變亮。此能力允許控制通過該等窗之光量且提供將電致變色窗用作為節能器件之機會。
雖然在20世紀60年代發現電致變色,但電致變色器件(特定言之,電致變色窗)仍不幸遭受各種問題且還未開始實現電致變色器件之完全商業潛力,儘管製作及/或使用電致變色器件之電致變色技術、裝置及有關方法之許多最近改進。
本發明描述製造電致變色窗之方法。製造一電致變色(或「EC」)器件以實質上覆蓋一玻璃薄片(舉例而言,浮法玻璃(float glass)),且基於該器件中之一或多個低缺陷區域界定一切割圖案,自該器件切割一或多個電致變色窗板。在各種實施例中,僅在製造且特徵化該電致變色器件之後至少部分界定該切割圖案。在一些情況中,考慮該電致變色器件之整體品質及/或該器件中之缺陷之位置之後界定該切割圖案。舉例而言,可探測該電致變色器件以判定所有缺陷之位置或缺陷之特定類型或類別。該切割圖案接著自可用窗板排除此等缺陷,引起一整體高品質產品及一高良率製程。在另一實例中,檢驗完整器件薄片以判定該EC器件之洩漏電流或該EC器件之電極層之一者或兩者之電阻率。若該洩漏電流高於一臨限值或一透明導電氧化物(TCO)層之電阻率高於一臨限值,則該等電致變色窗板之大小受限制以確保所得窗足以執行,儘管該器件之高洩漏或該TCO之高電阻率。
在特定實施例中,在製造製程中之一或多個點處執行該玻璃薄片及/或個別窗板之檢驗。舉例而言,在EC器件形成以便界定用於該玻璃薄片之一切割圖案之後及/或在切割該等個別窗板以測試該等個別窗板之後,可使用各種光學、電、化學及/或機械計量測試來探測產品。可檢驗該EC器件之個別層、下伏基板等等。舉例而言,檢驗可包含偵測該EC器件中之缺陷及/或該玻璃之邊緣。
該玻璃薄片之一或多個邊緣部分可在圖案化製程之前予以移除及/或作為圖案化製程之部分以移除潛在有關邊緣的缺陷。此外,舉例而言,可藉由透過機械及/或光學處理移除該玻璃中之缺陷來修改邊緣強度。個別地,舉例而言,可藉由局部雷射加熱來移除或減輕遍及該電致變色器件之缺陷區域。
可在切割該等窗板之前或之後增加用於隔離該等個別電致變色窗板上之EC器件之個別電極之雷射刻劃。類似地,可在切割該等窗板之前或之後製作用於將功率遞交至該等EC器件電極之匯流條。亦可在自該玻璃薄片切割該等電致變色窗板之前或之後執行稱為邊緣刪除之一技術(下文描述)。
自該等切割電致變色窗板製造絕緣玻璃單元(IGU),且視情況強化該IGU之該等窗板之一或多者。在特定實施例中,藉由將玻璃或其他增強基板疊層至該等切割窗板來完成強化。在一特定實施例中,在組裝該IGU之後執行該疊層。
一種製造一或多個電致變色窗板之方法可包含以下操作:(a)在一玻璃薄片上製造一電致變色器件;(b)界定用於切割該玻璃薄片之一切割圖案以便產生一或多個電致變色窗板,可在製造該電致變色器件之後藉由以一或多個實體特徵(特性)來特徵化該玻璃薄片及/或電致變色器件來至少部分界定該切割圖案;及(c)根據該切割圖案切割該玻璃薄片以產生一或多個電致變色窗板。在一實施例中,特徵化該玻璃薄片及/或電致變色器件包含:識別一或多個低缺陷區域;在該玻璃薄片之一或多個邊緣附近刻劃一或多個隔離渠溝;施加一暫時匯流條至該電致變色器件;及啟動該電致變色器件以便評估該電致變色器件之缺陷。識別該EC器件中之缺陷(包含不均勻區域)之其他方法包含施加偏光至該玻璃窗板及類似物。在一實施例中,基於該電致變色器件之一或多個低缺陷區域及/或不均勻區域產生映射資料組且比較該等資料組以便最大化該玻璃薄片之有效使用。
在一些實施例中,電致變色器件利用該等個別電致變色窗板上之所有非穿透匯流條。以此方式,在該等電致變色窗板中可得到多個可觀看區域。改良的電致變色窗板可整合在IGU中且該等窗板之一或多者可含有一強化特徵,諸如玻璃、塑膠或其他適宜材料之一疊層基板。
下文將參考相關聯圖式進一步詳細描述此等及其他特徵及優點。
當考慮圖式時可更完全理解下文詳細描述。
對於窗應用,電致變色窗板牢固的且相對摒除缺陷係重要的。照常規,藉由回火強化玻璃窗板。不幸地,回火製程可引起一電致變色器件中之缺陷。因此,用以產生電致變色窗之大多數努力利用首先按大小切割一玻璃窗板、接著回火該玻璃且最後在經回火窗板上形成該電致變色器件之一製造序列。通常藉由在預先切割且經回火玻璃窗板之一側上沈積一序列薄層而形成該電致變色器件。不幸地,頻繁地切割且接著形成該EC器件之所描述序列引起一些低品質電致變色窗,此係因為現代製造製程通常在一電致變色器件上產生一或多個可視缺陷。當然,製造者可拒絕容忍低品質器件,但低品質窗板之拒絕對應於良率減小。
如本文描述,各種製造方法可改良良率及品質。在此等方法中,最初製造一電子器件以實質上覆蓋一玻璃薄片。稍後係用於該玻璃薄片上界定之多個電致變色窗板之一切割圖案。該切割圖案可考慮各種因素,包含該薄片之實用性、製造之該EC器件中之缺陷、對於EC窗板之特定大小及形狀之經濟要求、該器件及/或玻璃薄片之不均勻性等等。
通常,有問題缺陷發生在該玻璃薄片之僅一非常小或有限區域中。一旦被識別,當界定該切割圖案中之電致變色窗板時可排除此等區域。以此方式,該切割圖案可考量該玻璃薄片之高(或低)缺陷區域。雖然通常期望探測大型玻璃薄片上之EC器件以識別且排除缺陷區域,但有時在不探測該器件情況下可適當排除特定區域。舉例而言,有時觀察到缺陷集中在大型玻璃薄片之周邊。因此有時期望自電致變色窗板之圖案排除周邊區域。在一實例中,在該玻璃上製造該電致變色器件之後移除該玻璃薄片之周邊大約1英寸與大約10英寸之間。在各種實施例中,當然排除此等周邊區域,被排除的周邊區域之精確量係基於一明確界定的產品製造製程之品質控制(QC)之知識。
