Electro-Optical Element Including Metallic Films and Methods For Applying The Same

Abstract

A method for manufacturing an electrochromic element comprises providing a first substrate having first and second surfaces and a first edge surface, providing a second substrate having third and fourth surfaces and a second edge surface, the third surfaces facing the second surface, providing an electrochromic medium located between the first and second substrates, the medium having a light transmittance that is variable upon application of electric field thereto, applying a conductive layer on a portion of at least one of the surfaces, wherein applying the layer is accomplished at substantially atmospheric pressure, and applying at least one of metallic particles, an organometallic, a metallo-organic, and combinations thereof, wherein the conductive layer has a bulk resistivity of greater than or equal to 150 μΩ·cm. The conductive layer may be applied via ink jetting, ultrasonic spraying, auger or jet pumping.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is an enlarged cross-sectional view of a prior art electrochromic mirror assembly incorporating a fourth surface reflector;

FIG. 2 is a front elevational view schematically illustrating an inside/outside electrochromatic rearview mirror system for motor vehicles;

FIG. 3 is an enlarged cross-sectional view of an electrochromic mirror incorporating a third surface reflector/electrode taken along the line III-III, FIG. 2;

FIG. 4 is a flow chart illustrating the sequence of the present inventive method;

FIG. 5 is a schematic cross-sectional view of a substrate and a bulk metal coating with a larger crystalyte structure;

FIG. 6 is a schematic cross-sectional view of a substrate and a bulk metal coating with a small crystalyte structure; and

FIG. 7 is a graph of a wavelength versus reflectance for Example No. 7.

Claims

1. A method for manufacturing an electrochromic element, the method comprising: providing a first substrate having a first surface, a second surface opposite the first surface, and a first edge surface;providing a second substrate having a third surface facing the second surface, a fourth surface opposite the third surface, and a second edge surface;providing an electrochromic medium located between the first and second substrates, wherein the electrochromic medium has a light transmittance that is variable upon the application of an electric field thereto; andapplying a conductive layer on at least a portion of at least a select one of the first surface, the second surface, the first edge surface, the third surface, the fourth surface, and the second edge surface, wherein applying of the conductive layer is accomplished at substantially atmospheric pressure and includes applying at least a select one of metallic particles, an organometallic, a metallo-organic, and combinations thereof, and wherein the conductive layer has a bulk resistivity of greater than or equal to 150 μΩ·cm.

2. The method of claim 1, wherein the step of applying the conductive layer provides the conductive layer with a bulk resistivity of greater then or equal to 100 μΩ·cm.

3. The method of claim 2, wherein the step of applying the conductive layer provides the conductive layer with a bulk resistivity of greater then or equal to 50 μΩ·cm.

4. The method of claim 1, wherein the step of applying the conductive layer provides the conductive layer with a peak-to-valley roughness of less than or equal to 20 nm.

5. The method of claim 4, wherein the step of applying the conductive layer provides the conductive layer with a peak-to-valley roughness of less than or equal to 10 nm.

6. The method of claim 5, wherein the step of applying the conductive layer provides the conductive layer with a peak-to-valley roughness of less than or equal to 5 nm.

7. The method of claim 1, wherein the step of applying the conductive layer provides the conductive layer with a reflectance of greater than or equal to 35% at a wavelength of about 550 nm.

8. The method of claim 7, wherein the step of applying the conductive layer provides the conductive layer with a reflectance of greater than or equal to 55% at a wavelength of about 550 nm.

9. The method of claim 8, wherein the step of applying the conductive layer provides the conductive layer with a reflectance of greater than or equal to 70% at a wavelength of about 550 nm.

10. The method of claim 1, wherein the step of applying the conductive layer provides the conductive layer as reflective.

11. The method of claim 1, wherein the step of applying the conductive layer provides the conductive layer as transmissive.

12. The method of claim 1, wherein the step of applying the conductive layer provides the conductive layer as transflective.

13. The method of claim 1, wherein the step of applying the conductive layer includes depositing metallic nanoparticles.

14. The method of claim 1, wherein the step of applying the conductive layer further includes depositing an organometallic metal precursor.

15. The method of claim 1, wherein the step of applying the conductive layer includes at least a select one of ink jet printing, ultrasonic spraying, auger pumping, and jet pumping.

16. The method of claim 1, further including: curing the conductive layer subsequent to the step of applying the conductive layer.

17. The method of claim 16, wherein the curing step includes curing the conductive by applying at least a select one of a UV light, a microwave, and convective heating.

18. The method of claim 1, wherein the step of applying the conductive layer includes providing the conductive layer as an electrode applied to at least a select one of the second surface and the third surface.

19. The method of claim 1, wherein the substrate to which the conductive layer is applied comprises glass.

20. The method of claim 1, wherein the step of applying the conductive layer further comprises at least a select one of chemical vapor deposition, flame spray deposition, and laser sintering.

21. A method for manufacturing an electrochromic element, the method comprising: providing a first substrate having a first surface, a second surface opposite the first surface, and a first edge surface;providing a second substrate having a third surface facing the second surface, a fourth surface opposite the third surface, and a second edge surface;providing an electrochromic medium between the first and second substrates, wherein the electrochromic medium has a light transmittance that is variable upon the application of an electric field thereto; andinkjet printing a conductive layer on at least a portion of at least a select one of said surface, the second surface, the first edge surface, the third surface, the fourth surface, and the second edge surface.

22. The method of claim 21, wherein the step of inkjet printing comprises applying at least a select one of metallic particles, an organometallic, a metallo-organic, and combinations thereof.

