Abstract
A switchable optical device including in this order a first substrate, a first conductive layer, a switchable layer, a second conductive layer and a second substrate, which device further contains one or both of the following:
i) the first conductive layer contains a first contact zone and a second contact zone, wherein the first contact zone is electrically insulated from the second contact zone and the switchable optical device contains an electrical interconnect for electrically connecting the second contact zone of the first conductive layer the second conductive layer,
ii) the switchable optical device contains at least one further sheet which is laminated to the first substrate and/or the second substrate, wherein first substrate, second substrate and the at least one further sheet have essentially the same thermal expansion coefficient.
A switchable glazing unit containing at least one glass pane and at least one switchable optical device.
Claims
1. Switchable optical device (10) comprising in this order a first substrate (12), a first conductive layer (14), a switchable layer (18), a second conductive layer (22) and a second substrate (24), characterized in that i) the first conductive layer (14) comprises a first contact zone (30) and a second contact zone (32), wherein the first contact zone (30) is electrically insulated from the second contact zone (32) and wherein the switchable optical device (10) comprises an electrical interconnect (38) for electrically connecting the second contact zone (32) of the first conductive layer (14) to the second conductive layer (22) and/or ii) the switchable optical device (10) comprises at least one further sheet (28) which is laminated to the first substrate (12) and/or the second substrate (14), wherein first substrate (12), the second substrate (24) and the at least one further sheet (28), have essentially the same thermal expansion coefficient.
2. The switchable optical device (10) of claim 1, characterized in that the electrical interconnect (38) is selected from conductive adhesives, structured conductive films, metal spacers (40) and combinations thereof.
3. The switchable optical device (10) of claim 1, characterized in that the first contact zone (30) of the first substrate (14) extends along at least two edges of the first substrate (12) and/or the second contact zone (32) extends along the entire length of at least one edge of the first substrate (12).
4. The switchable optical device (10) of claim 1, characterized in that a metallic conductor (42) extends over the entire area of the first contact zone (30) and/or a metallic conductor (42) extends over the entire area of the second contact zone (32).
5. The switchable optical device (10) of claim 1, characterized in that the second substrate (24) is smaller than the first substrate (12) and is arranged centered above the first substrate (12) or in that the second substrate (24) comprises at least one cut corner (44) and/or multiple cut-outs (46) arranged on at least one edge of the second substrate (24).
6. The switchable optical device (10) of claim 1, characterized in that the switchable optical device (10) further comprises a first metal contact sheet (68) which contacts the first contact zone (30) and a second metal contact sheet (68) which contacts the second contact zone (32), wherein the first and second metal contact sheets (68) extend beyond the first substrate (12) and are bent such that they cover parts of an edge-surface (70) of the first substrate (12) and, if present, of an edge-surface (72) of the further sheet (28) laminated to the first substrate (12).
7. Switchable glazing unit (200) comprising at least one glass pane and at least one switchable optical device (10), characterized in that the at least one switchable optical device (10) is mechanically decoupled from the at least one glass pane and in that a) the switchable glazing unit (200) comprises means for electrically contacting the at least one switchable optical device (10) which include at least one electrical spring contact (220, 110) and/or b) the switchable glazing unit (200) is constructed as an insulated glazing unit comprising two or more panes (202, 204, 206) with gaps between the panes (202, 204, 206) and the at least one switchable optical device (10) is used as one of the panes (202, 204, 206) of the insulated glazing unit, and/or c) the at least one switchable optical device (10) is a switchable optical device (10) according to claim 1.
8. The switchable glazing unit (200) of claim 7, characterized in that the switchable glazing unit (200) further comprises at least one window element (100) comprising the at least one switchable optical device (10), a frame (101) for mechanical decoupling and electrical contacting of the at least one switchable optical device (10) and at least one electrical spring contact (110) for contacting the at least one switchable optical device (10).
9. The switchable glazing unit (200) of claim 8, characterized in that the frame (101) is made from three types of frame profile parts (102, 104, 106), wherein the sides of the frame (101) are formed respectively by a first profile part (102) having a U-shaped profile and the top and bottom sides of the frame (101) are formed respectively by a second profile part (104) having a L-shaped profile and a third profile part (106) having a rectangular profile.
10. The switchable glazing unit (200) of claim 8, characterized in that the switchable glazing unit (200) further comprises electrical spring contacts (220) for electrically contacting the at least one switchable window element (100) and/or in that, that the switchable window element (100) further comprises an electrical cable, an electrical socket or an electrical contact surface for electrically contacting of the switchable window element (100).
11. The switchable glazing unit (200) of claim 7, characterized in that the electrical spring contact (220, 110) for contacting the at least one switchable optical device (10) according to aspect a) and/or for contacting the at least one switchable window element (100), if present, is configured as a bending spring (228) or a spring loaded contact pin (230).
12. The switchable glazing unit (200) of claim 7, characterized in that the switchable glazing unit (200) further comprises an insulated glazing unit having two or more panes (202, 204, 206) with gaps between the panes (202, 204, 206) and the at least one switchable optical device (10) is arranged adjacent to one of the panes (202, 204, 206).
