Electrochromic edge isolation-interconnect system, process, and device for its manufacture

A process for manufacturing an electrochromic device, the process comprising the steps of:

• providing a substrate having an expanse and a peripheral edge region, the edge region having a determined perimeter length;
• applying a first electrode layer on the expanse such that the first electrode layer extends substantially across the expanse and wraps around the peripheral edge region;
• applying a first contact to the first electrode layer along a significant length of the peripheral edge region;
• applying an isolative barrier to the first electrode layer and to the first contact in the peripheral edge region such that the barrier extends throughout the perimeter of the peripheral edge region;
• applying an electrochromic layer to the first electrode layer such that the electrochromic layer extends substantially across the first electrode layer;
• applying a second electrode layer to the electrochromic layer such that the second electrode layer extends substantially across the electrochromic layer and wraps around the peripheral edge region in an area already covered by the isolative barrier;
• and
• applying a second contact to the second electrode layer along a significant length of the peripheral edge region.

An electrochromic isolation-interconnect system to prevent an electrical short and to permit flow of current between opposite electrodes via an intermediate electrochromic layer, the system comprising:

• a substrate having an edge region and a generally flat surface having a central region;
• a first electrode layer substantially coating the surface of the substrate;
• a second electrode layer;
• an intermediate electrochromic layer located between and permitting electrically connection between the first and second electrode layers;
• and
• an isolation mechanism including a first channel formed in the second electrode layer to electrically isolate the first electrode layer from the second electrode layer in the central region.

An electrochromic edge contact-isolation system for permitting electrical current to flow between a first electrode layer and a second electrode layer only through an intermediate electrochromic layer, for maximizing the field of view through the system, and for facilitating electrical connection to the system, the system comprising:

• an optical substrate including a field of view;
• a coating on the substrate, the coating including a first electrode layer generally covering a surface of the substrate, an intermediate electrochromic layer generally covering the first electrode layer, and a second electrode layer generally covering the electrochromic layer;
• and
• an isolative channel formed in an edge region of the second electrode layer, the channel electrically isolating the first electrode layer from the second electrode layer throughout the field of view.

An electrochromic device comprising:

• a substrate having an edge region and a generally flat surface;
• electrochromic layered structure located on the generally flat surface, the electrochromic layered structure including a first electrode layer, a second electrode layer, and an electrochromic layer between the first and second electrode layers;
• an edge-isolation channel extending at least partially around edge region of the substrate;
• and
• edge-applied conductive material at least partially overlapping with the layered structure and providing layer-selective conductive edge-contact in the edge region for edge-wise electrical power input to the device.

An electrochromic system comprising:

• a frame including a recess;
• an electrochromic device mounted in the frame, the device including a substrate having an edge region, the device further including an electrode which extends into the edge region;
• a conductor located in the recess, the conductor adapted for powering the device;
• and
• a conductive elastomer extending within the recess, the elastomer electrically connecting the conductor and the electrode.

A process for manufacturing an electrochromic device, the process comprising the steps of:

• providing a transparent substrate having an expanse and a peripheral edge region, the edge region having a determined length;
• applying a first release agent to a portion of the edge region;
• applying a first electrode layer on the expanse such that the first electrode layer extends substantially across the expanse and into the edge region thereby contacting the first release agent;
• removing the first release agent;
• applying a second release agent in the edge region;
• applying an electrochromic layer to the first electrode layer such that the electrochromic layer extends across the first electrode layer and into the edge region thereby contacting the second release agent;
• applying a second electrode layer to the electrochromic layer such that the second electrode layer extends across the electrochromic layer and into the edge region;
• and
• removing the second release agent.

A process for manufacturing an electrochromic device, the process comprising the steps of:

• providing a substrate having an expanse;
• coating a first electrode layer, a second electrode layer and an intermediate electrochromic layer generally across the expanse;
• physically dividing the substrate into at least two sections, one of the sections having an edge region and a central region;
• forming an isolative channel in the edge region of said one of the sections to electrically isolate the layers in the central region;
• providing electrical contact to the first electrode;
• and
• providing electrical contact to the second electrode to power the electrochromic device.

An electrochromic device comprising:

• a substrate having an expanse and a beveled peripheral edge region including a pair of bevel regions which converge toward a bevel point;
• a first electrode layer applied to the substrate and extending substantially across the expanse and over at least one of the bevel regions to wrap around the peripheral edge region;
• an electrochromic layer applied to the first electrode, the first electrode layer physically isolating the electrochromic layer from the substrate;
• an isolative barrier applied to the first electrode layer and extending along a perimeter of the peripheral edge region;
• a second electrode layer applied to the electrochromic layer and extending substantially across the expanse and over at least one of the bevel regions to wrap around the peripheral edge region, the electrochromic layer physically isolating the second electrode layer from the first electrode layer throughout the expanse and the isolative barrier physically isolating the second electrode layer from the first electrode layer throughout the peripheral edge region;
• a first contact electrically connected to the first electrode layer along the peripheral edge region;
• a second contact electrically connected to the second electrode layer along the peripheral edge region;
• and
• the isolative barrier electrically isolating the first contact from the second electrode layer and electrically isolating the second contact from the first electrode layer.