Particle removal from electrochromic films using non-aqueous fluids

An electrochromic device prepared by a process comprising the steps of:

• depositing a first conductive layer over a substrate;
• depositing a first electrode layer over the first conductive layer, wherein the first electrode layer is one of an electrochromic layer or a counter electrode layer;
• depositing an ion conductor layer over the first electrode layer, wherein a film stack includes the first conductive layer, the first electrode layer, and the ion conductor layer;
• exposing the ion conductor layer to a non-aqueous liquid to remove particulate material having a size between about 0.1 μm and about 1000 μm, wherein the non-aqueous liquid is selected from the group consisting of a hydrofluorocarbon, a fluorocarbon, a polymeric fluorinated solvent, and a fluoride surfactant;
• depositing a second electrode layer over the film stack after exposing the ion conductor layer to the non-aqueous liquid, wherein the second electrode layer is the other of the electrochromic layer or the counter electrode layer;
• and
• depositing a second conductive layer on the second electrode layer, wherein the electrochromic device has a defect density of less than 1 defect/m2, and wherein the electrochromic device is configured for use in a window.

An electrochromic device prepared by a process comprising the steps of:

• depositing a first conductive layer over a substrate;
• depositing a first electrode layer over the first conductive layer, wherein the first electrode layer is one of an electrochromic layer or a counter electrode layer;
• depositing an ion conductor layer over the first electrode layer, wherein a film stack includes the first conductive layer, the first electrode layer, and the ion conductor layer;
• exposing the ion conductor layer to a non-aqueous liquid to remove particulate material having a size between about 0.1 μm and about 1000 μm, wherein the non-aqueous liquid is selected from the group consisting of a hydrofluorocarbon, a fluorocarbon, a polymeric fluorinated solvent, and a fluoride surfactant, and wherein the non-aqueous liquid comprises less than about 0.1% of water;
• depositing a second electrode layer over the film stack after exposing the ion conductor layer to the non-aqueous liquid, wherein the second electrode layer is the other of the electrochromic layer or the counter electrode layer;
• and
• depositing a second conductive layer on the second electrode layer, wherein the electrochromic device has a defect density of less than 1 defect/m2.