13. The switchable glazing unit (200) of claim 7, characterized in that a switchable area (80) of the at least one switchable optical device (10) is smaller than an optically clear area of the at least one glass pane and that the switchable glazing unit (200) additionally comprises a passepartout-frame (420) for covering spacer-blocks (410) and/or non-switching areas (82) of the at least one switchable optical device (10).
14. The switchable glazing unit (200) of claim 7, characterized in that at least one glass pane and/or at least one switchable optical device (10) comprises a transparent electrical heater film (62, 64).
15. The switchable glazing unit (200) of claim 7, characterized in that the at least one switchable optical device (10) is selected from liquid crystal based devices, electrochromic devices, gasochromic devices, thermochromic devices, thermally switchable devices, suspended particle devices or combinations of at least two of these switchable optical devices.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0124] The drawings show:
[0125] FIG. 1 a schematic side view of a switchable optical device,
[0126] FIG. 2 a top view of the switchable optical device,
[0127] FIGS. 3a to 3f a process for manufacturing of the switchable optical device,
[0128] FIG. 4 the switchable optical device in perspective view,
[0129] FIGS. 5a to 5f alternative embodiments of the switchable optical device,
[0130] FIG. 6 a switchable optical device having multiple cut-outs in perspective view,
[0131] FIGS. 7a and 7b alternative shapes for the cut-outs,
[0132] FIG. 8 an embodiment of the switchable optical device including film heaters,
[0133] FIG. 9 a window element in top view,
[0134] FIG. 10 a cross section of the contact area of the window element,
[0135] FIG. 11 the window element in perspective view,
[0136] FIG. 12 a first embodiment of a switchable glazing unit,
[0137] FIG. 13 a second embodiment of the switchable glazing unit,
[0138] FIGS. 14a and 14b alternative embodiments of electrical contacts,
[0139] FIGS. 15a and b a third embodiment of the switchable glazing unit,
[0140] FIG. 15c alternative electrical contacts,
[0141] FIG. 16 a forth embodiment of the switchable glazing unit,
[0142] FIG. 17 a fifth embodiment of the switchable glazing unit,
[0143] FIG. 18a a sixth embodiment of the switchable glazing unit,
[0144] FIG. 18b the sixth embodiment with different size of the switchable optical device, and
[0145] FIGS. 19a and 19b two embodiments of holders having spring contacts.
[0146] FIG. 1 shows a schematic side view of a switchable optical device 10. The switchable optical device 10 has a layer structure which comprises in this order a first substrate 12, a first conductive layer 14, a first alignment layer 16, a switchable layer 18, a second alignment layer 20, a second conductive layer 22 and a second substrate 24. Said layer structure forms a switchable element which has at least two states. The state of the switchable layer 18 is controlled by applying an electric driving signal to the first conductive layer 14 and the second conductive layer 22.
[0147] In the embodiment shown in FIG. 1, the switchable optical device 10 is constructed as a liquid crystal based device. The switchable layer 18 therefore comprises a liquid crystalline medium and is sealed by means of a glue line 36. The liquid crystalline medium which is located in the area of the switchable optical device within the glue line 36 may switch its state when an appropriate driving signal is applied to the first conductive layer 14 and second conductive layer 22. The area within the glue line 36 is also called switchable area 80 and the remaining area is also called non-switchable area 82.
[0148] The first conductive layer 14 is divided into a first area and a second area by means of an insulated zone 34. The first area comprises a first contact zone 30 and an electrode zone 29. The second area comprises a second contact zone 32. The first contact zone 30 and the second contact zone 32 as well as the insulted zone 34 are located in the non-switchable area 82 and the electrode zone 29 is located in the switchable area 80.
[0149] For supplying the electric driving signal to the second conductive layer 22, the second contact zone 32 of the first conductive layer 14 is used. The driving signal is transferred from the second contact zone 32 to the second conductive layer 22 by means of an electrical interconnect 38. In the embodiment of FIG. 1, the electrical interconnect 38 is formed by metal spacers 40 which are embedded in an adhesive material.
[0150] The switchable optical device 10 of FIG. 1 additionally comprises a further sheet 28 for providing additional mechanical stability. The further sheet 28 is laminated to the other surface of the first substrate 12 by means of an interlayer 26. Additionally or alternatively to the further sheet 28 the switchable optical device 10 may comprise a second layer structure forming a second switchable element. The second switchable element may, for example, be laminated to the first substrate 12 by means of the interlayer 26.
[0151] FIG. 2 shows a top view of a switchable optical device 10. The glue line 36 and the electrical interconnect 38 are visible as the second substrate 24, see FIG. 1, is transparent. As can be seen form FIG. 2, the first conductive layer 14, see FIG. 1, is divided by the insulated zone 34 in a first area comprising the first contact zone 30 and the electrode zone 29 and a second area comprising the second contact zone 32. In the shown embodiment of FIG. 2, the first contact zone 30 surrounds the electrode zone 29 and, in particular extends along a part of a first edge 86 and along an entire second edge adjacent to the first edge 86. The second contact zone 32 extends along a part of the first edge 86 and along the entire length of a third edge adjacent to the first edge 86.
