Thin-film devices and fabrication

Abstract

Thin-film devices, for example electrochromic devices for windows, and methods of manufacturing are described. Particular focus is given to methods of patterning optical devices. Various edge deletion and isolation scribes are performed, for example, to ensure the optical device has appropriate isolation from any edge defects. Methods described herein apply to any thin-film device having one or more material layers sandwiched between two thin film electrical conductor layers. The described methods create novel optical device configurations.

1 .- 69 . (canceled) 
     
     
         70 . An optical device laminate, comprising:
 a first lite;   a second lite laminated to the first lite, wherein the second lite comprises low-sodium annealed glass;   a lamination adhesive between the first lite and the and second lite; and   an optical device on an outward facing surface of the second lite;   wherein the second lite has a smaller area than the first lite and is set back from the first lite about the perimeter of the optical device laminate.   
     
     
         71 . The optical device laminate of  claim 70 , wherein the first lite comprises a material selected from the group consisting of a tempered glass, a heat-strengthened glass, a chemically-strengthened glass, and a polymer. 
     
     
         72 . The optical device laminate of  claim 71 , wherein the tempered glass is (i) between about 2 mm and about 25 mm thick or (ii) between about 0.5 mm and about 2.0 mm thick. 
     
     
         73 . The optical device laminate of  claim 70 , wherein the second lite is less than 0.3 mm thick, less than 0.2 mm thick, or less than 0.1 mm thick. 
     
     
         74 . The optical device laminate of  claim 70 , wherein the optical device is a solid state electrochromic device. 
     
     
         75 . The optical device laminate of  claim 70 , wherein the perimeter of the optical device laminate comprises an edge treatment. 
     
     
         76 . The optical device laminate of  claim 75 , wherein the edge treatment comprises an edge adhesive. 
     
     
         77 . The optical device laminate of  claim 76 , wherein the edge adhesive is configured to cover about a 1 mm wide band, about a 2 mm wide band, or about a 3 mm wide band about a perimeter edge of the first lite. 
     
     
         78 . The optical device laminate of  claim 76 , wherein the edge adhesive is configured to penetrate and seal one or more microcracks and/or defects in the second lite. 
     
     
         79 . The optical device laminate of  claim 78 , wherein the edge adhesive comprises a low viscosity adhesive. 
     
     
         80 . The optical device laminate of  claim 75 , wherein the edge treatment comprises a ground and/or polished edge. 
     
     
         81 . The optical device laminate of  claim 79 , wherein the edge treatment comprises a melted portion of the second lite about its perimeter. 
     
     
         82 . The optical device laminate of  claim 79 , wherein the edge treatment comprises a laser-treated portion. 
     
     
         83 . The optical device laminate of  claim 70 , wherein the second lite is a flexible low-sodium annealed glass. 
     
     
         84 . The optical device laminate of  claim 70 , wherein the optical device laminate is part of an insulated glass unit. 
     
     
         85 . A method of fabricating an optical device laminate, the method comprising:
 receiving a first lite;   laminating a second lite to a first lite to form the optical device laminate, wherein the second lite has a smaller area than the first lite and is set back from the first lite about the perimeter of the optical device laminate, and wherein the second lite comprises low-sodium annealed glass; and   fabricating an optical device on an outward facing surface of the flexible low-sodium annealed glass of the optical device laminate.   
     
     
         86 . The method of  claim 85 , wherein the first lite comprises a material selected from the group consisting of a tempered glass, a heat-strengthened glass, a chemically-strengthened glass, and a polymer. 
     
     
         87 . The method of  claim 86 , wherein the tempered glass is (i) between about 2 mm and about 25 mm thick or (ii) between about 0.5 mm and about 2.0 mm thick. 
     
     
         88 . The method of  claim 85 , wherein the second lite is less than 0.3 mm thick, less than 0.2 mm thick, or less than 0.1 mm thick. 
     
     
         89 . The method of  claim 85 , wherein the optical device is a solid state electrochromic device. 
     
     
         90 . The method of  claim 85 , further comprising applying an edge treatment. 
     
     
         91 . The method of  claim 90 , wherein the edge treatment is applied to a perimeter edge of the second lite, and is configured to strengthen and/or protect the perimeter edge. 
     
     
         92 . The method of  claim 90 , wherein applying the edge treatment comprises applying an edge adhesive. 
     
     
         93 . The method of  claim 92 , wherein the edge adhesive covers about a 1 mm wide band, about a 2 mm wide band, or about a 3 mm wide band about a perimeter edge of the first lite. 
     
     
         94 . The method of  claim 92 , wherein application of the edge adhesive comprises penetrating and sealing one or more microcracks and/or defects in the second lite. 
     
     
         95 . The method of  claim 92 , wherein the edge adhesive comprises a low viscosity adhesive. 
     
     
         96 . The method of  claim 92 , wherein application of the edge adhesive comprises a two-part application including (i) applying a low viscosity portion and (ii) applying more viscous portion thereafter. 
     
     
         97 . The method of  claim 90 , wherein the edge treatment comprises grinding and/or polishing at least one edge of the optical device laminate. 
     
     
         98 . The method of  claim 90 , wherein the edge treatment comprises heating an edge of the second lite to melt an outer portion. 
     
     
         99 . The method of  claim 90 , wherein the edge treatment comprises applying a laser at an edge of the optical device laminate. 
     
     
         100 . The method of  claim 99 , wherein application of the laser is configured to remove defect portions at the edge and/or to bevel the edge. 
     
     
         101 . The method of  claim 90 , wherein the second lite is a flexible low-sodium annealed glass. 
     
     
         102 . The method of  claim 90 , wherein the edge treatment comprises acid etching of the optical device laminate. 
     
     
         103 . The method of  claim 90 , wherein the edge treatment comprises applying a material tape around an edge of the optical device laminate.