TWI520842B - 電子式變色窗口及其製造方法與裝置 - Google Patents

電子式變色窗口及其製造方法與裝置 Download PDF

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TWI520842B
TWI520842B TW098141923A TW98141923A TWI520842B TW I520842 B TWI520842 B TW I520842B TW 098141923 A TW098141923 A TW 098141923A TW 98141923 A TW98141923 A TW 98141923A TW I520842 B TWI520842 B TW I520842B
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glass
parts
electronic color
changing
window glass
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郭炳松
哈斯戴特爾
班傑史帝芬
克里希那奈提Ｍ
霍夫曼溫費德
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應用材料股份有限公司
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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
    • 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
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • 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
    • B32B17/10009—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
    • B32B17/10045—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 with at least one intermediate layer consisting of a glass sheet
    • 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
    • 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
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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
    • B32B17/10045—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 with at least one intermediate layer consisting of a glass sheet
    • B32B17/10055—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 with at least one intermediate layer consisting of a glass sheet with at least one intermediate air space
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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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    • B32B17/10005—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
    • B32B17/10165—Functional features of the laminated safety glass or glazing
    • B32B17/10431—Specific parts for the modulation of light incorporated into the laminated safety glass or glazing
    • B32B17/10467—Variable transmission
    • B32B17/10495—Variable transmission optoelectronic, i.e. optical valve
    • B32B17/10513—Electrochromic layer
    • 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
    • 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
    • B32B17/1055—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
    • B32B17/10761—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 vinyl acetal
    • 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
    • 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
    • B32B17/1055—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
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S359/00—Optical: systems and elements
    • 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
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/12—Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing

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  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Civil Engineering (AREA)
  • Nonlinear Science (AREA)
  • Architecture (AREA)
  • 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)

Description

電子式變色窗口及其製造方法與裝置
本發明一般關於電子式變色窗口，且特別是用於適應多種窗口尺寸及功能並同時維持高良率、高產量及低成本之電子式變色窗口的改良製造方法。
智慧型窗口為結合具有可控制光及熱穿透性質之元件的玻璃單元(glazing unit)。該元件一般為直接沈積於玻璃表面上或層疊於玻璃表面上之層的形式。整合此智慧型窗口至建築物中可藉由調整窗口之光與熱性質而提供控制內部亮度及溫度的機會。電致變色元件、懸浮粒子元件(SPDs)及高分子分散液晶(PDLC)元件皆為可結合至智慧型窗口之實例；在這些特定元件中之光穿透率皆可以電子式控制，且結合這些元件之智慧型窗口亦如所知為電子式變色窗口。
電致變色元件目前廣泛結合於各種產品當中，包括智慧型窗口、後視鏡、及用於博物館展示的保護玻璃。電致變色元件為回應所施加橫過元件之電壓而可改變光(及熱)穿透率性質之元件。電致變色元件可製造為在透明及半透明態(其中穿透光為有色的)間電切換之元件。進一步的說，可製造一些過渡金屬氫化物電致變色元件為介於透明與反射態間切換的元件。電致變色元件之功能的更詳細討論在Granqvist,C.-G.,Nature Materials,v5,n2,2006年2月，第89-90頁中可找到。電致變色元件為目前在智慧型窗口使用中最具希望的電子式變色元件。