在界定該切割圖案之後之某點處提供用於該等個別窗板之刻劃及/或匯流條。如提到,在根據該圖案將該玻璃薄片切割成一或多個電致變色窗板之前及/或之後可將此等特徵提供至個別EC窗板。該切割自身可利用改良所得切割窗板之強度之一程序。此外,如下文闡述,該等邊緣可經「完成」以減輕由切割造成的問題。此外,在一些實施例中,IGU由該等切割電致變色窗板製造且視情況強化該IGU之該等窗板之一或多者。下文參考圖式描述本發明之態樣之更多細節。
圖1A描繪一種製程流程100,包含用於製造一或多個電致變色窗板之一序列操作。首先接收一玻璃薄片,參見110。出於本文描述的實施例之目的,意欲在該製程之一稍後階段處將一大型玻璃薄片切割成較小窗板。通常,該等窗板意欲用作為窗,所以基板之實體尺寸以及光學與機械性質應適用於所意圖之窗應用。在一典型實例中,在操作100處使用之大型玻璃薄片係至少一側之長度為大約3米與大約6米之間之一塊玻璃。在一些情況中,該玻璃係矩形,大約3米至6米高且大約1.5米至3米寬。在一特定實施例中,該玻璃薄片係約2米寬及3米高。在一實施例中,該玻璃係6英尺乘10英尺。無論該玻璃薄片之尺寸如何,設計EC窗板製造設備以容納且處理許多此等薄片,在此等薄片上接連依次製造EC器件。
用於該玻璃薄片之適宜玻璃包含浮法玻璃、Gorilla®
玻璃(可自美國密西根州(Michigan)Midland市之Dow Corning公司得到之鹼性鋁矽酸鹽之一商標名稱)及類似物。一般技術者將認識到可在玻璃基板上形成EC器件。本文描述的方法意欲包含除了有機玻璃之外的其他基板,舉例而言,樹脂玻璃在一些例項中亦可適用。出於簡化目的,本文使用「玻璃薄片」來涵蓋所有類型的窗基板,除非另有具體限制。
在一實施例中,該玻璃薄片係視情況塗佈有一透明導電氧化物(TCO)及一擴散阻障層之浮法玻璃。此等玻璃之實例包含由美國俄亥俄州托萊多市(Toledo, Ohio)之Pilkington以商標TEC®
Glass及由美國賓夕法尼亞州匹茲堡市(Pittsburgh, Pennsylvania)之PPG Industries以SUNGATE®
300及SUNGATE®
500出售之塗佈導電層之玻璃。玻璃薄片具有至少等於製造考慮的最大EC玻璃窗板之一大小。TEC®
Glass係塗佈有一含氟氧化錫導電層之一玻璃。此玻璃通常亦具有在該TCO與該浮法玻璃之間的一擴散阻障層以阻止鈉自該玻璃擴散至該TCO。在一實施例中,該玻璃薄片上不具有一預成型TCO或擴散阻障,舉例而言,在一實施例中,該擴散阻障、一第一TCO、一電致變色堆疊及一第二TCO在一受控周遭環境之下(在內)全部形成在一單一裝置中。該玻璃薄片可在其上製造一電致變色(EC)器件之前經熱強化。
接下來在描繪的製程中,在該玻璃薄片上製備一電致變色(EC)器件,參見120。在該玻璃薄片包含一預成型擴散阻障及TCO之情況中,接著該EC器件使用該TCO作為其之導體之一者。在該玻璃薄片係不具有任何預成型塗層之浮法玻璃之情況中,通常120涉及初始沈積一擴散阻障層,接著一透明導體(通常一TCO)層,之後形成該EC器件之剩餘部分。此包含具有一電致變色(EC)層、一反電極(CE)層及一離子導電(IC)層之一EC堆疊。形成該EC堆疊之後,沈積另一透明導體層(通常一TCO層)作為一第二導體(以遞交功率至該EC堆疊)。在此點處,完成該EC器件且操作120結束。亦可施加一或多個包覆層。在一實例中,施加一密封層以使該器件不接觸濕氣。在另一實例中,施加一低-E(發射率)塗層。
如熟習此項技術者理解,存在許多不同類型的電致變色器件,電致變色器件各自具有其自己之建構、電極組合物、電荷載體等等。此等器件之任一者可用在本文描述的該等窗中。描述特定實施例與所有固態及無機電致變色器件有關。此等所有固態及無機電致變色器件及製造其等之方法在以下美國專利申請案中更詳細描述:2009年12月22日申請之題名為「低缺陷電致變色器件之製造」(「Fabrication of Low-Defectivity Electrochromic Devices」)且命名Mark Kozlowski等人為發明者之序號12/645,111;2009年12月22日申請之題名為「電致變色器件」(「Electrochromic Devices」)且命名Zhongchun Wang等人為發明者之序號12/645,159;各自在2010年4月30日申請之序號12/772,055及12/772,075及各自在2010年6月11日申請之序號12/814,277及12/814,279,後四個申請案之每一者題名為「電致變色器件」(「Electrochromic Devices」),每一者命名Zhongchun Wang等人為發明者。以上專利申請案之每一者以引用方式併入本文中用於所有目的。在一實施例中,該電致變色器件係如以上申請案中描述之一低缺陷全部固態及無機電致變色器件。在一實施例中,在具有一受控周遭環境之裝置(即,沈積有該等層之一裝置)中在該玻璃薄片上製造該EC器件,不離開該裝置且(舉例而言)不破壞沈積步驟之間之真空,藉此減小污染且最終器件效能。此製造可包含在該玻璃薄片及包含兩個電極(TCO層)之該EC器件上沈積一擴散阻障。
如提到,可在製造流程中之各個點處內部進行檢驗。舉例而言,可在製程期間檢驗TCO、EC、IC、CE層之一或多者。可利用光學、電、化學或機械檢驗來特徵化該等層之一或多個參數。舉例而言,此等參數包含光學密度、薄片電阻率、厚度、缺陷、形態學及橫跨玻璃基板表面之此等之任一者之均勻性(uniformity)。個別地,可在玻璃薄片表面上製造整個EC器件之後執行一或多個檢驗。如本文其他地方闡述,此檢驗可特徵化該表面上之區域之缺陷及/或該EC器件中之不均勻性。