[0152] The second substrate 24, see FIG. 1, has two cut corners 44 which allow access to the first conductive layer 14. Beneath the cut corners 44, the conductive layer 14 comprises metallized surfaces 48 which may, for example, be contacted by means of a spring contact 220, see FIG. 12. As can be seen in FIG. 2, both metallized surfaces 48 abut against a first edge 86 of the first substrate 12 of the switchable optical device 10.
[0153] FIGS. 3a to 3f show a process for manufacturing of a switchable optical device 10.
[0154] In a first step a) shown in FIG. 3a, a first substrate 12 which is coated with the first conductive layer 14 is provided. The first conductive layer 14 may, for example, be a transparent ITO layer. The first conductive layer 14 is structured, for example by means of laser process or a photolithographic process, to form the insulated zone 34.
[0155] Further, in the example depicted in FIG. 3a, the first substrate 12 is laminated to a further sheet 28 by means of an interlayer 26.
[0156] In a second step b) shown in FIG. 3b, first alignment layer 16 for liquid crystals is applied. The first alignment layer 16 is, for example, a polyimide layer. The first alignment layer 16 is structured by rubbing using a roller 50.
[0157] In a third step c) shown in FIG. 3c, a glue line 36 for forming a seal for liquid crystalline medium is applied. Also, an electrical interconnect 38 is prepared by applying an adhesive comprising metal spacers 40, see FIG. 1. Optionally, the first alignment layer 16 is partially removed before applying the glue line 36 and/or before preparing the electrical interconnect 38.
[0158] In a forth step d) shown in FIG. 3d, the liquid crystalline medium is provided. In the example of FIG. 3d, the liquid crystalline medium is provided by means of one drop filling. Alternatively, other filing techniques such as, for example, ink jet printing or a vacuum filing process may be used. The liquid crystalline medium may comprise spacers to ensure a uniform thickness of the switchable layer 18.
[0159] A fifth step e) shown in FIG. 3e, is performed in vacuum. Air is evacuated, for example in a vacuum assembly-unit having a vacuum chamber 52 and a second substrate 24 having two cut corners 44 is provided. For handling of the second substrate 24 chucks 54 are used. The chucks 54 may, for example, be electrostatic chucks or gecko chucks. The second substrate 24 is placed onto the prepared glue line 36 by means of the chucks 54 so that the second substrate 24 is aligned to the first substrate 12.
[0160] In a last step f) shown in FIG. 3f the adhesives used in the glue line 36 and the electrical interconnect 38 are cured by means of UV-radiation. The UV-radiation is applied by means of UV-source 56. Optionally, a further heat-curing step may be applied.
[0161] Due to the cut corners 44 of the second substrate 24, access is provided to a first electrical contact 58 in the first contact zone 30 and to a second electrical contact 60 in the second contact zone 32. By applying a driving signal to the first and second electrical contacts 58, 60, the state of the switchable optical device 10 may be controlled. The first and second electrical contacts 58, 60 abut against the first edge 86 of the first substrate 12 of the switchable optical device 10.
[0162] FIG. 4 shows the switchable optical device 10 of FIGS. 1 and 2 in perspective view.
[0163] As already described with respect to FIG. 1, the switchable optical device 10 comprises in this order the further sheet 28, the interlayer 26, the first substrate 12, the first conductive layer 14, the first alignment layer 16, the switchable layer 18, the second alignment layer 20, the second conductive layer 22 and the second substrate 24. The switchable layer 18 is enclosed by a seal formed by the glue line 36 so that the switchable layer 18 is not visible in the perspective view of FIG. 4.
[0164] As shown in FIG. 4, a driving signal, such as an alternating sine wave signal, a square wave or a DC signal, may be applied to the first electrical contact 58 located in the first contact zone 30 and to the second electrical contact 60 located in the second contact zone 32. The first contact zone 30 of the first conductive layer 14 is in direct contact to the electrode zone 29, see FIGS. 1 and 2. For suppling the driving signal to the second conductive layer 22, the electrical interconnect 38 is used. The electrical interconnect 38 connects the second contact zone 32 to the second conductive layer 22 so that the driving signal may reach the second conductive layer 22 along the electric path 84.
[0165] FIGS. 5a to 5d show alternative embodiments of the switchable optical device 10 in a simplified schematic view in which most of the layers and the electrical interconnect 38 have been omitted.
[0166] In the second embodiment of FIGS. 5a and 5b, the second substrate 24 is of a smaller size than the first substrate 12. FIG. 5a shows a side view and FIG. 5b shows a top view of the switchable optical device 10. As can be seen in the top view of FIG. 5b, the second substrate 24 is aligned to the first edge 86 of the first substrate 12 and is otherwise centered above the first substrate 12. In this arrangement, parts of the first conductive layer 14 remain uncovered so that the first contact zone 30 and the second contact zone 32 are accessible and may be contacted, for example, by means of a spring contact 220, see FIG. 12. In order to improve the electrical conductivity, a metal conductor 48 may be provided in the first contact zone 30 and the second contact zone 32, for example by means of sputtering of a metal film or by applying a conductive metal foil or a bus bar.
