Methods for producing lower electrical isolation in electrochromic films

Abstract

The present invention provides for an electroactive device having a first conductive layer, a second conductive layer, and one or more electroactive layers sandwiched between the first and second conductive layers. One or more adjacent layers of the electroactive device may include a physical separation between a first portion and a second portion of the adjacent layers, the physical separation defining a respective tapered sidewall of each of the first and second portions. The one or more adjacent layers may include one of the first and second conductive layers. The remaining layers of the electroactive device may be formed over the physical separation of the one or more adjacent layers. The remaining layers may include the other of the first and second conductive layers.

1 . An electroactive device comprising:
 a first conductive layer and a second conductive layer, and one or more electroactive layers sandwiched between said first and second conductive layers,   wherein one or more adjacent layers of the electroactive device comprises a physical separation between a first portion and a second portion of said plurality of electroactive layers, said physical separation defining a respective tapered sidewall of each of the first and second portions, said one or more adjacent layers comprising one of said first and second conductive layers, and   wherein the remaining layers of the electroactive device are formed on said one or more adjacent layers over said physical separation, said remaining layers comprising the other of said first and second conductive layers.   
     
     
         2 . The electroactive device of  claim 1 , wherein said one or more adjacent layers further comprises at least one electroactive layer. 
     
     
         3 . The electroactive device of  claim 1 , wherein said remaining layers comprise each of the electroactive layers of the electroactive device. 
     
     
         4 . The electroactive device of  claim 1 , wherein the electroactive device is one of an electrochromic device, an electroluminescent device, a battery, a photochromic device, a thermochromic device, a suspended particle device, a liquid crystal display device, a photovoltaic device, and a light emitting diode. 
     
     
         5 . The electroactive device of  claim 1 , wherein the electroactive device is an electrochromic device, and wherein the one or more electroactive layers comprises:
 a first electrode comprising one of an electrochromic electrode layer and a counter electrode layer;   a second electrode comprising the other of said electrochromic electrode layer and said counter electrode layer; and   an ion-conductor layer for conducting ions between said first and second electrodes.   
     
     
         6 . The electroactive device of  claim 5 , wherein said one or more adjacent layers further comprises one of said first and second electrodes, and wherein said remaining layers further comprises said ion conductor layer and the other of said first and second electrodes. 
     
     
         7 . The electroactive device of  claim 5 , wherein said one or more adjacent layers further comprises said ion conductor layer and one of said first and second electrodes and said ion conductor layer, wherein said remaining layers further comprises the other of said first and second electrodes. 
     
     
         8 . The electroactive device of  claim 5 , wherein said remaining layers further comprises said ion conductor layer and each of said first and second electrodes. 
     
     
         9 . The electroactive device of  claim 1 , wherein said one or more adjacent layers are at least about twice as thick as the electroactive layers of said one or more remaining layers of the electroactive device. 
     
     
         10 . The electroactive device of  claim 1 , wherein said one or more adjacent layers are at least about three times as thick as the electroactive layers of said one or more remaining layers of the electroactive device. 
     
     
         11 . The electroactive device of  claim 1 , wherein the physical separation does not have melt spots along the tapered sidewalls. 
     
     
         12 . The electroactive device of  claim 1 , further comprising a substrate, wherein said conductive layer comprising the physical separation directly touches the substrate without delamination along the tapered sidewalls. 
     
     
         13 . The electroactive device of  claim 1 , wherein the incline of each of the tapered sidewalls is about 45 degrees or less relative to the plane of the substrate, such that each sidewall does not exhibit shadowing. 
     
     
         14 . The electroactive device of  claim 1 , further comprising a physical separation between the second portion and a third portion of said plurality of electroactive layers, said physical separation between the second and third portions defining a respective tapered sidewall of each of the second and third portions. 
     
     
         15 . A method of fabricating an electroactive device, the method comprising:
 providing a substrate;   forming one or more adjacent layers of the electroactive device on the surface of the substrate;   positioning a scribing implement incident to the side of the substrate having the one or more adjacent layers formed thereon;   removing a portion of the one or more adjacent layers of the electroactive device from the substrate using the scribing implement, thereby forming a physical separation between a first portion and a second portion of said one or more adjacent layers, said physical separation defining a respective tapered sidewall of each of the first and second portions;   forming one or more remaining layers of the electroactive device over the physical separation of the one or more adjacent layers.   
     