一般技術者應瞭解除了電致變色器件之外的其他可切換光學器件可用在描述的製程中。許多此等器件形成為一下伏基板上之層。適宜光學器件之實例包含各種液晶器件及包含旋轉元件之電泳器件及懸浮粒子器件。此等之任一者可經製造或設置在一大型玻璃薄片上或接著如本文描述的加以處理。
再次參考圖1A,一旦製備該EC器件,界定一切割圖案,參見130。如闡述,在沈積該電致變色器件之後界定一切割圖案提供判定使用製造的器件之哪些區域及在該等切割窗板中不使用哪些之相當靈活性。亦提供基於該製造的電致變色器件之整體品質判定該等窗板之適當大小之靈活性。當然,存在驅動切割圖案之一系列考慮,且切割圖案之僅一些者與製造的器件之品質或條件有關。總之,界定玻璃薄片上之EC窗板之一圖案使用之特性可包含以下之任一或多者:(1)局部缺陷或局部品質之其他量測(舉例而言,薄片電阻之一局部不均勻性);(2)對於特定產品等級之要求(舉例而言,一些終端使用者指定EC窗板之一特定等級或品質);(3)對於產品之特定大小及形狀之要求;(4)重製要求(由特定類型的EC窗板之破壞及/或低良率製造造成);(5)玻璃薄片及/或個別EC窗板上之EC器件類型之當前存貨;(6)整個玻璃薄片之區域之實用性;及(7)該EC器件之整體性質(舉例而言,EC器件洩漏電流及電極(TCO)電阻率)。一整體性質可指定最終EC窗板之適當大小或等級。舉例而言,高EC器件洩漏電流或高TCO電阻率可指示所得EC窗板必須相對小(舉例而言,不大於約20英寸)。換言之,基於整體性質分格化該等玻璃薄片(各自在其上具有一製造的EC器件)。
在一些實施例中,在該圖案中界定之該等窗板之一或多者經定大小且塑形用於住宅窗應用。在一些情況中,在該圖案中界定之該等窗板之一或多者經定大小且塑形用於商業窗應用。
基於以上考慮,界定一切割圖案用於切割該玻璃薄片以便產生一或多個電致變色窗板可包含:在製造該電致變色器件之後特徵化該玻璃薄片及/或電致變色器件之一或多個實體特徵。在一實施例中,特徵化該一或多個實體特徵包含以下之至少一者:1)識別該電致變色器件上之一或多個低缺陷區域;2)識別該電致變色器件中之一或多個不均勻區域;3)識別用於製作該電致變色器件之材料沈積在該玻璃薄片之背側之一或多個區域;4)識別該電致變色器件之一或多個效能特性;及5)識別該玻璃薄片中之一或多個缺陷。下文更詳細描述識別該電致變色器件中之一或多個低缺陷區域。舉例而言,該EC器件中之不均勻區域係由於該EC器件之諸層之厚度變異、該器件之性質變異(舉例而言,由於在形成該EC堆疊期間之不均勻加熱)等等而著色不均勻之區域。不均勻區域因此可獨立於(舉例而言)短相關光學缺陷之數目。可期望自該切割圖案移除此等區域,或將此等區域包含在該切割圖案中,但識別此等區域作為(舉例而言)將切割EC窗板之一不同品質之區域。而且,取決於製程條件,用於製作該電致變色器件之材料可由於過度噴塗而沈積在該玻璃薄片之背側上。此係不期望的且因此背側沈積之存在係EC器件形成之後該玻璃薄片之一有用特性。可清洗具有背側材料之區域以移除不想要的材料及/或自切割圖案排除此等區域。該電致變色器件之效能特性亦係用於特徵化該EC器件之一重要參數。如上文描述,舉例而言,可以不同方式使用一EC器件,取決於其是否落在一特點規格類別中。識別該玻璃薄片中之一或多個缺陷亦係重要的,舉例而言,不考慮該EC器件之效能,該玻璃薄片中可存在一缺陷,像困在該玻璃中之一氣泡或裂縫,由於其中不期望光學性質可自該切割圖案排除。
在一特定實施例中,藉由首先偵測且映射橫跨該玻璃薄片之該器件之缺陷且接著自該切割圖案中之一或多個電致變色窗板排除或摒棄高缺陷區域來界定該切割圖案(圖1A之操作130)。圖1B提供用於此實施例之一實例製程流程。首先,如方塊131中描繪,刻劃該玻璃薄片之器件以便界定一可用區域,該區域通常係在該玻璃薄片上製備之該器件之實質上整個區域。刻劃可提供兩個目的。首先刻劃電隔離兩個電極以提供一功能器件,其次刻劃明確移除該EC堆疊之缺陷部分。在一些情況中,該玻璃薄片之邊緣區域中沈積的EC薄膜展現滾邊及/或其他缺點,因此出現非常實際的短路問題。為解決此問題,隔離或移除該器件之該等邊緣區域。用於完成此之技術包含刻劃(圖1B中展示)、邊緣刪除或簡單移除該玻璃薄片及一些周邊部分上之相關聯器件。
刻劃之後,施加暫時匯流條,參見132。接著藉由施加電能來啟動該器件以著色或以其它方式改變該器件之光學性質,使得可特徵化該器件且可偵測任何缺陷,參見133。接著特徵化器件,包含識別任何缺陷及視情況根據類型及/或嚴重性分類該等缺陷,參見134。在一些實施例中,該EC器件中之不均勻性也在此階段處予以特徵化且當界定該切割圖案時加以考慮。在一些實施例中,此特徵化包含該玻璃窗板以及該玻璃窗板上之該EC器件。在一些實例中,由裸眼執行識別及/或分類。在其他實例中,由一自動掃描器件執行此操作。在一實施例中,藉由施加電能或光能減輕較大短型視覺缺陷。在一特定實施例中,藉由雷射刻蝕(laser ablation)外切此等缺陷以產生較小針孔類型缺陷。當識別低缺陷區域時,此等減輕的缺陷可包含在缺陷總數中。在另一實施例中,在自該玻璃薄片切割該等窗板之後執行此刻蝕或其他減輕。
應瞭解啟動該EC器件及仔細檢查該器件係偵測且識別缺陷之僅一方式。其他方法包含使用與該EC器件相互作用之各種電磁輻射形式之繞射、反射或折射,舉例而言,偏光及/或鎖定紅外線(IR)熱影像。鎖定IR熱影像係用於電子材料中之小洩漏電流之空間解析偵測之一非破壞性且非接觸技術,其涉及施加一溫度源至該材料(在此情況中該EC器件)及利用(舉例而言)一紅外線相機偵測溫度改變引起的洩漏電流。因此,實施例不僅包含啟動該EC器件以識別缺陷,而且可包含(或在替代中使用)識別缺陷之其他方法。
