Coil distortion correction technology for a potential-driven shade, and / or related methods

Abstract

Certain exemplary embodiments relate to potential-driven shades usable in insulating glass (IG) units, IG units including such shades, and / or related methods. In such units, a dynamic shade is disposed between substrates defining the IG unit and is movable between a retracted position and an extended position. The dynamic shade includes layers on the glass including a transparent conductor, an insulator or dielectric film, and a shutter. The shutter includes an elastic polymer, a conductor, and optional ink. The transparent conductor on the glass may be patterned into different regions. When shutter coil distortion is detected, a voltage(s) may be applied to one or more regions of the transparent conductor on the glass to attempt to compensate for the detected coil distortion or otherwise correct the coil distortion.

Description

Technical Field

[0001] Certain exemplary embodiments of the present invention relate to shades that can be used with insulating glass units (IG units or IGUs), IG units including such shades, and / or methods of manufacturing the same. More specifically, certain exemplary embodiments of the present invention relate to electrically actuated shades that can be used with IG units, IG units including such shades, and / or methods of manufacturing the same.

Background Art

[0002] The building sector is known for its high energy consumption, which has been shown to account for 30 - 40% of the world's primary energy consumption. In particular, in older structures built to less stringent building standards with lower energy efficiency, operating costs such as heating, cooling, ventilation, and lighting account for most of this consumption.

[0003] Windows, for example, provide natural light, fresh air, access, and connection to the outside world. However, they are often also a classic example of a major cause of wasted energy. The increasing trend to increase the use of architectural windows and balance the conflicting benefits of energy efficiency and human comfort has become increasingly important. Furthermore, concerns regarding global warming and carbon dioxide emissions have been a driving force for new, highly energy - efficient glazing systems.

[0004] In this regard, it becomes apparent that windows are typically the "weak link" in a building's insulation, and considering modern architectural designs that often include entire glass facades, it would be advantageous to have better - insulated windows in terms of controlling and reducing energy waste. Therefore, the development of highly insulating windows has significant environmental and economic benefits.

Summary of the Invention

[0005] Insulating glass units (IG units or IGUs) have been developed and have improved the insulation of buildings and other structures. FIG. 1 is a schematic cross-sectional view of an exemplary IG unit. In the exemplary IG unit of FIG. 1, the first substrate 102 and the second substrate 104 are substantially parallel and spaced apart from each other. The spacer system 106 is provided around the first substrate 102 and the second substrate 104, serves to maintain the substrates in a spaced-apart relationship substantially parallel to each other, and defines a gap or space 108 between the substrates. The gap 108 may be at least partially filled with an inert gas (e.g., Ar, Kr, Xe, etc.) in some cases to improve the overall insulating properties of the IG unit. In some cases, an optional outer seal may be provided in addition to the spacer system 106.

[0006] Windows are an inherent element in most buildings in that they have the ability to "supply energy" to the building in the form of winter solar gain and daylight throughout the year. However, current window technology often leads to excessive heating costs in winter and excessive cooling in summer, and often fails to capture the daylight benefits that allow light to be dimmed or turned off in many commercially available light sources.

[0007] Thin film technology is a promising way to improve window performance. Thin films can be applied directly onto glass during manufacturing, for example, or onto a polymer web that can be applied to existing windows at a lower cost and retrofitted accordingly. Progress has been made over the past 20 years, mainly by using static or "passive" low-emissivity (low-E) coatings to lower the U-value of windows and by using spectrally selective low-E coatings to reduce the solar heat gain coefficient (SHGC). Low-E coatings can be used in connection with IG units such as those shown and described in connection with FIG. 1. However, further enhancements are possible.

[0008] For example, it may be desirable to provide a more dynamic IG unit option that takes into account the desire to provide improved insulation to buildings and the like, utilizing the sun's ability to "feed energy" into the interior of the building and also desirably providing privacy in a more "on-demand" manner. It will be understood that such products would desirably also satisfy an aesthetic appearance.