SPDs及PDLC元件已結合於智慧型窗口中。SPDs為具有一含有一些微觀粒子懸浮液之薄膜且於薄膜兩側含有透明電極的元件。粒子為隨機定向且降低膜的穿透率。然而，當橫過膜施加電場時，粒子會與電場對齊，而增加膜之光穿透率。PDLCs包含夾在薄塑膠膜上之透明導體液晶層之間的液晶層。液晶粒子隨機定向於層中且散射光(層為半透明)。然而，當橫過液晶層施加電場時，晶體經對齊以提供光學透明薄膜。藉由施加橫過液晶層之電壓以控制透明度。
當電致變色元件結合至智慧型窗口中時，需要對電致變色元件具有至少十年保證生命週期，較佳為三十年或更多。然而，電致變色元件暴露至大氣中之氧及水可降級裝置之效能及降低裝置之生命週期。在絕緣玻璃單元(IGU)之內表面併入電致變色元件可在30年或更多年間提供對滿意效能所需之保護環境。SPD及PDLC元件亦自藉由IGU提供之環境保護而得到益處。
智慧型窗口一般為IGU形式。包括電子式變色元件220之IGU100圖示於第1至3圖中。控制器及電源供應器190藉由電引線195附加至電子式變色元件220。第3圖示出IGU之截面圖(非按原尺寸)，其包含兩片玻璃210及330，其藉由框架340沿著四個邊緣分隔開及藉由密封層350沿著四個邊緣密封在一起。內部體積380填充例如氬之惰性氣體，以提供熱隔離及非氧化環境。當一電子式變色元件220結合至IGU中，電子式變色元件220在玻璃210(朝向戶外部零件)之外部零件上製造及定位於其朝內表面上。參看第2圖，其為該玻璃210之外部零件之內表面的俯視圖。在IGU內之惰性環境不會影響電子式變色元件220之效能。
在IGU中的玻璃210之外部零件可為變色、疊層、強化(tempered)、熱硬化(heat-strengthened)等之玻璃。當電致變色元件220以上述方式結合至IGU中時，玻璃210之外部零件將經受熱應力。進一步來說，若玻璃210之外部零件也變色，此舉將增加玻璃中的熱應力。因而時常指定或需要強化或熱硬化玻璃。
目前製造包括電子式變色元件之智慧型窗口的基本哲學為結合所有玻璃功能-可變色元件、色彩/變色、厚度、強度、尺寸等至單片玻璃裡。然而，此哲學導向不具彈性且昂貴的製造程序(整合功能具有限制範圍)，其為不同功能之矛盾製造需求的結果。例如，考慮對於具有強化玻璃及電子式變色電致變色元件之智慧型窗口的製造程序所具有的問題，其中想要一範圍的窗口尺寸。(強化玻璃及電致變色元件)此兩種特徵結構的製程需求是與包括玻璃裁切之整合製程不相容的。此因在玻璃已強化後無法將其切割而製為不同尺寸零件，且若電致變色元件在強化前已沉積於玻璃上，隨後電致變色元件無法承受強化玻璃所需之製程。因此，須在沉積電致變色元件層之前切割及強化玻璃。此導致對於為控制多種玻璃片尺寸之製造設備的需求，其導致昂貴的製造設備及製程。進一步的說，控制多種不同基板尺寸在產率上可具有不良影響。例如，玻璃片之不同尺寸在沉積腔室中將呈現不同電場分布，其可不良地影響沉積層之均勻性。(這在涉及離子物種(例如，電漿增強製程)之沉積製程中是顯著的。)。另一實例為結合不同玻璃厚度的電致變色元件之沉積。對大多數典型薄膜沉積製程而言，當沉積電致變色元件之層時，想要控制基板溫度；然而不同厚度之玻璃將以不同速率加熱及冷卻，對較厚玻璃導向較低的產量及在控制製程均勻性中的困難度。明確地說，存有一種對於智慧型窗口之製造程序的需要，其中該製造程序具有彈性且與低成本、高產率及高產量製造相容。
本發明實施例基於下列概念：(1)將不同玻璃功能分離至一些玻璃零件中，及(2)開發玻璃層疊技術以結合玻璃零件而提供具有增強功能的整合玻璃產品。當想要不同功能而導向不相容的製程需求及/或折衷的效能時，此方法特別有價值。提供一種製造電子式變色窗口玻璃之方法，其輕易地容許廣泛種類的窗口尺寸及功能。此方法包括個別地製造電子式變色元件和窗口玻璃，且最終將電子式變色元件層疊至窗口玻璃。當製造電子式變色元件時，此方法允許更大得多的製程彈性，並提供窗口玻璃之規格的更大彈性。此等概念及方法允許成本效益、高產率及高產量之電子式變色窗口的製造。用此文所敘述之方法製造的電子式變色窗口玻璃可結合入IGUs中，及其他類型建築玻璃中。
本發明之實施例之方法允許在標準尺寸及厚度之基板上製造的電子式變色元件(所有薄膜製程在單一尺寸玻璃基板上完成)。此舉提供穩定生產環境，其適於具有良好製程控制、高產量及高效能的大量製造。只有在個別電子式變色元件自基板切割時，存有控制不同尺寸基板的需要。