如所指示,在該玻璃薄片上界定之該切割圖案可排除設置在該玻璃薄片上之該電致變色器件之一或多個高缺陷區域。因此,本文考慮的製造程序頻繁涉及在界定一切割圖案之前識別低或高缺陷區域。在特定實施例中,「低缺陷」區域係具有少於一臨限缺陷數目或密度之該電致變色器件之區域。可以各種方式識別且特徵化缺陷。在特定實施例中,如在美國專利申請案12/645,111及12/645,159中描述識別及/或分類缺陷,該等案先前以引用方式併入。
在特定實施例中,當界定一切割圖案時僅考慮視覺缺陷。視覺缺陷包含當該器件變暗時產生一光暈之短型缺陷。一光暈係該器件中之一區域,在該區域中橫跨該電致變色堆疊之一電短路造成圍繞該短路之一區域汲取電流至該短路中且因此包圍該短路之該區域不變暗。在製造該電致變色器件之後按慣例處理此等短路缺陷,舉例而言,雷射外切以隔離此等短路缺陷且移除光暈效應,其留下較小有關短路的針孔缺陷。在一典型實例中,裸眼可見的缺陷直徑為100微米級數。在一實施例中,對於大於100微米之大小形態之缺陷,可見缺陷、針孔及由隔離可見有關短路的缺陷產生之有關短路的針孔之總數目在一低缺陷區域中係少於大約每平方公分0.1個缺陷,在另一實施例中少於大約每平方公分0.08個缺陷,在另一實施例中少於大約每平方公分0.045個缺陷(電致變色窗板少於大約每平方米450個缺陷)。在一些實施例中,可在較高密度中容忍較小缺陷(舉例而言,對裸眼不可見之缺陷(以40微米或更少之級數))。
映射在該玻璃薄片中偵測且視情況分類之缺陷,參見圖1B之操作135。舉例而言,可藉由標記該玻璃以展示一旦該器件處於非作用中該等缺陷位於之地方及/或藉由將缺陷圖案儲存在一記憶體中作為一映射來完成此。分析此映射資訊以識別一或多個低缺陷區域,自該等區域切割一或多個EC窗板,參見136。描繪的方法之一實施例藉由以下界定該切割圖案:(a)基於該電致變色器件上之一或多個低缺陷區域產生一第一映射資料組;(b)基於一第二玻璃薄片上之一第二電致變色器件上之另外一或多個低缺陷區域產生一第二映射資料組;(c)比較該第一映射資料組與該第二映射資料組;及(d)使用該第一映射資料組與該第二映射資料組之比較來界定該切割圖案以最大化該玻璃薄片之有效使用。舉例而言,可使用該映射來匹配一單一IGU中使用之兩個相容EC薄片使得各別窗板中之缺陷不對齊。在一實施中,該第一映射資料組及該第二映射資料組儲存在一記憶體中且使用一適當演算法或其他邏輯執行(c)及(d)。因此,此等映射資料組及此等映射資料組之比較來界定該玻璃薄片之器件之最有效使用。舉例而言,用於兩個玻璃薄片之映射資料可指示該玻璃之最有效使用可用以切割兩個薄片以適應由於缺陷圖案之不同顧客之規格,若該等缺陷圖案不存在,則根據一單一顧客之規格指定切割該等薄片。此外,該邏輯可界定來自每一玻璃薄片之變化大小之窗板以便供應電致變色窗板用於多種窗類型及終端使用者,舉例而言,藉由窗板大小、缺陷位準及類似物。一旦一或多個低缺陷區域用於界定該切割圖案且製程流程130結束。
圖2A描繪一玻璃薄片200,舉例而言,大約3米乘大約2米或大約120英寸乘72英寸,其上具有一EC器件(圖中未分開展示)。在此實例中,根據製程流程100,界定一切割圖案(由點線指示)用於自玻璃薄片200切割一或多個電致變色窗板。舉例而言,取決於上文描述的缺陷、要求或其他參數,該切割圖案可係規則的(諸如圖案202)或不規則的(諸如圖案204)。舉例而言,圖案204展示集體組成一片玻璃之區域206a及206b,舉例而言,該片玻璃將由於滾邊及/或比該玻璃薄片之剩餘部分更高的缺陷位準而被丟棄。此等周邊區域亦可因為歸因於過度噴塗所致之EC器件材料之背側污染而被移除。自一單一玻璃薄片,該一或多個EC窗板可具有相同大小或取決於需要具有變化的大小。
在一些實施例中,在切割該玻璃薄片之前,可移除該薄片之一些或所有邊緣。在一些實施例中,圍繞該玻璃薄片之周邊之一些或所有移除大約1至10英寸玻璃。可出於各種原因完成此邊緣修整。舉例而言,該EC器件之品質圍繞該玻璃薄片之周邊可係低等的。圍繞該周邊之此低品質可係歸因於該EC器件堆疊之滾邊、該玻璃薄片之邊緣中之缺點(其可干擾該EC器件製造)、此等邊緣缺陷之傳播(例如,裂縫)及陰極尺寸(因為陰極尺寸在沈積期間與該玻璃薄片之尺寸有關)。而且,在歸因於過度噴塗之該玻璃薄片之背側上沈積材料可需要修整該玻璃之邊緣。該EC器件中之不均勻性可歸因於處理該EC器件期間之支撐托板之接觸或該玻璃之邊緣附近之不均勻加熱而發生。在不供電給該EC器件情況下可瞭解此等缺陷之一些者且因此可在測試該器件之前執行邊緣修整。因此可執行邊緣修整理所當然或作為(舉例而言)執行EC形成之測試運行之結果,且發現該等製程參數要求在器件製造之後執行邊緣修整以移除不均勻性及/或背側過度噴塗。
再次參考圖1A,在針對該一或多個EC窗板界定該切割圖案之後,根據待自該玻璃薄片切割之每一個別EC窗板之需要執行刻劃,參見140。下文參考圖3A至圖3C描述用於製造個別EC窗板之刻劃之一更詳細描述。在此製程流程中,在自該玻璃薄片切割該等個別EC窗板之前做出刻劃。此節省需要的時間及資源以便刻劃該等個別窗板,此係因為各種窗板大小考慮為產生於該單一玻璃薄片。在其他實施例中,在將該玻璃薄片切割成個別EC窗板(在內)之後做出刻劃。
在描繪的實例中,在已經在該玻璃薄片上刻劃該等EC器件之後,根據該切割圖案自該玻璃薄片切割該等EC器件,參見150。可藉由任何適宜製程完成該切割。在一些情況中,藉由一邊緣精加工操作完成該切割。機械切割通常涉及利用一硬工具(諸如一輪上之一鑽石尖端)刻痕於該玻璃,隨後沿刻痕線斷裂該玻璃。因此,機械切割包含「刻痕」及折斷。有時術語「刻痕」在玻璃窗製造工業中稱為「刻劃」。然而,為避免與本文描述的其他操作混淆,「刻劃」之使用將專用於此等其他操作。