[0009] Certain exemplary embodiments address these and / or other concerns. For example, certain exemplary embodiments of the present invention relate to a potential-driven shade that can be used with an IG unit, an IG unit including such a shade, and / or a method of manufacturing the same.

[0010] In certain exemplary embodiments, an insulating glass (IG) unit is provided. The first substrate and the second substrate each have an inner major surface and an outer major surface, and the inner major surface of the first substrate faces the inner major surface of the second substrate. A spacer system serves to maintain the first substrate and the second substrate in a spaced-apart relationship substantially parallel to each other and to define a gap therebetween. A dynamically controllable shade is inserted between the first substrate and the second substrate. The shade includes a first conductive coating provided directly or indirectly on the inner major surface of the first substrate, the first conductive coating being divided into a plurality of zones electrically insulated from each other, a dielectric film or an insulator film provided directly or indirectly on the first conductive coating, and a shutter including a polymeric substrate supporting a second conductive coating, the polymeric substrate being extensible to a shutter closed position and retractable to a shutter open position, and the first conductive coating and / or the second conductive coating being electrically connectable to a power source controllable to set a potential difference and generate an electrostatic force to drive the polymeric substrate to the shutter closed position.

[0011] In certain exemplary embodiments, the glass substrate includes a dynamically controllable shade provided on the glass substrate. The shade includes a first conductive coating provided directly or indirectly on a major surface of the substrate, the first conductive coating being divided into a plurality of zones electrically insulated from each other, a dielectric film or insulator film provided directly or indirectly on the first conductive coating, and a shutter including a polymer substrate supporting a second conductive coating. The polymer substrate is extensible to a shutter closed position and retractable to a shutter open position. The first conductive coating and / or the second conductive coating are electrically connectable to a power source controllable to set a potential difference and generate an electrostatic force to drive the polymer substrate to the shutter closed position.

[0012] In certain exemplary embodiments, a method of manufacturing an insulating glass (IG) unit is provided. The method includes having a first substrate and a second substrate, each having an inner major surface and an outer major surface, wherein the inner major surface of the first substrate faces the inner major surface of the second substrate, and providing a dynamically controllable shade on the first substrate and / or the second substrate. The shade includes a first conductive coating provided directly or indirectly on the inner major surface of the first substrate, the first conductive coating being divided into a plurality of zones electrically insulated from each other, a dielectric film or insulator film provided directly or indirectly on the first conductive coating, and a shutter including a polymer substrate supporting a second conductive coating, the polymer substrate being extensible to a shutter closed position and retractable to a shutter open position. The first substrate and the second substrate are connected to each other in a substantially parallel and spaced relationship such that a gap is defined therebetween and the dynamically controllable shade is located in the gap. The first conductive coating and / or the second conductive coating are electrically connectable to a power source controllable to set a potential difference and generate an electrostatic force to drive the polymer substrate to the shutter closed position.

[0013] In certain exemplary embodiments, the sensing circuit may be configured to measure capacitance in different zones.

[0014] In certain exemplary embodiments, the polymeric substrate may be structured to coil up upon retraction and unwind upon extension, and the IG unit may further comprise a controller configured to estimate whether the coil of the polymeric substrate is distorted during extension and / or retraction based on the measured capacitance.

[0015] In certain exemplary embodiments, the distortion of the coil of the polymeric substrate may be estimated based on different zones having measured capacitances that differ from the measured capacitances of one or more reference zones by more than a predetermined threshold (e.g., one or more reference zones are the outermost zone(s) within the IG unit).

[0016] In certain exemplary embodiments, the controller may be further configured to control the power supply to selectively deliver voltage(s) to the zones to correct the estimated distortion of the coil of the polymeric substrate.

[0017] In certain exemplary embodiments, the polymeric substrate may be configured to preferentially extend proximate to the zones that receive voltage(s) compared to other zones that do not receive voltage(s).

[0018] In certain exemplary embodiments, a method of operating a dynamic shade within an insulating glass (IG) unit is provided. The method includes having an IG unit fabricated according to the techniques disclosed herein and providing voltage(s) to one or more zones to assist in correcting for distortion of the shutter. For example, the method may include selectively activating a power supply and moving the polymeric substrate between a shutter open position and a closed position and supplying power to the zones to selectively correct for distortion of the coil of the polymeric substrate.