[0167] FIG. 5c shows a third embodiment of the switchable optical device 10 in a top view. Both the first substrate 12 as well as the second substrate 24 have essentially the same size and shape but the second substrate 24 is provided with multiple cut-outs 46 which allow access to the first contact zone 30 and the second contact zone 32, respectively. The second substrate 24 is aligned to the edges of the first substrate 12. As already shown in the second embodiment of FIGS. 5a and 5b, the first and second contact zone 30, 32 may be provided with a metal conductor 48 for improving the conductivity. The cut-outs 46 assigned to the second contact zone 30 extend along another edge which is adjacent to the first edge 86. In the example sown in FIG. 5c, the cut-outs 46 have the shape of a semi-circle.
[0168] FIG. 5d shows a fourth embodiment of the switchable optical device 10 which is similar to the first embodiment of FIGS. 1 and 2. Both the first substrate 12 as well as the second substrate 24 have essentially the same shape and size. The second substrate 24 differs from the first substrate 12 in having two cut corners 44 which allow access to metallized surfaces 48 in the first contact zone 30 and second contact zone 32, respectively. The first and second contact zones 30, 32 each abut against the first edge 86 of the first substrate 12. The first contact zone 30 extends along the entire length of an edge adjacent to the first edge 86 and the second contact zone 32 extends along the entire length of another edge adjacent to the first edge 86.
[0169] The first and second contact zones 30, 32 each comprise metal conductors 42 in the form of a sputtered metal film. In the embodiment shown in FIG. 5d, the material of the metallized surface 44 is identical to the sputtered film of the metal conductors 42.
[0170] FIG. 5e shows a fifth embodiment of the switchable optical device 10 which is similar to the second embodiment described with respect to FIGS. 4a and 5b. Similar to the second embodiment of the switchable optical device 10, the second substrate 24 of the switchable optical device 10 of the fifth embodiment is of a smaller size than the first substrate 12. Figure Se shows a top view of the switchable optical device 10. In contrast to the second embodiment shown in FIG. 5b, the second substrate 24 is smaller but of the same shape than the first substrate 12 and is centered above the first substrate 12. In this arrangement, parts of the first substrate 12 along all four of the edges remain uncovered so that the first contact zone 30 and the second contact zone 32 are accessible and may be contacted, for example, by means of a spring contact 220, see FIG. 12. Each of the first contact zone 30 and the second contact zone 32 extend along two adjacent edges. Accordingly, the insulated zone 34 has an angled shape having a first part aligned parallel to the first edge 86 and a second part being aligned parallel to an adjacent second edge. In this configuration, all four edges may be used for electrical contacting of the switchable optical device 10, wherein two adjacent edges are assigned to the same contact zone 30, 32, respectively, of the switchable optical device 10.
[0171] In order to improve the electrical conductivity, a metal conductor 48 may be provided in the first contact zone 30 and the second contact zone 32, for example by means of sputtering of a metal film or by applying a conductive metal foil.
[0172] FIG. 5f shows a sixth embodiment of the switchable optical device 10 which is similar to the fifth embodiment described with respect to FIG. 5e. As described with respect to the fifth embodiment of the switchable optical device 10, the second substrate 24 of the switchable optical device 10 of the sixth embodiment is of a smaller size than the first substrate 12 but has the same shape and is centered above the first substrate 12. In this arrangement, parts of the first substrate 12 along all four of the edges remain uncovered so that the first contact zone 30 and the second contact zone 32 are accessible and may be contacted. In contrast to the fifth embodiment, each of the first contact zone 30 and of the second contact zone 32 are divided into two sub-zones as two insulated zones 34 are used. The respective first and second sub-zones are located along opposing edges, respectively. In this configuration, all four edges may be used for electrical contacting of the switchable optical device 10, wherein opposing edges are assigned to the same contact zone 30, 32 of the switchable optical device 10.
[0173] In order to improve the electrical conductivity, a metal conductor 48 may be provided in the first contact zone 30 and the second contact zone 32, for example by means of sputtering of a metal film or by applying a conductive metal foil.
[0174] The features of the different embodiments of the switchable optical device 10 may be combined. For example, the arrangement of the first contact zone 30 and of the second contact zone 32 as shown in the fifth and sixth embodiments of FIGS. 5e and 5f, respectively, may be combined with second substrates 24 having the same size and shape as the first substrate 12 and having cut-outs 46. The cut-outs may, for example, be shaped as shown in FIG. 5c.
[0175] FIG. 6 shows a fifths embodiment of a switchable optical device 10 having multiple cut-outs 46 in an exploded perspective view. The switchable optical device 10 of the fifths embodiment is identical to the third embodiment of FIG. 5c except for the shape of the cut-outs 46. In the fifth embodiment, the cut-outs 46 have a rectangular shape.
[0176] In FIGS. 7a and 7b alternative shapes for the cut-outs 46 are shown. In FIG. 7a, the cut-outs 46 have a shape of a rounded rectangle. In FIG. 7b, a sine-wave pattern for the cut-outs 46 is shown.
[0177] The cut-outs 46 may be produced by means of laser cutting of the second substrate 24.
[0178] FIG. 8 shows a schematic side view of an embodiment of the switchable optical device 10 which includes film heaters 62, 64.
