IP Library Granted Patent US 7,746,534
Granted Patent B2
US 7,746,534 · App. 11/833,701 · Granted Jun 29, 2010

Thin-film coatings, electro-optic elements and assemblies incorporating these elements

Assignee: Gentex Corporation
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Quick Facts
Patent No.
US 7,746,534
App. No.
11/833,701
Granted
Jun 29, 2010
Kind
B2
Abstract

Electro-optic elements are becoming commonplace in a number of vehicular and architectural applications. Various electro-optic element configurations provide variable transmittance and or variable reflectance for windows and mirrors. The present invention relates to various thin-film coatings, electro-optic elements and assemblies incorporating these elements.

Claims (36)

1. An optical element comprising:

a first substrate;

at least one thin-film layer deposited on the first substrate, and

a boundary-modifying material adjoining a boundary formed by any two of the substrate and the at least one thin-film layer,

wherein the boundary-modifying material differs from materials forming the substrate and the at least one thin-film layer, wherein an accumulation of the boundary-modifying material does not exceed ten atomic layers, and wherein the boundary-modifying material includes an element from a group consisting of chalcogenides and pnictogens.

2. The optical element of claim 1 , wherein the boundary-modifying material includes at least one of sulfur and selenium.

3. The optical element of claim 1 , wherein an accumulation of the boundary-modifying material does not exceed an atomic monolayer.

4. The optical element of claim 1 , wherein an accumulation of the boundary-modifying material does not exceed five atomic layers.

5. The optical element of claim 1 , wherein an accumulation of the boundary-modifying material does not exceed two atomic layers.

6. The optical element of claim 1 , wherein the first substrate comprises glass.

7. The optical element of claim 1 , wherein the at least one thin-film layer comprises one of ITO, IZO, zinc oxide, AZO, TiO 2 , W, Mo, Fe, Ni, Co, Rh, Ir, Cu, Ag, Au, Zn, Cd, Hg, Ga, In, Tl, Ge, Sn, Pb, As, Sb, Cr and Bi.

8. A method for manufacturing an optical element, the method comprising:

providing a first base having a surface;

disposing a modifying material below the surface; and

overcoating the surface with a thin-film overlayer;

wherein the modifying material differs from materials forming the base and the thin-film overlayer, the modifying material includes an element from a group consisting of chalcogenides and pnistogens, and an accumulation of the modifying material does not exceed ten atomic layers.

9. The method of claim 8 , wherein the disposing a modifying material includes disposing at least one of sulfur and selenium.

10. The method of claim 8 , wherein the in the accumulation of the modifying material does not exceed an atomic monolayer.

11. The method of claim 8 , wherein the in the accumulation of the modifying material does not exceed five atomic layers.

12. The method of claim 8 , wherein the in the accumulation of the modifying material does not exceed two atomic layers.

13. The method of claim 8 , wherein the first base comprises a first substrate and a first thin-film layer deposited thereon and the surface of the first base is defined by an outer surface of the first thin-film layer.

14. The method of claim 13 , wherein the first substrate is made of glass and wherein at least one of the first thin-film layer and the thin-film overlayer contains at least one of ITO, IZO, zinc oxide, AZO, TiO 2 , W, Mo, Fe, Ni, Co, Rh, Ir, Cu, Ag, Au, Zn, Cd, Hg, Ga, In, Tl, Ge, Sn, Pb, As, Sb, and Bi.

15. The method of claim 8 , wherein the first base is made of glass and the thin-film overlayer contains at least one of ITO, IZO, zinc oxide, AZO, TiO 2 , W, Mo, Fe, Ni, Go, Rh, Ir, Cu, Ag, Au, Zn, Cd, Hg, Ga, In, Tl, Ge, Sn, Pb, As, Sb, and Bi.

16. The optical element of claim 1 , wherein the first substrate is made of glass and the at least one thin-film layer includes a layer of Chromium deposited on the first substrate and a layer of silver-gold alloy deposited over the layer of Chromium, and wherein the boundary-modifying material is accumulated at the boundary between the layer of Chromium and the layer of silver-gold alloy.

17. The optical element of claim 1 , wherein the first substrate is made of glass and the at least one thin-film layer includes a layer of TiO 2 deposited on the first substrate, a layer of ITO deposited on top of the TiO 2 layer, and a layer of silver-gold alloy deposited over the layer of ITO, and wherein the boundary-modifying material is accumulated at the boundary between the layer of ITO and the layer of silver-gold alloy.

18. The optical element of claim 1 , wherein the boundary-modifying material enhances at least one of adhesion, environmental stability, conductivity, and nucleation characteristics of the at least one thin-film layer.

19. The optical element of claim 1 , further comprising:

a second substrate, wherein the first and second substrates cooperate to form a cavity therebetween; and

an electrochromic medium located within the cavity.

20. The method of claim 8 , wherein the disposing comprises at least one of ion treatment, plasma treatment, chemical treatment, and physical vapor deposition.

21. The method of claim 8 , further comprising:

placing a second base so as to form a cavity between the first and second bases; and

situating an electrochromic medium within the cavity.

22. The optical element of claim 16 , wherein the boundary-modifying material is sulfur.

23. The optical element of claim 17 , wherein the boundary-modifying material is sulfur.

24. The optical element of claim 1 , wherein an accumulation of the boundary-modifying material occurs in a material substantially under the boundary.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Sep 16, 2008
From: TONAR, WILLIAM L.; ANDERSON, JOHN S.; FORGETTE, JEFFREY A.; NEUMAN, GEORGE A.; DOZEMAN, GARY J.; CAMMENGA, DAVID J.; LUTEN, HENRY A.; POE, G. BRUCE; BRUMMEL, NELSON F.; PERRON, LANSEN M.
To: GENTEX CORPORATION
Reel/Frame 021540/0891 →
Continuity (4)
Continuation In Part 1171384900 · Mar 5, 2007
Provisional Application 6087347400 · Dec 7, 2006
Provisional Application 6088868600 · Feb 7, 2007
Related Publication 20080310005A1 · Dec 18, 2008