23. The method of claim 22, wherein the step of inkjet printing comprises applying nanometallic particles.

24. The method of claim 21, wherein the step of inkjet printing provides the conductive layer as a transflective layer.

25. The method of claim 21, wherein the step of inkjet printing further includes depositing at least a select one of an organometallic metal precursor and a metallic organic metal precursor.

26. The method of claim 21, further including: curing the conductive layer subsequent to the inkjet printing step.

27. The method of claim 26, wherein the curing step includes applying at least a select one of a UV light, a microwave, and convective heating.

28. The method of claim 21, further including: in situ curing of the conductive layer during the ink jet printing step.

29. The method of claim 21, wherein the step of inkjet printing includes providing the conductive layer as an electrode applied to at least a select one of the second surface and the third surface.

30. The method of claim 21, wherein the substrate to which the conductive layer is applied comprises glass.

31. A method for manufacturing an electrochromic element, the method comprising: providing a first substrate having a first surface, a second surface opposite the first surface, and a first edge surface;providing a second substrate having a third surface facing the second surface, a fourth surface opposite the third surface, and a second edge surface;providing an electrochromic medium between the first and second substrates, wherein the electrochromic medium has a light transmittance that is variable upon the application of an electric field thereto; andultrasonic spraying a conductive layer on at least a portion of at least a select one of the first surface, the second surface, the first edge surface, the third surface, the fourth surface, and the second edge surface.

32. The method of claim 31, wherein the ultrasonic spraying step comprises applying at least a select one of metallic particles, an organometallic, a metallo-organic, and combinations thereof.

33. The method of claim 31, wherein the step of applying the conductive layer provides the conductive layer as transflective.

34. The method of claim 31, wherein the step of ultrasonic spraying includes depositing at least a select one of an organometallic metal precursor and a metallic organic metal precursor.

35. The method of claim 31, further including: curing the conductive layer subsequent to the ultrasonic spraying step.

36. The method of claim 35, wherein the ultrasonic spraying step includes curing the conductive by applying at least a select one of a UV light, a microwave, and convective heating.

37. The method of claim 35, further including: in situ curing of the conductive layer during the ultrasonic spraying step.

38. The method of claim 31, wherein the step of ultrasonic spraying includes providing the conductive layer as an electrode applied to at least a select one of the second surface and the third surface.

39. The method of claim 31, wherein the substrate to which the conductive layer is applied comprises glass.

40. A method for manufacturing an electrochromic element, the method comprising: providing a first substrate having a first surface, a second surface opposite the first surface, and a first edge surface;providing a second substrate having a third surface facing the second surface, a fourth surface opposite the third surface, and a second edge surface;providing an electrochromic medium between the first and second substrates, wherein the electrochromic medium has a light transmittance that is variable upon the application of an electric field thereto; andapplying a conductive layer on at least a portion of at least a select one of the first surface, the second surface, the first edge surface, the third surface, the fourth surface, and the second edge surface, wherein applying of the conductive layer includes at least a select one of auger pumping and jet pumping.

41. The method of claim 40, wherein the step of applying the conductive layer includes applying at least a select one of metallic particles, an organometallic, a metallo-organic, and combinations thereof.

42. The method of claim 41, wherein the step of applying the conductive layer includes applying nanometallic particles.

43. The method of claim 40, wherein the step of applying the conductive layer provides the conductive layer as transflective.

44. The method of claim 40, wherein the step of applying the conductive layer further includes depositing at least a select one of an organometallic metal precursor and a metallo organic metal precursor.

45. The method of claim 40, further including: curing the conductive layer subsequent to the step of applying the conductive layer.

46. The method of claim 45, wherein the curing step includes applying at least a select one of a UV light, a microwave, and convective heating.

47. The method of claim 40, further including: in situ curing of the conductive layer during the step of applying the conductive layer.

48. The method of claim 40, wherein the step of applying the conductive layer includes providing the conductive layer as an electrode applied to at least a select one of the second surface and the third surface.

49. The method of claim 40, wherein the substrate to which the conductive layer is applied comprises glass.

50. A method for manufacturing an electrochromic element, the method comprising: providing a first substrate having a first surface, a second surface opposite the first surface, and a first edge surface;providing a second substrate having a third surface facing the second surface, a fourth surface opposite the third surface, and a second edge surface;providing an electrochromic element between the first and second substrates, wherein the electrochromic medium has a light transmittance that is variable upon the application of an electric field thereto; andapplying a conductive layer on at least a portion of at least a select one of the first surface, the second surface, the first edge surface, the third surface, the fourth surface, and the second edge surface, wherein applying of the conductive layer includes at least a select one of combustion chemical vapor deposition, flame spray deposition, and laser sintering.

51. The method of claim 50, wherein the step of applying the conductive layer includes applying at least a select one of metallic particles, an organometallic, a metallo-organic, and combinations thereof.

52. The method of claim 51, wherein the step of applying the conductive layer includes applying nanometallic particles.

53. The method of claim 50, wherein the step of applying the conductive layer provides the conductive layer as transflective.

54. The method of claim 50, wherein the step of applying the conductive layer further includes depositing an inorganic metal precursor.

55. The method of claim 50, further including: curing the conductive layer subsequent to the step of applying the conductive layer.

56. The method of claim 55, wherein the curing step includes applying at least a select one of a UV light, a microwave, and convective heating.

57. The method of claim 50, further including: in situ curing of the conductive layer during the step of applying the conductive layer.

58. The method of claim 50, wherein the step of applying the conductive layer includes providing the conductive layer as an electrode applied to at least a select one of the second surface and the third surface.

59. The method of claim 50, wherein the substrate to which the conductive layer is applied comprises glass.