切割可產生微裂紋及近接該切割之內部應力。此等可引起該玻璃之破碎或折斷(尤其在邊緣附近)。為減輕由切割產生的問題,舉例而言,切割玻璃可經受藉由機械及/或雷射方法之邊緣精加工。機械邊緣精加工通常涉及利用(舉例而言)含有黏土、石頭、鑽石等等之一砂輪之精加工。通常,水在機械邊緣精加工期間流過邊緣。所得邊緣表面相對圓且沒有裂縫。雷射邊緣精加工通常產生一平坦實質上無缺陷表面。舉例而言,穿過該玻璃之一初始切割(垂直於該玻璃之表面)可做出一實質上無缺陷切割。然而,該玻璃之周邊之直角邊緣易受歸因於處置而破壞。在一些實施例中,隨後使用一雷射來切割此等90度邊緣以產生一稍微更圓或多邊形邊緣。
切割及光學邊緣精加工製程之實例包含以下:(1)機械切割;(2)機械切割及機械邊緣精加工;(3)雷射切割;(4)雷射切割及機械邊緣精加工;及(5)雷射切割及雷射邊緣精加工。
在一實施例中,以實際強化及/或改良所得窗板之邊緣品質之一方式自該玻璃薄片切割該等窗板。在一特定實例中,使用藉由張力引起刻痕的雷射來完成此。在此方法中,使用一氣體雷射(舉例而言,具有10.6微米之一波長之一CO2
雷射)沿一切割線加熱該玻璃之表面以沿該切割線在該玻璃中產生一壓縮應力。使用一冷卻器件(舉例而言,一氣體噴射器及/或噴水器)快速冷卻經加熱的切割線。此造成沿該切割線在該玻璃中形成一刻痕。接著舉例而言,藉由一習知機械折斷器件沿該刻痕折斷該玻璃。使用此方法,該等切割線非常工整,即,在該玻璃中存在最小的(若有)缺陷,該等缺陷由於施加至該窗板之應力可傳播且進一步造成斷裂。在一實施例中,隨後機械及/或雷射精加工該等邊緣以移除90度邊緣以產生一較圓及/或多邊形邊緣。
再次參考圖1A,視情況,在該等個別EC窗板上實行邊緣刪除,參見160。邊緣刪除係用於將該電致變色器件整合至(舉例而言)一IGU中之一製造製程之部分,其中在將該器件整合至該IGU或窗中之前移除該EC器件之邊緣部分,舉例而言,滾邊(該器件之層歸因於(舉例而言)一遮罩之邊緣附近之不均勻性而可接觸之處)及/或做出一切割之處。在使用未遮罩玻璃之處,在整合至該IGU之前移除可延伸至IGU框架下方(其對於長期可靠性係不期望的)之塗層。當自該玻璃薄片切割一窗板時亦使用邊緣刪除,此係因為該等窗板將具有延行至該窗板之邊緣之EC材料。在一實施例中,切割隔離渠溝且藉由邊緣刪除移除該等窗板之周邊之該EC器件之被隔離部分。可在描述的之製程流程中形成該EC器件之後之任何階段處執行邊緣刪除。在一些實施例中,執行邊緣刪除之製程係一機械製程(諸如一研磨或噴沙製程)。一磨輪可用於研磨。在一實施例中,舉例而言,藉由雷射完成邊緣刪除,其中使用一雷射刻蝕來自該窗板之周邊之EC材料。該製程可移除包含下伏TCO層之所有EC層或其可移除除了此底部TCO層之外的所有EC層。當使用該邊緣刪除來提供用於一匯流條之一暴露的接觸時,後一情況係適當的,該匯流條必須連接至該底部TCO層。在一些實施例中,使用一雷射刻劃以隔離延伸至該玻璃之邊緣之該底部TCO之部分與連接至該匯流條之部分以便避免自該玻璃之該邊緣至該器件有一導電路徑。
當待使用邊緣刪除時,可在自該玻璃薄片切割該等EC窗板之前或之後完成邊緣刪除。在特定實施例中,可在切割該等EC窗板之前在一些邊緣區域中實行邊緣刪除,且在切割該等EC窗板之後再次實行邊緣刪除。在特定實施例中,在切割該等窗板之前執行所有邊緣刪除。在切割該等窗板之前使用「邊緣刪除」之實施例中,可在預期新近形成的EC窗板之切割(因此邊緣)將在何處中移除該玻璃薄片上之該EC器件之部分。換言之,還不存在實際邊緣,僅存在將作出一切割以產生一邊緣之一界定區域。因此,「邊緣刪除」意指包含移除預期存在一邊緣之區域中之EC器件材料。
再次參考圖1A,在選用之邊緣刪除之後,施加匯流條至該一或多個EC窗板,參見170。如邊緣刪除一樣,可在自該玻璃薄片切割該等EC窗板之後或之前但在刻劃之後執行匯流條之增加。藉由在自該玻璃薄片切割該等窗板之前執行刻劃、邊緣刪除及匯流條施加,避免對於多種EC窗板大小之相關聯特殊處置步驟。即,在自該玻璃薄片切割個別窗板之前執行各種操控及/或組件整合允許使用最大效率使用用於處置均勻大小之該等玻璃薄片之裝置。然而,在一實施例中,根據150切割該玻璃薄片,接著根據160執行邊緣刪除,此後根據140刻劃該等EC器件。在此實施例中,在該等個別EC窗板之邊緣處執行邊緣刪除,接著施加刻劃。在另一實施例中,根據150切割該玻璃薄片,接著根據140刻劃該等EC器件,接著根據160執行邊緣刪除。切割之後之刻劃及刪除之一優點係邊緣刪除製程中之均勻性,此係因為僅移除來自實際切割邊緣之周邊(而不是來自切割之後預期存在一邊緣之區域)之材料。此方法可包含較高品質控制,此係因為該玻璃之邊緣可用作為用於該邊緣刪除之一導引。
在完成具有完全組裝的EC器件之該等窗板之後,使用該一或多個EC窗板製造IGU,參見180。通常,藉由放置密封分離器來形成一IGU,舉例而言,圍繞該玻璃薄片之周邊之一密封墊或密封件(舉例而言,由PVB(聚乙烯醇縮丁醛)、PIB或其他適宜彈性體製成)。在一些實施例中,該密封分離器包含一金屬或其他剛性材料、間隔物及該間隔物與每一玻璃窗板之間之密封劑。在將該等窗板密封至該間隔物之後,一次級密封件經設置圍繞該間隔物之周邊,舉例而言,防水且增加對總成之結構支撐之一聚合材料。通常,但非必要,在組裝期間在IGU框架或間隔物中包含一乾燥劑以吸收任何濕氣。在一實施例中,該密封分離器包圍該等匯流條且電引導該等匯流條延伸穿過該密封件。通常,但非必要,該IGU填充有惰性氣體(諸如氬)。舉例而言,完成的IGU可安裝在一框架或特定牆壁中且連接至一電源及一控制器以操作該電致變色窗。