[0019] The features, aspects, advantages, and exemplary embodiments described herein may be combined to implement further embodiments.

[0020] These and other features and advantages may be better and more fully understood by reference to the following detailed description of exemplary embodiments in conjunction with the drawings.

Brief Description of the Drawings

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[0035] Certain exemplary embodiments of the present invention relate to a potential-driven shade that can be used with an IG unit, an IG unit including such a shade, and / or a method of manufacturing the same. Referring now more particularly to the drawings, FIG. 2 is a schematic cross-sectional view of an exemplary insulating glass unit (IG unit or IGU) incorporating a potential-driven shade that can be used in connection with certain exemplary embodiments. More specifically, FIG. 2 is similar to FIG. 1 in that a first glass substrate 102 and a second glass substrate 104 that are substantially parallel and spaced apart are separated from each other using a spacer system 106, and a gap 108 is defined therebetween. A first potential-driven shade 202a and a second potential-driven shade 202b are provided within the gap 108 proximate to the inner major surfaces of the first substrate 102 and the second substrate 104, respectively. As will become apparent from the description provided below, shades 202a and 202b are controlled by the generation of a potential difference between shades 202a and 202b and a conductive coating formed on the inner surfaces of substrates 102 and 104. Also, as will become apparent from the description provided below, each of shades 202a and 202b can be made using a polymer film coated with a conductive coating (e.g., a coating including a layer containing Al, Cr, ITO, etc.). An aluminum-coated shade can provide partial-total reflection of visible light and up to a fairly significant amount of total solar energy.

[0036] Shades 202a and 202b are normally retracted (e.g., rolled up), but rapidly extend (e.g., deploy) when an appropriate voltage is applied in order to cover at least a portion of substrates 102 and 104, such as a “conventional” blind. The rolled-up shades may have a very small diameter and are typically much smaller than the width of the gap 108 between the first substrate 102 and the second substrate 104, whereby they can function therebetween and can be essentially hidden from view when rolled up. The deployed shades 202a and 202b adhere strongly to the adjacent substrates 102 and 104.

[0037] Shades 202a and 202b extend from a retracted configuration to an extended configuration along all or a portion of the vertical length of the visible or "frame" regions of substrates 102 and 104. In the retracted configuration, shades 202a and 202b have a first surface area that substantially enables radiation transmission through the frame region. In the extended configuration, shades 202a and 202b have a second surface area that substantially controls radiation transmission through the frame region. Shades 202a and 202b may have a width that extends across all or a portion of the horizontal width of the frame regions of substrates 102 and 104 to which they are attached.

[0038] Each of shades 202a and 202b is disposed between a first substrate 102 and a second substrate 104 and is preferably attached, at or near the top of the substrate, at one end to the inner surface of the substrate (or a dielectric or other layer disposed on the substrate). In this regard, an adhesive layer may be used. In FIG. 2, shades 202 and 204 are shown partially deployed (partially extended). Shades 202a and 202b, and any adhesive layer or other attachment structure, are preferably hidden from view such that they are only visible when shades 202a and 202b are at least partially deployed.

[0039] The diameter of the fully wound-up shade is preferably about 1-5 mm, although in certain exemplary embodiments it may be greater than 5 mm. Preferably, the diameter of the wound-up shade is less than or equal to the width of gap 108, which is typically about 10-15 mm, to facilitate rapid and repeated deployment and winding-up operations. In the embodiment of FIG. 2, two shades 202a and 202b are shown, although in certain exemplary embodiments only one shade may be provided, and it will be understood that one shade may be provided on the inner surface of either the inner or outer substrate 102 or 104. In exemplary embodiments with two shades, the combined diameter is preferably less than or equal to the width of gap 108, for example, to facilitate the deployment and winding-up operations of both shades.