[0179] The switchable optical device 10 of FIG. 8 has essentially the same structure as the switchable optical device of FIG. 1. The switchable optical device 10 has a layer structure which comprises in this order a first film heater 62, the further sheet 28, the interlayer 26, the first substrate 12, the first conductive layer 14, the switchable layer 18 surrounded by the glue line 36, the second conductive layer 22, the second substrate 24 and a second film heater 64. Further, the switchable optical device 10 includes the electrical interconnect 38 for contacting the second conductive layer 22.
[0180] The film heaters 62, 64 are preferably constructed as transparent conductive film, for example an ITO or FTO film. When an electric current is applied to the film heater 62, 64, the film heater 62, 64 warms up due to the electrical resistance of the transparent conductive film.
[0181] In FIG. 9 a section of a window element 100 is shown in top view.
[0182] The window element 100 comprises a switchable optical device 10 and a frame 101. The frame 101 comprises profile parts 102, 104, 106 (see FIGS. 10 and 11) which are connected to each other by means of connecting elements such as screws 108. The switchable optical device 10 is received in the frame 101.
[0183] The frame 101 additionally comprises electrical spring contacts 110 for electrically contacting metallized surfaces 48 of the switchable optical device 10. In the section shown in FIG. 9, only the first electrical contact 58 with its metallized surface 48 is visible. The metallized surface 48 is accessible through the cut corner 44.
[0184] FIG. 10 shows a cross section view of the window element 100 of FIG. 9 along the line marked with A-A. The window element 100 comprises the frame 101 and the switchable optical device 10. The frame 101 comprises profile parts 102, 104, 106 and receives the switchable optical device 10. The profile parts 102, 104, 106 are connected to each other by means of screws 108.
[0185] The frame 101 comprises the electrical spring contact 110 for contacting the metallized surface 48. The electrical spring contact 110 comprises a shaft 118 and a conductive rubber surface 112 which is in contact with the metallized surface 48 of the switchable optical device 10. A spring 116, which abuts a shoulder of the profile part 102 tensions the rubber surface 112 of the electrical spring contact 110 against the metallized surface 44 of the switchable optical device 10 to ensure a reliable electrical connection while at the same time avoiding mechanical stress. The cable 122 is secured to the shaft 118 by means of nuts 114.
[0186] A cable 122 is connected to the electrical spring contact 110 in order to supply a driving signal to the switchable optical device 10. The electrical spring contact 110 is protected by means of a cover 124.
[0187] FIG. 11 shows a section of the frame 101 of the window element 100 in a perspective view. As can be seen in FIG. 11, the frame 101 of the window element 100 consists of three types of profile parts 102, 104, 106. A first profile part 102 is essentially “U”-shaped and forms the sides of the frame 101. The top and bottom sides of the frame 101 are each formed by a second profile part 104, which is essentially “L”-“shaped and a third profile part 106 which is essentially of rectangular shape.
[0188] A second profile part 104 and a third profile part 106 are joined and form a profile having essentially a “U”-shape. For assembling of the frame 101 around a switchable optical device 10, the two first profile parts 102 are provided and cut to the size of the switchable optical device. Further, two second profile parts 104 and two third profile parts 106 are provided and cut to the size of the switchable optical device 10. The two first profile parts 102 are arranged on opposing sides of the switchable optical device 10 such that the switchable optical device 10 engages in the recess of the U-shape. Then second profile parts 104 are respectively connected to third profile parts 106 by means of screws 108. As last step, the second parts 104 are connected to the first profile parts 102.
[0189] Preferably, the size of the frame 101 is chosen such that the switchable optical device 10 has space to expand in order to avoid mechanical stress due to thermal expansion.
[0190] The frame 101 may further comprise air channels 120 which allow the passage of air when the frame 101 is mounted in a window.
[0191] FIG. 12 shows a first embodiment of a switchable glazing unit 200.
[0192] The switchable glazing unit 200 of FIG. 12 is configured as an insulated glazing unit having a first pane 202, a second pane 206 and a middle pane 204. A gap is arranged between the first pane 202 and the middle pane 204 and between the middle pane 204 and the second pane 206, respectively. Spacers 208 are inserted between the first pane 202 and the middle pane 204 and between the middle pane 204 and the second pane 206, respectively.
[0193] The first pane 202 and the second pane 206 are configured as glass panes. An example for the material of the glass panes is soda-lime glass, including tempered or heat-strengthened versions thereof, which may be produced in a float glass process.
[0194] The spacers 208 are attached to the panes 202, 204, 206 by means of a first seal 210 which is, for example, a butyl seal. The outward facing sides of the spacers 208 are sealed by means of a second seal 212 which is, for example, a polysulfone seal. The spacers 208 may comprise a desiccant.
[0195] The middle pane 204 is configured as a switchable optical device 10 which is received by a first holder 216 at the bottom and by a second holder 217 at the top. Both the first holder 216 and the second holder 217 have a recess for receiving the switchable optical device 10. Further holders may be arranged at the sides of the switchable optical device 10. At the second holder 217, a space 218 is arranged in order to accommodate for thermal expansion of the switchable optical device 10.