     
         16 . The method of  claim 15 , wherein the respective tapered sidewalls defined by the physical separation therebetween are formed with a substantially linear profile. 
     
     
         17 . The method of  claim 15 , wherein the respective tapered sidewalls defined by the physical separation therebetween are formed with a substantially Gaussian profile. 
     
     
         18 . The method of  claim 15 , wherein the respective tapered sidewalls defined by the physical separation therebetween are formed with an incline of about 45 degrees or less relative to the plane of the substrate, such that each sidewall does not exhibit shadowing. 
     
     
         19 . The method of  claim 15 , wherein the electroactive device formed by the method is an electrochromic device. 
     
     
         20 . A method of fabricating an electroactive device comprising a first conductive layer, a second conductive layer, and one or more electroactive layers sandwiched between said first and second conductive layers, the method comprising:
 providing a substrate;   forming one or more adjacent layers of the electroactive device on the surface of the substrate, said one or more adjacent layers comprising one of the first and second conductive layers;   providing a laser with a pulse width of about 100 picoseconds or shorter;   removing a portion of said one or more adjacent layers from the substrate using the laser;   forming the remaining layers of the electroactive device over the one or more adjacent layers, said remaining layers comprising the other of said first and second conductive layers.   
     
     
         21 . The method of  claim 20 , wherein said one or more adjacent layers further comprises at least one electroactive layer. 
     
     
         22 . The method of  claim 20 , wherein said remaining layers further comprise all of the one or more electroactive layers sandwiched between said first and second conductive layers. 
     
     
         23 . The method of  claim 20 , wherein the pulse width of the laser is about 10 picoseconds or shorter. 
     
     
         24 . The method of  claim 23 , wherein the pulse width of the laser is about 6 picoseconds. 
     
     
         25 . The method of  claim 20 , wherein the laser has an operational wavelength between about 515 nm and about 532 nm. 
     
     
         26 . The method of  claim 20 , wherein the electroactive device formed by the method is an electrochromic device. 
     
     
         27 . The method of  claim 26 , wherein the laser is positioned incident to the side of the substrate having the one or more adjacent layers formed thereon. 
     
     
         28 . A system for fabricating an electrochromic device, the system comprising:
 a housing for containing a substrate on which the electrochromic device is formed;   a deposition system configured to deposit one or more layers of the electrochromic device onto the substrate;   a laser mounted in the housing incident to the side of the substrate on which the electrochromic device is formed, said laser positioned to produce a beam on the surface of the substrate;   a positioning device for moving the beam relative the substrate; and   a collection system for collecting particulate materials or vapors generated by focusing of the beam on the surface of the substrate.   
     
     
         29 . A method of fabricating an electrochromic device in the system of  claim 28 , the method comprising:
 providing a substrate in the housing, and without removing said substrate from the housing:
 forming one or more adjacent layers of the electrochromic device on the surface of the substrate; 
 removing a portion of the one or more adjacent layers using the laser; and 
 forming one or more remaining layers of the electrochromic device over the one or more adjacent layers. 
   
     
     
         30 . A system for fabricating an electrochromic device, the system comprising:
 a housing for containing a substrate on which the electrochromic device is formed;   a deposition system configured to deposit one or more layers of the electrochromic device onto the substrate;   a laser mounted in the housing, said laser having a pulse width of 100 picoseconds or shorter and positioned to produce a beam on the substrate;   a positioning device for moving the beam relative the substrate; and   a collection system for collecting particulate materials or vapors generated by focusing of the beam on the surface of the substrate.   
     
     
         31 . A method of fabricating an electrochromic device in the system of  claim 30 , the method comprising:
 providing a substrate in the housing, and without removing said substrate from the housing:
 forming one or more adjacent layers of the electrochromic device on the surface of the substrate; 
 removing a portion of the one or more adjacent layers using the laser; and 
 forming one or more remaining layers of the electrochromic device over the one or more adjacent layers.