[0040] An electronic controller may be provided to assist in driving the shades 202a and 202b. The electronic controller may be electrically connected to the shades 202a and 202b and the substrates 102 and 104, for example, via suitable lead wires or the like. The lead wires can be made invisible through the assembled IG unit. The electronic controller is configured to provide an output voltage to the shades 202a and 202b. In certain exemplary embodiments, an output voltage in the range of about 100 - 500V DC can be used to drive the shades 202a and 202b. In this regard, an external AC or DC power source, a DC battery, etc. may be used. For example, it will be understood that higher or lower output voltages may be provided depending on manufacturing parameters and materials including the shades 202a and 202b, layers on the substrates 102 and 104, etc.

[0041] The controller may be coupled to a manual switch, remote (e.g., wireless) control, or other input device, for example, to indicate whether the shades 202a and 202b should retract or extend. In certain exemplary embodiments, the electronic controller may include a processor operably coupled to a memory storing instructions for receiving and decoding control signals, the control signals selectively applying voltages to control the extension and / or retraction of the shades 202a and 202b. Additional instructions may be provided to implement other functions. For example, a timer can be provided so that the shades 202a and 202b can be programmed to extend and retract at user-specified or other times, and a temperature sensor can be provided so that the shades 202a and 202b can be programmed to extend and retract when a user-specified indoor temperature and / or outdoor temperature is reached. A light sensor can be provided so that the shades 202a and 202b can be programmed to extend and retract based on the amount of light outside the structure.

[0042] As described above, two shades 202a and 202b are shown in FIG. 2, although in certain exemplary embodiments, only a single shade may be incorporated. Further, as described above, such shades may be designed to extend vertically and horizontally along and substantially over the entire IG unit, and different exemplary embodiments may include shades that cover only portions of the IG unit in which they are disposed. In such cases, multiple shades may be provided to achieve a more selectable range for simulating a planar shutter in view of internal or external structures such as muntins.

[0043] In certain exemplary embodiments, for example, a lock suppression portion may be disposed at the bottom of the IGU along the width of the IGU, which helps prevent the shade from deploying its entire length. The lock suppression portion may be made of a conductive material such as metal. The lock suppression portion may also be coated with a low dissipation rate polymer such as, for example, polypropylene, fluorinated ethylene propylene (FEP), polytetrafluoroethylene (PTFE).

[0044] Exemplary details of the operation of shades 202a and 202b are provided in connection with FIGS. 3-4. More specifically, FIG. 3 is a cross-sectional view showing the components on the exemplary glass of the example IGU of FIG. 2 that enable shutter operation according to a particular exemplary embodiment, and FIG. 4 is a cross-sectional view of the exemplary shutter of the IGU of the embodiment of FIG. 2 according to a particular exemplary embodiment. FIG. 3 shows a glass substrate 302 that may be used for either or both of the substrates 102 and 104 of FIG. 2. The glass substrate 302 supports the components 304 on the glass and the shutter 312. In certain exemplary embodiments, when not wound, the conductor 404 may be closer to the substrate 302 than the ink layer 406. In other exemplary embodiments, this configuration may be reversed such that, for example, when not wound, the conductor 404 may be farther from the substrate 302 than the ink layer 406.

[0045] The components 304 on the glass include a transparent conductor 306 together with a dielectric material 308 that can be adhered to the substrate 302 via a transparent low haze adhesive 310 or the like. These materials are preferably substantially transparent. In certain exemplary embodiments, the transparent conductor 306 is electrically connected to a lead wire to a controller via a terminal. In certain exemplary embodiments, the transparent conductor 306 functions as a fixed electrode of a capacitor, and the dielectric material 308 functions as a dielectric of this capacitor.

[0046] The transparent conductor 306 may be formed of any suitable material such as, for example, ITO, tin oxide (e.g., SnO2 or other suitable stoichiometry). The transparent conductor 306 may be, in certain exemplary embodiments, 10 to 500 nm thick. The dielectric material 308 may be, in certain exemplary embodiments, a low dissipation rate polymer. Suitable materials include, for example, polypropylene, FEP, PTFE, polyethylene terephthalate (PET), polyimide (PI), and polyethylene naphthalate (PEN). The dielectric material 308 may have a thickness of 4 to 25 micrometers in certain exemplary embodiments. The thickness of the dielectric material 308 can be selected to balance the reliability of the shade (e.g., while a thinner dielectric layer typically reduces reliability, a thicker dielectric layer typically requires a higher applied voltage for operational purposes).