[0196] The switchable optical device 10 comprises the first substrate 12, the second substrate 24 and the functional layers forming the switchable element as described with respect to FIG. 1. The switchable optical device 10 of the embodiment of FIG. 12 does not comprise a further sheet 28.
[0197] In the embodiment shown in FIG. 12, the second holder 217 is configured to be flush with the spacers 208. In such a configuration, non-switchable areas 82 of the switchable optical device 10, see FIG. 1, may be hidden. The first holder 216 of the embodiment shown in FIG. 12 extends beyond the spacers 208. In such a configuration, the first holder 216 may compensate for a smaller size of the switchable optical device 10 compared to the first pane 202 and second pane 206. If the size of the switchable optical device 10 is sufficiently large, both the first holder 216 as well as the second holder 217 may be configured to be flush with the spacers 208.
[0198] The first holder 216 arranged at the bottom of the switchable optical device 10 comprises a spring contact 220 which in the embodiment of FIG. 12 is configured as a bending spring 228. The spring contact 220 engages the metallized surface 48 of the switchable optical device 10. In the cross section view of FIG. 12, only a single spring contact 220 is visible, but the first holder 216 comprises two spring contacts 220 in order to contact the first electrical contact 58 as well as the second electrical contact 60 of the switchable optical device 10, see FIG. 4. In order to have good corrosion resistance it is preferred to use plated noble metal contacts for spring contact 220. Preferably, gold is used as noble metal.
[0199] For installation of the switchable glazing unit 200 in a window frame 310 (see FIG. 15a), a support block 214 is provided. The support block 214 comprises an electrical socket 226 for receiving of an electrical connector 224 of the switchable glazing unit 200. The electrical connector 224 is connected to the spring contact 200.
[0200] FIG. 13 shows a second embodiment of the switchable glazing unit 200.
[0201] The switchable glazing unit 200 of FIG. 13 is configured as an insulated glazing unit having a first pane 202, a second pane 206 and a middle pane 204. A gap is arranged between the first pane 202 and the middle pane 204 and between the middle pane 204 and the second pane 206, respectively. Spacers 208 are inserted between the first pane 202 and the middle pane 204 and between the middle pane 204 and the second pane 206, respectively.
[0202] The first pane 202 and the second pane 206 are configured as glass panes. An example for the material of the glass panes is soda-lime glass which may be produced in a float glass process. The first pane 202 is, when the switchable glazing unit 200 is used as a window, arranged to face outwards as indicted in FIG. 13 by sun 302. Optionally, a low-e coating 203 may be arranged on the surface of the first pane 202 which faces inwards towards the middle pane 204, see for example FIG. 18a.
[0203] The spacers 208 are attached to the panes 202, 204, 206 by means of a first seal 210 which is, for example, a butyl seal. The outward facing sides of the spacers 208 are sealed by means of a second seal 212 which is, for example, a polysulfone seal.
[0204] A switchable optical device 10 is used as middle pane 204. The switchable optical device 10 of the embodiment of FIG. 13 does not comprise a further sheet 28. An electrical connection to the first and second electrical contacts 58, 60 of the switchable optical device 10, see FIG. 4, are configured as cables 222 which are attached to the electrical contact 58, 60 of the switchable optical device 10, see FIG. 14a.
[0205] When installed in a window, it is preferred to use a support block having a channel for accommodating the cables 222.
[0206] FIG. 14a shows an enlarged perspective view of the first electrical contact 58 of the switchable window 10 used in the switchable glazing of FIG. 13. The first conductive layer 14 of the switchable optical device is accessible through a cut corner 44 of the second substrate 24. The cable 222 is directly attached to the first conductive layer 14 on the first substrate 12 by means of ultrasonic soldering. The connection of the cable 222 to the conductive layer 14 is covered by means of a potting material 66.
[0207] FIG. 14b shows an alternative embodiment of the electrical contacts of the switchable optical device 10 used in the switchable glazing 200 of FIG. 13.
[0208] The switchable optical device 10 comprises a further sheet 28 laminated to the first substrate 12. A metal contact sheet 68 is attached to the first conductive layer 14, see FIG. 1, and extends beyond the first substrate 12. The metal contact sheet 68 is bent around the edge of the first substrate 12 and covers a part of an edge surface 70 of the first substrate 12 and of an edge surface 72 of the further sheet 28.
[0209] The metal contact sheet 68 provides a contact surface which may be contacted by means of a spring contact 220. For example, a bending spring 228 may be used in a window frame 310 to contact the metal contact sheet 68, see FIG. 15a.
[0210] FIG. 15a shows a third embodiment of the switchable glazing unit 200.
[0211] The switchable glazing unit 200 of FIG. 15a is configured as an insulated glazing unit having a first pane 202 and a second pane 206. A gap is arranged between the first pane 202 and the second pane 206 and a spacer 208 is inserted between the first pane 202 and the second pane 206.