根據本發明之態樣，製造具有多種尺寸及功能之電子式變色窗口玻璃的方法包含：(a)提供一大規格玻璃基板；(b)在大規格玻璃基板上製造複數電子式變色薄膜元件；(c)將大規模玻璃基板切割成複數電子式變色零件，各電子式變色零件包括複數電子式變色薄膜元件中之一者；(d)提供複數窗口玻璃零件；(e)將複數電子式變色零件中之各者與對應之複數窗口玻璃零件中之一者匹配；及(f)層疊各匹配電子式變色元件及窗口玻璃零件。層疊可導致電子式變色元件夾在玻璃基板及窗口玻璃零件中或在層疊零件之表面上。電子式變色元件可為電致變色元件；然而，電子式變色元件可為SPD、PDLC元件或氣致變色(gasochromic)元件。電子式變色元件通常為薄膜元件且可使用所需之以下製程製造：機器人控制基板；在真空中處理；電漿處理；及/或加熱基板。玻璃零件可經由熱處理、強化、變色、層疊、高強度等且可自多種不同尺寸及厚度中選擇。
進一步而言，本發明實施例之製造方法包含在生產線(其中使用標準大規格玻璃基板)上製造電子式變色元件的概念，而不論最終電子式變色元件之尺寸。因此，本發明之進一步態樣包括製造具有多種尺寸及功能的電子式變色窗口，其包含：(a)提供多個相同大規格玻璃基板；(b)在多個大規格玻璃基板上製造複數電子式變色薄膜元件；(c)將多個大規格玻璃基板切割成複數電子式變色零件，各電子式變色零件包括複數電子式變色薄膜元件中之一者；(d)提供複數窗口玻璃零件；(e)將複數電子式變色零件中之各者與對應之複數窗口玻璃零件中一者匹配；及(f)層疊各匹配電子式變色零件及窗口玻璃零件。
根據本發明又另一態樣，電子式變色窗口包含：一片窗口玻璃；一玻璃基板；形成於該玻璃基板上之一電致變色薄膜元件；及介於電致變色薄膜與窗口玻璃間之層疊層，該層疊層將該電致變色薄膜元件附著至該窗口玻璃。該層疊層可包括諸如聚乙烯丁醛(PVB)及乙烯乙酸乙烯酯(EVA)之接合劑。
根據本發明之進一步態樣，一種用於形成具有多種尺寸及功能之電子式變色窗口玻璃的裝置，其包含：一第一系統，用以在大規格玻璃基板上製造複數電子式變色薄膜元件；一第二系統，用以將大規格玻璃基板切割成複數電子式變色零件，各電子式變色元件包括複數電子式變色薄膜元件中之一者；及一第三系統，用以層疊匹配電子式變色零件及窗口玻璃零件，其中複數電子式變色零件中之各者與對應之複數窗口玻璃零件匹配。此裝置可進一步包含一第四系統，用以自各層疊零件建立IGUs。
本發明現參照圖式詳細地描述，其提供本發明之範例實施例以使彼等熟悉此技術領域者可實施本發明。須注意的是，以下之圖式及範例並非將本發明之範疇限制為單一實施例，但可藉由交換一些或全部所描述或例示之元件的方式使其他實施例為可能。再者，本發明之特定實施例可部分或完全地實施於習知部件中，該習知部件之彼等部分只有對本發明之理解為必須者將被描述，該習知部件之其他部分的詳細描述將被省略以免混淆本發明。在本發明說明書中，示出單一部件之一實施例不應視為其限制；更確切地說，本發明意欲涵蓋包括複數相同部件之其他實施例，且反之亦然，除非此文中另有明確說明。再者，申請人不意欲將本說明書中的任何術語認為是不一般的或特別意義，除非此文中另有明確闡述。進一步而言，本發明藉由參照本文所述之例示方法的習知部件而涵蓋現今及未來的習知等效物。
一般而言，本發明實施例基於以下概念：(1)將不同玻璃功能分離至一些玻璃零件中，及(2)開發玻璃層疊技術以結合玻璃零件而提供具有增強功能的整合玻璃產品。本文提供之範例關於具有不同功能之兩個玻璃零件的層疊；然而，此概念可應用於具有不同功能之三或多個玻璃零件的層疊。
本發明實施例慮及製造電子式變色窗口之替代方法，其中該電子式變色元件和窗口玻璃係個別製造，且隨後該窗口玻璃經層疊至該電子式變色元件上。此方法允許對製造電子式變色元件在製程情況之選擇中之彈性，在窗口玻璃之功能選擇的彈性、及窗口尺寸的寬廣選擇。此等概念及方法允許對於結合入建築玻璃(如IGUs)之電子式變色窗口的成本效益製造。提供關於薄膜電致變色電子式變色元件的詳細描述範例；然而，此概念可應用於其他電子式變色元件，包括SPDs及PDLC元件。