[0047] As is known, many low emissivity (low-E) coatings are conductive. Thus, in certain exemplary embodiments, a low-E coating may be used instead of the transparent conductor 306. The low-E coating may be a silver-based low-E coating, for example, one, two, three, or more layers containing Ag may be sandwiched between dielectric layers. In such cases, the need for the adhesive 310 may be reduced or completely eliminated.

[0048] The shutter 312 may include an elastic layer 402. In certain exemplary embodiments, a conductor 404 may be used on one side of the elastic layer 402, and optionally, a decorative ink 406 may be applied on the other side. In certain exemplary embodiments, the conductor 404 may be transparent, and as shown, the decorative ink 406 is optional. In certain exemplary embodiments, the conductor 404 and / or the decorative ink 406 may be translucent or otherwise capable of imparting color or aesthetic features to the shutter 312. In certain exemplary embodiments, the elastic layer 402 may be formed from a shrinkable polymer such as, for example, PEN, PET, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), etc. The elastic layer 402 may be, in certain exemplary embodiments, 1 to 25 micrometers thick. The conductor 404 may be formed from the same or different materials as those used for the conductor 306 in different exemplary embodiments. For example, a metal or metal oxide material may be used. In certain exemplary embodiments, a material having a thickness of 10 to 50 nm including a layer containing, for example, ITO, Al, Ni, NiCr, tin oxide, etc. can be used. In certain exemplary embodiments, the resistance of the conductor 404 may be in the range of 40 to 200 ohms per square.

[0049] The decorative ink 406 may include pigments, particles, and / or other materials that selectively reflect and / or absorb the desired visible colors and / or infrared rays.

[0050] As shown in FIG. 2, the shades 202a and 202b are typically wound as helical rolls, and the outer ends of the helix are secured to the substrates 102 and 104 (e.g., a dielectric on the substrate) by an adhesive. The conductor 404 may be electrically connected to a lead wire or the like via a terminal and may function as a variable electrode of a capacitor having the conductor 306 as a fixed electrode of the capacitor and the dielectric 308 as a dielectric of the capacitor.

[0051] When the electric drive unit is provided between the variable electrode and the fixed electrode, for example, when an electric drive of voltage or current is applied between the conductor 404 of the shutter 312 and the conductor 306 on the substrate 302, the shutter 312 is attracted toward the substrate 302 by the electrostatic force generated by the potential difference between the two electrodes. Pulling the variable electrode causes the coiled shade to deploy. Due to the electrostatic force on the variable electrode, the shutter 312 is securely held against the fixed electrode of the substrate 302. As a result, the ink coating layer 406 of the shade selectively reflects or absorbs specific visible colors and / or infrared rays. In this way, the deployed shade selectively blocks and / or reflects specific light or other radiation to control radiation transmission, thereby changing the overall function of the IG unit to be partially or selectively transmissive or even opaque.

[0052] When the electric drive between the variable electrode and the fixed electrode is removed, the electrostatic force on the variable electrode is likewise removed. Due to the spring constants present in the elastic layer 402 and the conductor 404, the shade returns to its original tight wound position. Since the movement of the shade is mainly controlled by a capacitive circuit, current essentially flows only while the shade is either deploying or winding up. As a result, the average power consumption of the shade is very low. In this way, in at least some examples, several standard AA batteries can be used to operate the shade for several years.