[0212] The second pane 206 is configured as a glass pane. An example for the material of the glass pane is soda-lime glass which may be produced in a float glass process. A switchable optical device 10 having a further sheet 28 as described with respect to FIG. 1 is used as first pane 202. The switchable device 10 is arranged such that, when the switchable glazing unit is used as a window of a building or a vehicle, the further sheet 28 faces outside as indicated by the sun 302. On the surface of the second pane 206 which faces inwards towards the switchable optical device 10, a low-e coating 203 is arranged.
[0213] The spacers 208 are attached to the panes 202, 206 by means of a first seal 210 which is, for example, a butyl seal. The outward facing sides of the spacers 208 are sealed by means of a second seal 212 which is, for example, a polysulfone seal.
[0214] For supplying a driving signal, the switchable optical device 10 comprises metal contact sheets 68 which are contacted by the spring contact 220. In the embodiment of FIG. 15a, the spring contact 220 is configured as a spring loaded pin 230. In order to have good corrosion resistance it is preferred to use plated noble metal contacts for the spring contact 220. Preferably, gold is used as noble metal.
[0215] In the embodiment of FIG. 15a, the switchable glazing unit 200 is part of a window 300 having window frame 310 which accommodates the switchable glazing unit 200. A support block 214 and a block 312 are provided to support and secure the switchable glazing unit 200 in the window frame 310. The window frame 310 may comprise a connection box 314 for housing electrical connectors 316. The electrical connectors 316 are connected to the spring contact 220 by means of a cable 222.
[0216] A controller may be used to generate driving signals for the switchable optical device. The controller may be connected to the electrical connectors 316.
[0217] FIG. 15b shows a detailed view of the switchable optical device 10 having a metal contact sheet 68 which is attached to the first conductive layer 14 on the first substrate 12. Potting material 66 may be applied to protect the connection of the metal contact sheet 68 to the first conductive layer 14. The metal contact sheet 68 is attached to the first conductive layer 14, see FIG. 1, and extends beyond the first substrate 12. The metal contact sheet 68 is bent around the edge of the first substrate and covers a part of an edge surface 70 of the first substrate 12 and of an edge surface 72 of the further sheet 68, see FIG. 14b.
[0218] FIG. 15c shows a variant of the third embodiment of the switchable glazing unit 200 as described with respect to FIG. 15a having alternative electrical contacts. In the variant of FIG. 15c, a cable 222 is directly connected to the switchable optical element 10.
[0219] FIG. 16 shows a forth embodiment of the switchable glazing unit 200 which is formed by retro-fitting of an existing window 300.
[0220] The window 300 comprises a window frame 310 and an insulated glazing unit having a first pane 202, and a second pane 206.
[0221] For retro-fitting of the window 300, a window element 100 and mounting elements 400 are provided. In a first step, the mounting elements 400 are attached to the first pane 202 of the insulated glazing unit of the existing window 300. The mounting elements 400 may, for example, be attached by means of an adhesive. In a second step, the switchable glazing unit 200 is formed by attaching the window element 100 to the mounting elements 400, for example by means of connecting elements such as screws or by means of an adhesive. The window element 100 as shown in FIG. 16 comprises the frame 101 and the switchable optical device 10 as shown in FIGS. 9 to 11.
[0222] In the example depicted in FIG. 16, the window element 100 is attached to the side of the window 300 which faces towards the outside of the building or vehicle.
[0223] FIG. 17 shows a fifth embodiment of the switchable glazing unit 200 which may be formed by retro-fitting of an existing window 300.
[0224] The existing window 300 comprises a window frame 310 and an insulated glazing unit having a first pane 202, a second pane 206 and spacers 208. The insulated glazing unit is supported in the window frame 310 by means of a support block 214.
[0225] In the example shown in FIG. 17, a switchable optical device 10 is provided which is of the same size than the first and second panes 202, 206 of the existing window 300. The switchable optical device 10 is attached to the second pane 206 by means of mounting elements 402 having an air channel. The mounting elements 402 are attached to the second pane 206 by means of an adhesive 404. Also, the switchable optical device 10 is attached to the mounting elements 402 by means of an adhesive 404. The air channels of the mounting element 402 allow for venting of the air gap formed between the switchable optical device 10 and the second pane 206.
[0226] The switchable optical device 10 comprises metal contact sheets 68 for providing an electrical connection. In the example of FIG. 17, the contact sheets 68 are contacted by means of a spring contact 220 configured as a bending spring 228. The spring contact 220 is attached to an electrical connector 322. The electrical connector 322 is supported by a compensation element 320 which is preferably an elastic element.
[0227] A block 312 and a clamping bar 318 are provided to secure the switchable optical device 10 and to hide non-switchable areas 82 of the switchable optical device 10. The clamping bar 318 is attached to the window frame 310.
[0228] FIG. 18a shows a sixth embodiment of the switchable glazing unit 200 which may be formed by retro-fitting of an existing window 300.
[0229] The existing window 300 comprises a window frame 310 and an insulated glazing unit having a first pane 202, a second pane 206 and spacers 208. The insulated glazing unit is supported in the window frame 310 by means of a support block 214. On the surface of the second pane 206 which faces inwards towards the first pane 202, a low-e coating 203 is arranged.