參考圖2B,根據所得之一切割圖案(舉例而言,如本文描述的)切割玻璃薄片200。在此實例中,產生四個(EC)窗板208。此外,在此實例中,窗板208之兩者配對且與一密封分離器210組合以形成一IGU 212。在此實例中,IGU 212具有兩個EC窗板。通常,但非必要,該等窗板經配置使得EC器件面對該IGU內部以便保護其免受外界干擾。具有兩個或兩個以上電致變色窗板之電致變色窗在2010年8月5日申請之題名為「多窗板電致變色窗」(「Multipane Electrochromic Windows」)之美國專利申請案號12/851,514中予以描述,該案以引用方式併入本文中用於所有目的。本文描述的方法特定用於製造多窗板電致變色窗中使用之一或多個電致變色窗板。此等多窗板電致變色窗之一優點係完全對齊且因此終端使用者可觀察之兩個缺陷之可能性非常小。此優點在使用低缺陷窗板時突出。舉例而言,在一單一窗中使用兩個電致變色窗板之實施例中,可使用上文提到的(缺陷)映射資料組以進一步確保當個別窗板對位(registered)在一IGU中時個別窗板上之缺陷不對齊。此係圖案化該玻璃薄片中可考慮之另一準則。
在特定實施例中,該玻璃薄片達至5毫米或甚至達至6毫米厚(達至1/4英寸)。在一些實施例中,強化一或多個窗板。再次參考圖1A,視情況,強化該IGU之一個或兩個窗板,參見190。舉例而言,在一實施例中,強化包含連同(舉例而言)浮法玻璃之一較厚窗板、強化玻璃之一窗板、一聚合窗板(諸如樹脂玻璃、Gorilla®
Glass)及類似物疊層該IGU之該等窗板之一或多者。在另一實施例中,強化包含施加一聚合塗層至該IGU之一或多個窗板。此等聚合塗層之實例包含有機矽氧烷(ormosil)聚合塗層(環氧樹脂、胺固化劑及矽烷)、溶膠-凝膠塗層、丙烯酸釉及其他安全釉(舉例而言,滿足一或多個衝擊測試標準之商業可用釉)。再次參考圖1A,在強化該IGU之一或多個窗板之後,製程流程100結束。
在一些實施例中,使用一邊緣防撞墊以在併入該IGU中之後保護該玻璃之邊緣。舉例而言,該保護允許該IGU自製造商安全運送至安裝。一保護性邊緣防撞墊可施加至具有或不具有強化窗板之IGU。在一實施例中,該保護性防撞墊係配備在圍繞該IGU之周邊之該玻璃邊緣上之一U通道蓋帽。該保護性防撞墊可由一彈性或塑膠材料製成。在一實例中,該保護性防撞墊係一乙烯基蓋帽。
在併入於一IGU中之後連同一增強基板(或窗板)疊層一EC窗板具有許多優點。舉例而言,在該EC窗板被組裝在一IGU中之後之疊層在疊層製程期間保護該EC器件且提供易於掌控。此在若該EC器件在該IGU之一面向內表面上(即,在該IGU之內部絕緣區域中)尤其真實,此係因為疊層製程涉及在相對嚴酷條件下接觸組成該疊層結構之該等玻璃窗板之外表面。在此等條件下,該EC器件若位於一疊層結構之外表面上可被損壞。因此該IGU在疊層期間保護該器件。若該EC器件位於該IGU上之玻璃之一面向外表面上,該EC窗板之疊層可需要利用該強化窗板及/或用於附接其(該疊層窗板)之黏合劑直接疊層在該EC器件上。雖然可在不損壞該EC器件情況下進行疊層,但此方法具有一些缺點。最明顯地,該IGU可係一較少有效熱絕緣體,此係因為僅阻擋該IGU之內部之輻射。此外,位於該IGU之周邊之該EC器件之暴露邊緣在安裝之後可提供濕氣之一進入點。
許多不同疊層製程可用在揭示的實施例中。實例包含輥壓及高壓蒸汽、真空裝袋及液態樹脂疊層,其等之每一者在窗製造工業中熟知。在一實施例中,使用液態樹脂疊層以在一EC窗板併入於一IGU中之後強化該EC窗板。
圖3A示意性描繪用於一IGU 300之液態樹脂疊層之一製程流程之態樣。在圖3A中,舉例而言,相比於圖2B中描述之IGU 212較不詳細繪製IGU 300。在此實例中,IGU 300具有一EC窗板及一非EC窗板。通常,施加一雙面帶305至該EC窗板之一周邊區域。舉例而言,一間隙315留在該窗板之一角落中之周邊帶中。施加一增強窗板310至該雙面帶,使得形成三窗板(亦參見圖3B,在此實例中,該增強窗板疊層至該IGU之該EC窗板,且亦存在該IGU之非EC窗板,其不是該疊層之部分)結構320。舉例而言,在該EC窗板與增強窗板310之間形成之容積中,自如描繪之底部引入一液態樹脂325。舉例而言,此可藉由當窗板310施加至該帶且與該EC窗板對位(registered)時留下該帶之背面之一小部分來完成。呈一薄刀刃形狀之一施配噴嘴插入在窗板310與具有背面剩餘部分之該帶之部分之間。將該樹脂引入至該容積中且移除該刀刃之後,移除剩餘的帶背面使得該樹脂離開之僅途徑係間隙315。如由彎曲點式粗箭頭所指示,接著旋轉單元320使得該液態樹脂325流向間隙315(如左下圖中由粗點式箭頭向下指示)。將適當樹脂量引入該容積使得當該樹脂覆蓋該等窗板之間及該帶內之整個區域時,該等窗板彼此實質上平行。一旦用樹脂填充該容積,該樹脂固化,舉例而言,經由加熱、一催化劑及/或暴露於UV輻射以在該等窗板之間形成一牢固結合。在最後總成中,如圖3A之右下方中描繪,固化的樹脂具有該疊層之期望光學、機械及其他性質。使用液態樹脂在疊層期間賦予該EC窗板最小應力(若有)。
圖3B係展示最後總成320之更多細節之一橫截面。IGU部分300包含一第一窗板301及一EC窗板302,該EC窗板302在其上包含一EC器件303。窗板301及302藉由一密封分離器304而分離,該密封分離器304橫跨該等窗板之周邊且具有其與每一窗板之間之密封件。由該等窗板及該密封分離器界定一內部空間330。帶305位於該IGU之內部空間外部之該EC窗板之表面(且近接其周邊)與窗板310之間。在該EC窗板與窗板310之間產生之容積內部係該固化樹脂325。