[0053] In one embodiment, the substrate 302 may be a 3 mm thick transparent glass commercially available from the assignee. An acrylic adhesive having a low haze may be used for the adhesive layer 310. Sputtered ITO having a resistance of 100 to 300 Ω / square may be used for the conductor 306. The polymer film may be a 12 micrometer thick low haze (e.g., <1% haze) PET material. As the decorative ink 406, a PVC-based ink available from Sun Chemical Inc. may be applied at a thickness of 3 to 8 micrometers. As the elastic layer 402, a PEN material commercially available from DuPont having a thickness of 6, 12, or 25 micrometers can be used. An opaque conductor 406 with Al vapor deposited having a nominal thickness of 375 nm can be used. For the transparent option, sputtered ITO may be used. In both cases, the resistance may be 100 to 400 ohms / square. In certain exemplary embodiments, the ITO or other conductive material(s) may be sputtered or otherwise formed on their respective polymer carrier layers. Of course, these exemplary materials, thicknesses, electrical properties, and their various combinations and partial combinations, etc., should not be considered limiting unless specifically claimed.

[0054] As understood from the above description, the dynamic shade mechanism uses a coiled polymer having a conductive layer. In certain exemplary embodiments, the conductor 402 may be formed to be integral with the polymer 402 or may be an external coating applied, deposited, or otherwise formed on the polymer 402. As also described above, the decorative ink 406 may be used with a transparent conductive material (e.g., ITO-based) and / or a partially transparent or opaque conductive layer. The opaque or partially transparent conductive layer can eliminate the need for ink in certain exemplary embodiments. In this regard, in certain exemplary embodiments, a metal or substantially metal material may be used. Aluminum is an example of a material that can be used with or without the decorative ink.

[0055] One or more overcoat layers may be provided on the conductor to reduce visible light reflection and / or change the color of the shade, which may help to provide a more aesthetically pleasing product, and / or may serve by "splitting" the conductor such that a phase shifter layer appears therebetween. Thus, the overcoat may be included to improve the overall aesthetic appearance of the shade. Thus, the shutter 312 may include a reflection-reducing overcoat, a dielectric mirror overcoat, etc. Such reflection-reducing overcoats and dielectric mirror overcoats may be provided on the conductor 404 and on the main surface of the shade polymer 402 containing PEN (for example) on the opposite side of the decorative ink 406. However, it will be understood that, for example, if the conductor 404 is not transparent, the ink 406 need not be provided. For example, a mirror coating such as Al can eliminate the need for the decorative ink 406. It will also be understood that the reflection-reducing overcoat and the dielectric mirror overcoat may, in certain exemplary embodiments, also be provided on the main surface of the shade polymer 402 containing PEN (for example) on the opposite side of the conductor 404.

[0056] In addition to, or instead of, using optical interference techniques to reduce reflection, it is also possible to add a textured surface to the base polymer, chemically or physically modify the conductive layer, and / or add an ink layer to achieve, for example, further reduction of unwanted reflection, etc. to achieve the same or similar end results.

[0057] Considering that other materials, including the thin film and / or shutter, must withstand a number of winding and unwinding operations according to the overall shade function, the material may be selected, and it will be understood that the formed overall layer laminate has mechanical and / or other properties that facilitate it. For example, excessive stress in a thin film laminate is typically considered disadvantageous. However, in some cases, excessive stress can lead to cracking, "delamination" / removal, and / or other damage to conductor 404 and / or one or more overcoat layers formed on conductor 404. Therefore, in certain exemplary embodiments, low stress (especially low tensile stress) may be particularly desirable in relation to the layer(s) formed on the polymer substrate of the shutter.

[0058] In this regard, the adhesion of a sputtered thin film depends, among other things, on the stress in the deposited film. One way to adjust the stress is to use the deposition pressure. The stress versus sputtering pressure does not follow a monotonic curve. Instead, it is specific to each material and is injected at a transition pressure that is a function of the ratio of the melting temperature of the material to the substrate temperature. Stress engineering can be achieved by gas pressure optimization, keeping these guideposts in mind.

[0059] Other physical and mechanical properties of the shade that can be considered include the elastic modulus of the polymer and the layer formed on the polymer, the density ratio of the layer (which can affect stress / strain), etc. These properties can be balanced with their effects on internal reflection, conductivity, etc.