[0230] In the example shown in FIG. 18a, a switchable optical device 10 is provided having the same size than the first and second panes 202, 206 of the existing window 300. The switchable optical device 10 is held by a first holder 216 at the bottom and is held by a second holder 217 at the top. The second holder 217 provides a space 218 to accommodate for thermal expansion of the switchable optical device 10. The first and second holders 216, 217 are attached to the second pane 206 by means of an adhesive 404. Further, the first holder 216 is supported by the window frame 310.
[0231] A clamping bar 318 is provided to secure the first holder 216 and to hide non-switchable areas 82 of the switchable optical device 10. The clamping bar 318 is attached to the window frame 310.
[0232] The switchable optical device 10 of FIG. 18a is provided with a film heater 62. The film heater 62 as well as the first and second electrical contacts 58, 60, see FIG. 4, are contacted by means of spring contacts 220 located in the first holder 216.
[0233] FIG. 18b shows the sixth embodiment of the switchable glazing 200 having a switchable optical device 10 of different size.
[0234] In the example shown in FIG. 18b, a switchable optical device 10 is provided which is of a smaller size than the first and second panes 202, 206 of the existing window 300. To compensate for the size difference, spacer blocks 410 are provided which support the switchable optical device 10. The first and second holders 216, 217 are attached to the second pane 206 by means of an adhesive 404. Further, the first holder 216 is supported by the spacer blocks 410.
[0235] In order to hide the size difference and in addition to hide non-switchable areas 82 of the switchable optical device 10, a passepartout-frame 420 is provided in form of an enlarged clamping bar 318. The clamping bar 318 is attached to the window frame 310.
[0236] FIGS. 19a and 19b show two embodiments of first holders 216 with spring contacts 220.
[0237] In FIG. 19a, a section of a switchable optical device 10 is shown having a cut corner 44 which exposes the metallized surface 48. Further, the switchable optical device 10 has a film heater 62 on the opposing side.
[0238] The first holder 216 comprises a recess 260 for receiving the switchable optical device 10. Further, the first holder 216 comprises a spring contact 220 for engaging the metallized surface 48. A further spring contact 220′ is arranged to contact the film heater 62. Additionally, the first holder 216 as depicted in FIG. 19a comprises an air vent 240 which allows for the passage of air.
[0239] FIG. 19b shows an alternative embodiment of the first holder 216 which comprises a plurality of spring contacts 220 for engaging a metallized surface 48 which is exposed by multiple cut-outs 46 as depicted, in FIGS. 5c and 6.
[0240] A further spring contact 220′ is arranged to contact a film heater 62 of the switchable optical device. Additionally, the first holder 216 as depicted in FIG. 19b comprises multiple air vents 240 which allows for the passage of air and a channel 250 for accommodating cables.
LIST OF REFERENCE NUMERALS
[0241] 10 switchable optical device [0242] 12 first substrate [0243] 14 first conductive layer [0244] 16 first alignment layer [0245] 18 switchable layer [0246] 20 second alignment layer [0247] 22 second conductive layer [0248] 24 second substrate [0249] 26 interlayer [0250] 26′ interlayer with UV protection [0251] 28 further sheet [0252] 29 electrode zone [0253] 30 first contact zone [0254] 32 second contact zone [0255] 34 insulated zone [0256] 36 glue line [0257] 38 electrical interconnect [0258] 40 metal spacer [0259] 42 metallic conductor [0260] 44 cut corner [0261] 46 (multiple) cut-out [0262] 48 metallized surface [0263] 50 roller [0264] 52 vacuum chamber [0265] 54 handling chuck [0266] 56 UV-source [0267] 58 first electrical contact [0268] 60 second electrical contact [0269] 62 first film heater [0270] 64 second film heater [0271] 66 potting [0272] 68 metal contact sheet [0273] 70 edge surface of first substrate [0274] 72 edge surface of further sheet [0275] 80 switchable area [0276] 82 non-switchable area [0277] 84 electric path [0278] 86 first edge [0279] 100 window element [0280] 101 frame [0281] 102 first profile part [0282] 104 second profile part [0283] 106 third profile part [0284] 108 screw [0285] 110 electrical spring contact [0286] 112 conductive rubber [0287] 114 nut [0288] 116 spring [0289] 118 shaft [0290] 120 air channel [0291] 122 cable [0292] 124 cover [0293] 200 switchable glazing unit [0294] 202 first pane [0295] 203 low-e layer [0296] 204 middle pane [0297] 206 second pane [0298] 208 spacer [0299] 210 first seal [0300] 212 second seal [0301] 214 support block [0302] 216 first holding element [0303] 217 second holding element [0304] 218 space [0305] 220 electric spring contact [0306] 222 cable [0307] 224 connector [0308] 226 socket [0309] 228 bending spring [0310] 230 spring loaded pin [0311] 240 vent [0312] 250 channel [0313] 300 window [0314] 302 sun [0315] 310 window frame [0316] 312 block [0317] 314 connection box [0318] 316 electrical connector [0319] 318 clamping bar [0320] 320 compensation element [0321] 322 electrical connector [0322] 330 el. connector for heater [0323] 400 mounting element [0324] 402 mounting element with air channel [0325] 404 adhesive [0326] 410 spacer-block [0327] 420 passepartout frame