因為基於樹脂的疊層依賴於夾在待疊層之兩個玻璃窗板之間之一樹脂薄片或薄膜,所以樹脂類型之選擇可賦予一光學特性至該窗單元。在特定實施例中,該樹脂可含有賦予一期望光學性質至所得疊層之添加劑。此等光學性質之實例包含顏色、不透明度、散射及反射性。在一特定實例中,該樹脂賦予一藍色。此當與具有一自然微黃色染色劑之一些EC器件使用時尤其有利。可藉由在引入疊層之容積中之前將染料、顏料、散射顆粒、金屬粉屑等等加至該液態樹脂來賦予該光學性質。在特定實施例中,由於在該樹脂被引入該等窗板之間之該容積之後發生之一化學反應之一結果而實現該藍色。舉例而言,可藉由催化該樹脂之固化之相同能量或試劑來催化該反應。在另一實施例中,舉例而言,藉由暴露於正常周圍照明及/或特定輻射及/或加熱後固化,該樹脂在固化之後改變至一藍色。
參考圖4A至圖4C描述電致變色窗板之特定實例。圖4A係用一玻璃薄片405開始製造之一電致變色窗板400之一橫截面圖,舉例而言,如製程流程100中概述。圖4B展示EC窗板400之另一側之橫截面圖,且圖4C展示EC窗板400之一俯視圖(圖4A係如圖4C中描繪之右側或左側之圖,且圖4B係如圖4C中描繪自底側向上看之圖)。圖4A展示已自該玻璃薄片切割、邊緣刪除、雷射刻劃且已附接匯流條之後之個別電致變色窗板。該玻璃窗板405具有一擴散阻障410及在該擴散阻障上之一第一透明導電氧化物(TCO)415。該TCO層415係用於形成在該玻璃薄片上製造之該電致變色器件之電極之兩個導電層之第一者。在此實例中,該玻璃薄片包含下伏玻璃及該擴散阻障層。因此,在此實例中,形成該擴散阻障,接著該第一TCO,接著該EC堆疊,接著第二TCO。在一實施例中,在一整合沈積系統中製造該電致變色器件(EC堆疊及第二TCO),其中在製造該堆疊期間之任何時間該玻璃薄片不離開該整合沈積系統。在一實施例中,亦使用該整合沈積系統來形成該第一TCO層,其中在沈積該EC堆疊及該(第二)TCO層期間該玻璃薄片不離開該整合沈積系統。在一實施例中,在該整合沈積系統中沈積該等層(擴散阻障、第一TCO、EC堆疊及第二TCO)之所有者,其中在沈積期間該玻璃薄片不離開該整合沈積系統。
形成該EC器件之後,執行邊緣刪除及雷射刻劃。圖4A描繪在此實例中已自包圍雷射刻劃渠溝430、431、432及433之一周邊區域移除該器件之區域440,該等雷射刻劃渠溝通過該第二TCO及該EC堆疊(但不通過該第一TCO),製成雷射刻劃渠溝以隔離該EC器件之部分435、436、437及438,在自可操作EC器件之邊緣刪除期間潛在損壞該等部分。在一實施例中,雷射刻劃430、432及433通過該第一TCO以有助於隔離該器件(雷射刻劃431不通過該第一TCO,否則其切斷與該第一TCO及該EC堆疊之匯流條2之電連通)。用於該等雷射刻劃之雷射通常(但非必要)係脈衝類型雷射(舉例而言,二極體泵固態雷射)。舉例而言,可使用來自(美國麻薩諸賽州牛津市(Oxford Massachusetts)之)IPG Photonics或來自(立陶宛維爾紐斯(Vilnius Lithuania)之)Ekspla之一適宜雷射執行該等雷射刻劃。舉例而言,亦可藉由一鑽石尖端刻劃機械執行刻劃。一般技術者應瞭解,可在不同深度處執行該等雷射刻劃及/或在一單一製程中執行該等雷射刻劃,藉此在圍繞該EC器件之周邊之一連續路徑期間改變雷射切割長度。在一實施例中,執行邊緣刪除至該第一TCO下方之深度。在另一實施例中,舉例而言,如圖4A至圖4C中描繪,執行一第二雷射刻劃以隔離該玻璃窗板之邊緣附近之該第一TCO之一部分與面向內部之部分。在一實例中,此刻劃至少沿施加匯流條2至該第一TCO之邊緣,該第一TCO在匯流條2與該邊緣之間。
完成雷射刻劃之後,附接匯流條。施加非穿透匯流條(1)至該第二TCO。施加非穿透匯流條(2)至與該第一TCO接觸之未沈積該器件之一區域(舉例而言,自保護該第一TCO免受器件沈積之一遮罩),或在此實例中,用於移除材料向下至該第一TCO之一區域。在此實例中,匯流條1與匯流條2兩者係非穿透匯流條。一穿透匯流條通常被壓至該EC堆疊中且穿過該EC堆疊以與該堆疊之底部處之該TCO接觸。一非穿透匯流條不穿透該等EC堆疊層,而在一導電層(舉例而言,一TCO)之表面上做出電及實體接觸。
可使用一非傳統匯流條(舉例而言,絲網及微影圖案化方法)電連接該等TCO層。在一實施例中,經由絲網(或使用另一圖案化方法)一導電墨水(之後熱固化或燒結該墨水)利用該器件之透明導電層來建立電連通。使用上文描述的器件組態之優點包括較簡單製造(舉例而言,比使用穿透匯流條之習知技術更少的雷射刻劃),且事實上該EC器件著色匯流條1且在匯流條1之下(不像當匯流條1係一穿透類型匯流條時,切割穿過該器件之一隔離渠溝之習知方法一樣),其提供一較大著色區域。舉例而言,可使用穿透匯流條取代非穿透匯流條1,但此將犧牲著色區域且在該玻璃上製造該EC堆疊之前需要穿過該第一TCO之一刻劃。一實施例考慮在該玻璃薄片上製造該EC器件之前對該玻璃薄片上執行此第一刻劃以用於一或多個EC器件。在此等實施例中,舉例而言,如參考圖1A及圖1B描述,方法流程之剩餘部分保持相似。