第4圖圖示電子式變色窗口玻璃(非按照尺寸)，其根據本發明實施例製造，結合入一IGU(如第1圖之IGU)。電子式變色元件420位在玻璃基板460上。具有電子式變色元件420之玻璃基板460經層疊至玻璃410(本文中稱為窗口玻璃)之外部零件。電子式變色元件420在層疊結構中遠離玻璃410之外部零件。層疊層470可包括聚乙烯丁醛(PVB)及乙烯乙酸乙烯酯(EVA)之接合劑。層疊製程較佳地為真空層疊製程，其中玻璃410之外部零件及電子式變色元件420的堆疊(其間具有接合劑於其中)，被放置於一真空袋中，該真空袋被抽空以在堆疊上施加均勻壓力，且隨後此袋被放置於一高溫及高壓熔爐中或一壓力鍋中。製程溫度及壓力將取決於電子式變色元件之類型。對於電致變色元件，溫度範圍通常自125℃至175℃。儘管溫度範圍通常將仍居中於接近150℃處，溫度範圍可更廣。壓力可高達20bar(且可能更高)，如所需，典型壓力可接近13bar。控制此壓力以避免在層疊期間損害電子式變色元件。真空袋之使用僅為用於提供均勻壓力而不損害電子式變色元件420之方法的一實例。可使用其他方法提供壓力及溫度，其可經施加而不損害電子式變色元件420。
第5圖圖示第4圖之替代配置。第5圖中，電子式變色元件在層疊結構中朝向玻璃410的外部零件-電子式變色元件420與層疊層470接觸。在此實施例中，層疊製程可為以上所述之真空層疊製程，或堆疊可在中間溫度輾捲(roll)且隨後為了最終層疊而放置於一高溫及高壓熔爐或一壓力鍋中。(在中間溫度輾捲而非在較高溫度是預期在元件上提供一更均勻壓力且因此在附著強度及實體外觀方面有較好的層疊品質。)
當電子式變色元件為電致變色元件時，須考量元件免於外界氧化物的保護，如以上所述。此保護可藉由結合至IGU中提供。另外，或此外，可如Kwak等人於美國專利申請號12/134,437中所述而提供一封裝層(未圖示)。此封裝層對不想要的氧化物扮演一擴散阻障層。
第6圖圖示根據本發明實施例之用於製造電子式變色窗口玻璃之流程圖。此方法包含：提供一大規格玻璃基板(610)；在大規格玻璃基板上製造複數電子式變色薄膜元件(620)；將大規模玻璃基板切割成複數電子式變色零件，各電子式變色零件包括複數電子式變色薄膜元件中之一者(630)；提供複數窗口玻璃零件，其可具有不同尺寸及具有不同性質(640)；將複數電子式變色零件中之各者與對應之複數窗口玻璃零件中之一者匹配(650)；層疊各匹配電子式變色元件及窗口玻璃零件(660)；及(選擇性)製造複數絕緣玻璃單元(IGUs)，其可具有不同尺寸及功能。
電子式變色元件為諸如電致變色元件之薄膜元件，且可使用以下所需製程來製造：以機器人控制基板；在真空中處理；電漿處理；及/或加熱基板。更多薄膜電致變色元件的細節及用於此等元件的製造方法可在Kwak等人之美國專利申請號12/134,437中找到。相關薄膜沉積製程的一些實例包括如物理氣相沉積(PVD)、化學氣相沉積(CVD)及電漿增強沉積技術的真空沉積技術。在薄膜沉積期間，希望加熱基板。窗口玻璃零件可受熱處理、強化、變色、層疊、高強度等且可自多種不同尺寸及厚度中選擇。既然電子式變色元件之製造可在個別的基板上完成，在元件的製造上及窗口玻璃零件的規格上可有較大的彈性。例如，在窗口玻璃零件的製備中，玻璃片可切割成想要的尺寸且隨後經強化。多個電子式變色元件可在大玻璃基板上有效地製造且隨後可自該片切割出個別元件。可隨後層疊強化零件及元件以形成電子式變色窗口，適於整合至IGU。
電子式變色零件可全為同一尺寸，或可為不同尺寸。參看第6圖中的製程630。換言之，具有電子式變色元件的玻璃基板可切割成複數相同尺寸零件，或切割成複數不同尺寸零件，取決於在基板上已製造之電子式變色元件。可提供對應於電子式變色零件之尺寸的窗口玻璃零件之尺寸，所有皆根據電子式變色窗口玻璃的規格。參看第6圖中的製程640及650。一般而言，電子式變色零件將小於或相等於窗口玻璃零件，如第2-5圖中所示。(在第4圖中圖示之元件的替代實施例，玻璃基板460為與窗口玻璃零件410相同的尺寸，且框架340坐落於玻璃基板460之表面上。雖然電子式變色元件420仍應較小於窗口玻璃零件410，以便嵌入框架340與密封劑350中。)
再者，根據本發明實施例，第6圖中的流程圖可延伸用於電子式變色窗口的製造程序，其中處理多種相同大規格基板。因此，一種製造具有多種尺寸及功能之電子式變色窗口玻璃的方法係包含：提供多個相同大規格玻璃基板；在多個大規格玻璃基板上製造複數電子式變色薄膜元件；將多個大規格玻璃基板切割成複數電子式變色零件，各電子式變色零件包括複數電子式變色薄膜元件中之一者；提供複數窗口玻璃零件；將複數電子式變色零件中之各者與對應之複數窗口玻璃零件中一者匹配；層疊各匹配電子式變色零件及窗口玻璃零件；及(選擇性)製造複數絕緣玻璃單元(IGUs)，其可具有不同尺寸及功能。此製造程序同時包括多個相同基板之串列處理，及其中處理允許之多個相同基板的平行處理。
