Narrow pre-deposition laser deletion
Certain aspects pertain to methods of fabricating an optical device on a substantially transparent substrate that include a pre-deposition operation that removes a width of lower conductor layer at a distance from the outer edge of the substrate to form a pad at the outer edge. The pad and any deposited layers of the optical device may be removed in a post edge deletion operation.
1. A method of fabricating an electrochromic device having one or more layers of the electrochromic device sandwiched between a first transparent conductor layer and a second transparent conductor layer, the method comprising:
(i) receiving a rectangular glass substrate with the first transparent conductor layer over its work surface;
(ii) removing a first strip of the first transparent conductor layer along three sides about a perimeter of the rectangular glass substrate, wherein the first strip is inset from an outer edge of the rectangular glass substrate;
(iii) depositing the one or more layers of the electrochromic device and the second transparent conductor layer over substantially entire work surface of the rectangular glass substrate; and
(iv) removing a second strip at a sufficient depth to remove layers of the second transparent conductor layer, the electrochromic device and the first transparent conductor layer along substantially entire perimeter of the rectangular glass substrate.
2. The method of claim 1 , wherein the second strip is of sufficient width that its inner edge coincides with or is to inside of the outer edge of the first strip.
3. The method of claim 1 , further comprising removing a region of the second transparent conductor layer and the one or more layers of the electrochromic device revealing an exposed portion of the first transparent conductor layer.
4. The method of claim 3 , wherein removing the region of the second transparent conductor layer and the one or more layers of the electrochromic device includes removing a portion of the first transparent conductor layer in the region.
5. The method of claim 3 , further comprising applying a first bus bar to the exposed portion of the first transparent conductor layer.
6. The method of claim 5 , further comprising applying a second bus bar to the second transparent conductor layer.
7. The method of claim 6 , wherein the second bus bar is applied to the second transparent conductor layer on a portion that does not cover the first transparent conductor layer.
8. The method of claim 7 , wherein the second bus bar is applied along an edge of the electrochromic device, opposite the first bus bar.
9. The method of claim 1 , further comprising incorporating the rectangular glass substrate into an insulated glass unit, wherein the electrochromic device faces a sealed volume of the insulated glass unit.
10. The method of claim 1 , wherein each of the first transparent conductor layer and the second transparent conductor layer comprise fluorinated tin oxide or indium tin oxide.
11. The method of claim 1 , wherein (ii) and (iv) are performed using laser ablation.
12. The method of claim 1 , wherein the one or more layers of the electrochromic device and the second transparent conductor layer are deposited over substantially entire work surface of the rectangular glass substrate due to the rectangular glass substrate being masked about the outer edge.
13. The method of claim 1 , wherein the first strip is inset at a distance of between about 1 mm and about 10 mm from the outer edge of the rectangular glass substrate.
14. The method of claim 1 , wherein the first strip is inset at a distance of between about 5 mm and about 10 mm from the outer edge of the rectangular glass substrate.
15. The method of claim 1 , wherein the first strip is inset at a distance of about 10 mm from the outer edge of the rectangular glass substrate.
16. The method of claim 1 , wherein the first strip has a width between about 1 mm and about 5 mm.
17. The method of claim 1 , further comprising tapering an edge of the first transparent conductor layer along an inner edge of a portion of the first transparent conductor layer remaining after the first strip is removed, and before the one or more layers of the electrochromic device are deposited.
18. The method of claim 1 , further comprising forming a laminate with the rectangular glass substrate, wherein the electrochromic device is disposed on a face of the rectangular glass substrate that is opposite a lamination adhesive used to form the laminate.
19. The method of claim 18 , further comprising incorporating the laminate into an insulating glass unit.
20. The method of claim 1 , wherein the electrochromic device is an all solid-state and inorganic electrochromic device.
21. The method of claim 1 , wherein the rectangular glass substrate is float glass, tempered or untempered.
22. The method of claim 1 , further comprising depositing a vapor barrier layer on the second transparent conductor layer prior to, or after, (iv).
23. The method of claim 1 , wherein the first strip of the first transparent conductor layer is removed along at least one of the three sides to the outer edge of an adjacent side.