如上文描述,連接該等匯流條之後,將該器件整合至一IGU中,舉例而言,其包含佈線該等匯流條及類似物。在一些實施例中,該等匯流條之一者或兩者在完成的IGU內部,然而在一實施例中,一匯流條在該IGU之密封件外部且一匯流條在該IGU內部。圖5A描繪整合至一IGU 500中如參考圖4A至圖4C描述之該EC窗板之一橫截面。使用一間隔物505以分離EC窗板400與另一窗板510。該第二窗板510在此實例中係一非EC窗板,然而,本發明並不限於此。窗板510可具有在其上之一EC器件及/或一或多個塗層(諸如低E塗層及類似物)。在此實例中,間隔物505與EC器件400之該第一TCO之間係一初級密封件515。此密封件亦在分離器505與該第二玻璃窗板之間。圍繞分離器505之周邊係一次級密封件520(匯流條佈線橫穿該密封件用於連接至控制器)。此等密封件有助於使濕氣不進入該IGU之內部空間515。
圖5B描繪疊層一增強窗板530之後之IGU 500。在此實例中,使用一液態樹脂疊層,因此,固化樹脂535位於該增強窗板與該EC窗板之玻璃之間。雖然圖中未描繪,但一般技術者應瞭解若玻璃2在其上亦具有一EC器件,則亦可疊層其。一實施例係包含藉由一內部空間分離之兩個EC窗板之一IGU,在一實例中,兩個EC器件在該IGU之該內部空間中,其中增強兩個EC窗板。在一實施例中,利用如本文描述之液態樹脂疊層增強該等EC窗板。在其他實施例中,藉由施加如本文描述之一塗層來增強或強化該等EC窗板之一者或兩者。
雖然已詳細描述先前發明以有利於理解,但描述的實施例應看作說明性且非限制性。一般技術者將瞭解可在隨附申請專利範圍之範圍內實踐特定改變及修改。
200:玻璃薄片
202:圖案
204:圖案
206a:區域
206b:區域
208:窗板
210:密封分離器
212:絕緣玻璃單元(IGU)
300:IGU
301:第一窗板
302:EC窗板
303:EC器件
304:密封分離器
305:雙面帶/帶
310:窗板
315:間隙
320:三窗板結構/旋轉單元/最後總成
325:液態樹脂
400:電致變色窗板
405:玻璃薄片
410:擴散阻障
415:透明導電氧化物(TCO)/TCO層
430:雷射刻劃渠溝
431:雷射刻劃渠溝
432:雷射刻劃渠溝
433:雷射刻劃渠溝
435:EC器件之部分
436:EC器件之部分
437:EC器件之部分
438:EC器件之部分
440:區域
500:IGU
505:間隔物
510:窗板
515:初級密封件/內部空間
520:次級密封件
530:增強窗板
535:固化樹脂
圖1A至圖1B描繪描述本發明之製造方法之態樣之製程流程。
圖2A至圖2B係描繪本發明之製造方法之態樣之示意圖。
圖3A描繪一強化薄片至一IGU之液態樹脂疊層。
圖3B描繪關於圖3A描述之疊層的IGU之一橫截面。
圖4A至圖4B係描繪一電致變色器件之兩個側視圖之一橫截面圖。
圖4C係描繪關於圖4A至圖4B描述之電致變色器件之示意性俯視圖。
圖5A係展示整合至一IGU中參考圖4A至圖4C描述之器件之一橫截面圖。
圖5B係展示圖5A中之IGU之一橫截面圖,其中藉由疊層來強化EC窗板。
400:電致變色窗板
430:雷射刻劃渠溝
431:雷射刻劃渠溝
432:雷射刻劃渠溝
433:雷射刻劃渠溝
435:電致變色(EC)器件之部分
436:EC器件之部分
437:EC器件之部分
438:EC器件之部分
440:區域
Claims (19)
- 一種絕緣玻璃單元,其包括: 一第一窗板,其具有一疊層(laminate),該疊層包括具有一電致變色器件安置於其上之一基板及與一疊層層(lamination layer)一起疊層(laminated)之一增強基板,其中該疊層層經組態以修改該絕緣玻璃單元之至少一光學性質; 一第二窗板; 一間隔物,其在該第一窗板及該第二窗板之間;及 一初級密封件,其用於將該第一窗板結合至該間隔物且將該第二窗板結合至該間隔物。
- 如請求項1之絕緣玻璃單元,其中該至少一光學性質包括顏色、不透明度、散射及反射性之一者。
- 如請求項1之絕緣玻璃單元,其中該疊層層經組態以修改該絕緣玻璃單元之顏色以賦予一藍色。
- 如請求項1之絕緣玻璃單元,其中該疊層層包括一補償(compensating)光學性質。
- 如請求項1之絕緣玻璃單元,其中該疊層層包括一樹脂。
- 如請求項5之絕緣玻璃單元,其中該樹脂包括一染料、一顏料、一散射顆粒、及金屬粉屑之一或多者。
- 如請求項5之絕緣玻璃單元,其中該樹脂在固化之前為一液態樹脂。
- 如請求項7之絕緣玻璃單元,其中該液態樹脂藉由加熱、一催化劑及/或暴露於紫外線輻射而固化。
- 如請求項1之絕緣玻璃單元,其中該基板具有一電致變色器件安置於其上且該增強基板藉由輥壓(roll pressing)及高壓蒸汽(autoclaving)、真空裝袋及液態樹脂疊層之至少一者而一起疊層。
- 如請求項1之絕緣玻璃單元,其中該增強基板經直接疊層至該電致變色器件。
- 如請求項1之絕緣玻璃單元,其中具有一電致變色器件安置於其上之該基板為退火(annealed)玻璃。
- 如請求項11之絕緣玻璃單元,其中該增強基板為強化(tempered)玻璃。
- 如請求項1之絕緣玻璃單元,其中該增強基板比具有該電致變色器件於其上之該基板厚。
- 如請求項1之絕緣玻璃單元,其中該增強基板包括浮法玻璃、強化玻璃及一聚合材料之一者。
- 如請求項14之絕緣玻璃單元,其中該聚合材料為樹脂玻璃(plexiglass)。
- 如請求項1之絕緣玻璃單元,其中該電致變色器件安置於在該第一窗板及該第二窗板之間之一內部容積之一面向內之表面上。
- 如請求項1之絕緣玻璃單元,其中該電致變色器件為全部固態且無機。
- 如請求項1之絕緣玻璃單元,其進一步包含安置於該電致變色器件之電極上之匯流條。
- 如請求項1之絕緣玻璃單元,其進一步包含安置於該疊層之該增強基板上之另一電致變色器件。
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