第7圖為根據本發明一些實施例之用於製造具有多種尺寸及功能之電子式變色窗口玻璃之裝置及IGUs的示意圖。可使用第7圖之裝置(例如)根據第6圖之流程圖來製造IGUs。第7圖之裝置包含四個系統。第一系統720在大規格玻璃基板上製造複數電子式變色薄膜元件。第二系統730將大規格玻璃基板切割成複數電子式變色零件，各電子式變色零件包括複數電子式變色薄膜零件。第三系統730層疊經匹配的電子式變色零件及窗口玻璃零件，其中複數電子式變色零件之各者與對應之複數窗口玻璃零件中之一者匹配。第四系統770自各層疊零件建立IGUs。在第7圖中的虛線指示(在線上方)控制大規格、標準尺寸、玻璃之裝置，及(在線下方)控制具有多種不同尺寸的較小玻璃零件之裝置。
本發明之製造方法亦可應用於使用懸浮粒子元件(SPDs)、高分子分散液晶(PDLC)元件及氣致變色元件來控制光穿透度之IGUs。
雖然本發明已參照其實施例詳細地描述，在不背離此發明之精神及範疇下，形式及細節中的變化及修飾對彼等熟習此技藝者為顯而易見。隨附之申請專利範圍將涵蓋此變化及修飾。本發明由以下申請專利範圍所界定。
100．．．IGU
190．．．控制器及電源供應器
195．．．電引線
210．．．玻璃
220．．．電子式變色元件
330．．．玻璃
340．．．框架
350．．．密封劑
380．．．內部體積
410．．．窗口玻璃零件
420．．．電子式變色元件
460．．．玻璃基板
470．．．層疊層
610．．．提供大規格玻璃基板
620．．．在玻璃基板上製造電子式變色薄膜元件
630．．．將玻璃基板切割成分離的電子式變色零件
640．．．提供多種尺寸及具有不同性質的窗口玻璃零件
650．．．將電子式變色零件與窗口玻璃零件匹配
660．．．將電子式變色零件層疊至匹配玻璃零件
670．．．製造具有不同尺寸及功能IGUs
720．．．薄膜元件製造系統
730．．．玻璃切割工具
760．．．層疊工具
770．．．IGU製造系統
本發明之此等及其他態樣及特徵結構藉由本發明之以上描述及伴隨之圖式對彼等熟習此技藝者將變得顯而易見。
第1圖圖示結合一電子式變色元件之一絕緣玻璃單元的透視圖。
第2圖為第1圖之絕緣玻璃單元之外玻璃片之內表面的俯視圖，圖示電子式變色元件。
第3圖為第1圖之絕緣玻璃單元之橫截面圖。
第4圖圖示第1圖之絕緣玻璃單元具有根據本發明第一實施例之配置之橫截面圖。
第5圖圖示第1圖之絕緣玻璃單元具有根據本發明第二實施例之配置之橫截面圖。
第6圖圖示根據本發明實施例之用於製造具有電子式變色元件之絕緣玻璃單元的流程圖。
第7圖圖示根據本發明實施例之用於製造具有電子式變色元件之絕緣玻璃單元的裝置。
610．．．提供大規格玻璃基板
620．．．在玻璃基板上製造電子式變色薄膜元件
630．．．將玻璃基板切割成分離的電子式變色零件
640．．．提供多種尺寸及具有不同性質的窗口玻璃零件
650．．．將電子式變色零件與窗口玻璃零件匹配
660．．．將電子式變色零件層疊至匹配玻璃零件
670．．．製造具有不同尺寸及功能IGUs

Claims (25)

  1. 一種製造電子式變色窗口玻璃的方法，該電子式變色窗口玻璃具有多種尺寸及功能，該方法包含：提供一大規格玻璃基板；在該大規格玻璃基板上製造複數電子式變色薄膜元件；將該大規格玻璃基板切割成複數電子式變色零件，各電子式變色零件包括該複數電子式變色薄膜元件中之一者；提供複數窗口玻璃零件；將該複數電子式變色零件中之各者與對應之該複數窗口玻璃零件之一者匹配；及層疊該匹配電子式變色零件之各者與窗口玻璃零件。
  2. 如申請專利範圍第1項所述之方法，其中，在該層疊期間，該電子式變色薄膜元件係面向對應之該複數窗口玻璃零件之一者之表面。
  3. 如申請專利範圍第1項所述之方法，其中，在該層疊期間，該電子式變色薄膜元件係遠離對應之該複數窗口玻璃零件之一者之表面。
  4. 如申請專利範圍第1項所述之方法，其中該等窗口玻 璃零件包括熱處理玻璃零件。
  5. 如申請專利範圍第4項所述之方法，其中該等窗口玻璃零件包括強化玻璃零件。