[0060] As is known, the temperature inside the IG unit can become very high. For example, an IG unit containing a black pigment according to the embodiment of FIG. 2 has been observed to reach a temperature of 87° C. when, for example, the black portion of the shade faces the sun in a high solar radiation climate with high temperatures (such as in the southwestern region of the United States like Arizona). PEN has a higher glass transition temperature (~120° C.) compared to other common polymers such as PET (Tg = 67 - 81° C.), polypropylene or PP (Tg = about 32° C.), so it may be advantageous to use PEN material for the rollable / unrollable polymer. Further, when PEN is exposed to a temperature approaching its glass transition temperature, the performance of the mechanical properties of the material (including the modulus of elasticity, yield strength, tensile strength, stress relaxation modulus of the material, etc.), which are advantageous otherwise, may deteriorate over time, especially under high temperature exposure. When these mechanical properties deteriorate significantly, the shade no longer functions (e.g., the shade does not retract).

[0061] To help the shade better withstand high temperature environments, substitution from PEN to a polymer with higher temperature resistance may be advantageous. Two potential polymers are PEEK and polyimide (PI or Kapton). PEEK has a Tg of about 142° C., and Kapton HN has a Tg of about 380° C. Both of these materials have better mechanical properties in high temperature environments compared to PEN. This is especially true for temperatures above 100° C. The following chart refers to the mechanical properties of PEN (Teonex), PEEK, and PI (Kapton HN). UTS represents the ultimate tensile strength in the chart.

Table 1

[0062] It is understood that changing the shade substrate from its current material (PEN) to an alternative polymer (e.g., PEEK or PI / Capton) with increased high-temperature mechanical properties can be advantageous. In particular, when the shade is installed in a high-temperature climate, the shade may be better able to withstand the internal IG temperature. In certain exemplary embodiments, it will be understood that the use of the alternative polymer can be associated with layers on the shutter and / or glass.

[0063] In addition, or alternatively, certain exemplary embodiments may use a dyed polymer material. For example, dyed PEN, PEEK, PI / Capton, or other polymers can be used to create shades with various colors and / or aesthetics. For example, a dyed polymer may be advantageous for transparent / translucent applications, e.g., when the transparent conductive layer is a transparent conductive coating or the like.

[0064] The spring force of the alternative coiled shade can be beneficially modified to be usable for various lengths. In this regard, the properties of the conductive layer that increase the coil strength include an increase in the modulus of elasticity, an increase in the difference in the coefficient of thermal expansion (CTE) between the polymer substrate and the conductive layer, and an increase in the ratio of the modulus of elasticity to density. Some of the pure metals that can be used to increase the coil strength compared to Al or Cr include Ni, W, Mo, Ti, and Ta. The modulus of elasticity of the studied metal layers ranged from 70 GPa for Al to 330 GPa for Mo. The CTE of the studied metal layers was from 23.5×10 -6 / K for Al to 4.8×10 -6It was in the range up to / k. Generally, the higher the elastic modulus, the greater the CTE mismatch between PEN or other polymers and metals, the lower the density, etc., the better the material selection for coil formation. Incorporating Mo and Ti-based conductive layers into the shade has been found to result in a significantly higher spring force of the coil than what can be achieved with Al. For example, advantageously, it may include a polymer substrate based on PEN, PEEK, PI, etc., and support a layer containing Al (in the order away from the substrate), followed by a layer containing Mo. A thin film layer(s) in the conductive coating and / or the conductive coating itself having an elastic modulus greater than Al and a low CTE may be provided.

[0065] The PEN, PI, or other polymer substrate used as a shutter may support a thin layer containing Al for stress engineering purposes, and may also support a conductive layer directly or indirectly containing Mo, Ti, etc. on the thin layer. The conductive layer may support a corrosion-resistant layer containing Al, Ti, stainless steel, etc. The side surface of the substrate on the opposite side of these layers may optionally support decorative ink, etc.

[0066] Certain exemplary embodiments may include micro perforations or through holes that allow light to pass through the shade and provide a progressive amount of solar transmittance based on the angle of the sun.

