Manufacturing of electrochromic devices

1. Method for manufacturing of electrochromic device, comprising the steps of:

providing a first sheet comprising a first plastic substrate at least partially coated with a first electron conducting layer and a first electrochromic layer;

providing a second sheet comprising a second plastic substrate at least partially coated with a second electron conducting layer and a counter electrode layer;

laminating an electrolyte layer interposed between said first sheet and said second sheet into an electrochromic laminate sheet ( 30 ); and

defining at least a major part of an interior portion, in a lateral direction, of at least one electrochromic device by forming a seal through said electrochromic laminate sheet at a distance from a peripheral edge of said first sheet and from a peripheral edge of said second sheet, thereby obtaining an interior portion of each one of said at least one electrochromic device having a size smaller than said first sheet and said second sheet.

2. Method according to claim 1 , wherein said distance is larger than a largest one of mean diffusion lengths of:

oxygen;

water; and

an electrolyte component;

in said electrolyte layer during a predetermined time period.

3. Method according to claim 1 , wherein said step of defining comprises forming of a seal in a substantially closed path.

4. Method according to claim 1 , comprising the further step of:

cutting away at least a part of said electrochromic laminate sheet;

whereby said cutting step is performed in conjunction with or after said step of defining.

5. Method according to claim 4 , wherein said step of cutting away at least a part of said electrochromic laminate sheet is performed essentially along said seal formed by said step of defining.

6. Method according to claim 4 , wherein said step of cutting is performed in a substantially closed path, thereby releasing an electrochromic device, having a size smaller than said first sheet and said second sheet, from remaining parts of said electrochromic laminate sheet.

7. Method according to claim 4 , wherein said step of defining is performed along a multitude of closed paths, thereby defining a multitude of electrochromic devices, interior portions of which having sizes smaller than said first sheet and said second sheet.

8. Method according to claim 4 , wherein said step of cutting is performed along a multitude of closed paths, thereby releasing a multitude of electrochromic devices, having sizes smaller than said first sheet and said second sheet, from remaining parts of said electrochromic laminate sheet.

9. Method according to claim 1 , wherein said step of defining is performed by local heat generation in said electrochromic laminate sheet.

10. Method according to claim 9 , wherein said step of defining is performed by ultrasonic welding.

11. Method according to claim 10 , wherein said ultrasonic welding is performed by moving an ultrasonic horn along a surface of said electrochromic laminate sheet, whereby a centre line of said ultrasonic horn being tilted relative to a surface normal of said electrochromic laminate sheet.

12. Method according to claim 9 , wherein said step of defining is performed by laser welding.

13. Method according to claim 4 , wherein said steps of defining and cutting are performed jointly by ultrasonic welding of said electrochromic laminate sheet.

14. Method according to claim 13 , comprising the further step of reinforcing said seal after said step of defining.

15. Method according to claim 4 , wherein said steps of defining and cutting are performed jointly by laser welding of said electrochromic laminate sheet.

16. Method according to claim 15 , comprising the further step of reinforcing said seal after said step of defining.

17. Method according to claim 1 , wherein said step of defining is performed through said first plastic substrate, said second plastic substrate and at least one of:

said first electron conducting layer;

said second electron conducting layer;

said electrolyte layer;

said first electrochromic layer; and

said counter electrode layer.

18. Method according to claim 1 , comprising the further step of providing at least one of said first sheet and said second sheet with at least one additional layer.

19. Method according to claim 18 , wherein said at least one additional layer is selected from the list of:

bus bar;

chemical compatibility layer;

anti-scratch layer;

anti-fog layer;

anti-reflection layer;

diffusion barrier;

photocatalytic layer; and

specularly or diffusively reflecting layer.

20. Electrochromic device, manufactured by a method according to the steps of:

providing a first sheet comprising a first plastic substrate at least partially coated with a first electron conducting layer and a first electrochromic layer;

providing a second sheet comprising a second plastic substrate at least partially coated with a second electron conducting layer and a counter electrode layer;

laminating an electrolyte layer interposed between said first sheet and said second sheet into an electrochromic laminate sheet ( 30 ); and

defining at least a major part of an interior portion, in a lateral direction, of at least one electrochromic device by forming a seal through said electrochromic laminate sheet at a distance from a peripheral edge of said first sheet and from a peripheral edge of said second sheet, thereby obtaining an interior portion of each one of said at least one electrochromic device having a size smaller than said first sheet and said second sheet.