  6. 如申請專利範圍第1項所述之方法，其中該等窗口玻璃零件包括變色玻璃零件。
  7. 如申請專利範圍第1項所述之方法，其中該等窗口玻璃零件包括層疊玻璃零件。
  8. 如申請專利範圍第1項所述之方法，其中該等窗口玻璃零件包括高強度玻璃零件。
  9. 如申請專利範圍第1項所述之方法，其中該等窗口玻璃零件包括具有不同玻璃尺寸的零件。
  10. 如申請專利範圍第1項所述之方法，其中該等窗口玻璃零件包括具有不同玻璃厚度的零件。
  11. 如申請專利範圍第1項所述之方法，其中該電子式變色薄膜元件係一電致變色元件。
  12. 如申請專利範圍第1項所述之方法，其中該電子式變 色薄膜元件係一懸浮粒子元件。
  13. 如申請專利範圍第1項所述之方法，其中該電子式變色薄膜元件係一高分子分散液晶元件。
  14. 如申請專利範圍第1項所述之方法，其中該製造包括在該大規格玻璃基板上之一薄膜的真空沉積。
  15. 如申請專利範圍第14項所述之方法，其中該製造包括在該大規格玻璃積板上之一薄膜的的電漿沉積。
  16. 如申請專利範圍第1項所述之方法，其中該製造包括加熱該大規格玻璃基板。
  17. 如申請專利範圍第1項所述之方法，其中該等複數電子式變色零件包括不同尺寸的零件。
  18. 一種製造電子式變色窗口玻璃之方法，該電子式變色窗口玻璃具有多種尺寸及功能，該方法包含：提供多個相同大規格玻璃基板；在該多個大規格玻璃基板上製造複數電子式變色薄膜元件；將該多個大規格玻璃基板切割成複數電子式變色零件，各電子式變色零件包括該複數電子式變色薄膜元件 中之一者；提供複數窗口玻璃零件；將該複數電子式變色零件中之各者與對應之複數窗口玻璃零件中一者匹配；及層疊各該等匹配電子式變色零件及窗口玻璃零件。
  19. 如申請專利範圍第18項所述之方法，其中該等窗口玻璃零件包括具有不同玻璃尺寸的零件。
  20. 如申請專利範圍第18項所述之方法，其中該等窗口玻璃零件包括具有不同玻璃厚度的零件。
  21. 一種電子式變色窗口，其包含：一片窗口玻璃；一玻璃基板；一電致變色薄膜元件，其形成於該玻璃基板上；及一層疊層，其介於該電致變色薄膜元件與該窗口玻璃之間，該層疊層將該電致變色薄膜元件附著至該窗口玻璃。
  22. 如申請專利範圍第21項所述之電子式變色窗口，其中該層疊層包括一接合劑，該接合劑選自由下列組成之群組：聚乙烯丁醛及乙烯乙酸乙烯酯。
  23. 如申請專利範圍第21項所述之電子式變色窗口，其中該片窗口玻璃包含：一片經熱處理之玻璃、一片經變色之玻璃、一片經層疊之玻璃或一片高強度之玻璃。
  24. 一種用於形成電子式變色窗口玻璃之裝置，該電子式變色窗口玻璃具有多種尺寸及功能，其包含：一第一系統，用以在一大規格玻璃基板上製造複數電子式變色薄膜元件；一第二系統，用以將該大規格玻璃基板切割成複數電子式變色零件，各電子式變色零件包括該複數電子式變色薄膜元件中之一者；及一第三系統，用以層疊經匹配之電子式變色零件及窗口玻璃零件，其中該複數電子式變色零件之各者係與對應之複數窗口玻璃零件之一者匹配。
  25. 如申請專利範圍第24項所述之裝置，其進一步包含：一第四系統，用以將各層疊電子式變色零件建立至個別絕緣玻璃單元中。
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EP2376396A4 (en) 2014-01-01
US7710671B1 (en) 2010-05-04
JP2012511498A (ja) 2012-05-24
US20110304899A1 (en) 2011-12-15
KR20110094335A (ko) 2011-08-23
CN102307822A (zh) 2012-01-04
KR101616835B1 (ko) 2016-04-29
EP2376396A2 (en) 2011-10-19
TW201029838A (en) 2010-08-16
CN104842605A (zh) 2015-08-19
US8218224B2 (en) 2012-07-10
US20100208326A1 (en) 2010-08-19
WO2010068525A2 (en) 2010-06-17

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