[0067] Further manufacturing, operation, and / or other details and alternatives may be implemented. For example, reference is made to U.S. Patent Nos. 8,982,441, 8,736,938, 8,134,112, 8,035,075, 7,705,826, and 7,645,977, and U.S. Patent Application No. 16 / 028,546 filed on July 6, 2018. The entire contents of each of the above documents are incorporated herein by reference. In particular, the perforation configuration, polymer material, conductive coating design, stress engineering concept, building-integrated photovoltaic (BIPV), and other details are disclosed therein, and at least their teachings can be incorporated into specific exemplary embodiments.

[0068] One problem associated with dynamic shade designs is that the shutter contacts the bottom stopper or holder with enough force to produce a rattling sound as it rapidly extends or retracts. That is, in certain exemplary embodiments, the components on the glass (including TCC306 and polymer 308) are provided over all or substantially all of the surface of the substrate 302. The upper and bottom stoppers seat on these components on the glass and can be electrically connected to the TCC306. During deployment of the shutter, the shutter will extend until it hits the end stopper and makes a rattling sound. Some people perceive this rattling sound as discomfort, and thus, the rattling sound makes using the shade less comfortable for at least some people.

[0069] To help address the rattling sound problem, certain exemplary embodiments implement means for decelerating the shutter when it extends, and more specifically, when the shutter extends to a length proximate the bottom stopper or holder. Since deceleration occurs when the shutter is nearly fully extended, the shutter still extends very well. In other words, the static force that starts and maintains movement through the initial stages of the extension does not change and is selectively altered towards the fully extended position.

[0070] This deceleration can be achieved in certain exemplary embodiments by affecting the electrostatic force in the region proximate the bottom stopper. A weaker electrostatic force can allow the shutter to extend or deploy at a slower speed.

[0071] Thus, the shutter can be extended towards the bottom stopper in a controlled manner by the region of altered electrostatic force, which can be created by introducing a difference in conductivity in the corresponding region proximate the bottom stopper.

[0072] FIG. 5 is a plan view of a substrate 102 incorporating component 304 on glass from the IGU of FIG. 2, along with region 506 that promotes this difference in conductivity, according to a particular exemplary embodiment. The example of FIG. 5 shows upper stopper 502 and bottom stopper 504. The shutter extends in the direction of the arrow from upper stopper 502 to bottom stopper 504.

[0073] This region 506 having an altered electrostatic force can be created in a number of different ways. For example, FIG. 6A is a cross-sectional view of FIG. 5 taken through a first exemplary region that promotes a difference in conductivity, according to a particular exemplary embodiment. As shown in FIG. 6A, component 304' on glass is partially removed in region 506. That is, polymer film insulator 308', TCC 306', and optionally, adhesive 310' are discontinuous in this region. They extend towards the side of substrate 302 but are missing from a central region proximate bottom stopper 504. In this configuration, component 304 on glass may be considered to be absent from region 506 shown in FIG. 5.

[0074] The configuration of this Figure 6A can be manufactured in a number of different ways. As an example, when the polymer film insulator 306 with TCC308 is simply applied (e.g., rolled) onto the substrate 302, it can be applied to the substrate 302 in areas away from the region 506. For example, a large area can be applied from the top of the substrate up to the top of the region 506, and smaller strips can be applied along the sides of the region 506. In another example, masking can be used to ensure that any TCC and polymer film insulator provided in the region 506 can be easily removed. When these materials are provided as sheets, sputtering can be used to form the TCC, and when the polymer is provided by wet techniques or the like, masking may be useful. In yet another example, the substrate 302 can be blanket coated (e.g., using pre-formed sheets that are spread over the entire substrate, such as using sputtering and liquid coating), and then the blanked coating material can be removed in the region 506. Depending on the approach used to form the component 304 on the glass, in the region 506 as well, an adhesive may or may not remain within the component 304' on the glass.

[0075] As an alternative to the arrangement of FIG. 6A, FIG. 6B is a cross-sectional view of FIG. 5 taken through a second exemplary region that promotes a conductivity difference between the component on the glass and the component on the shutter, according to a particular exemplary embodiment. The component 304'' on the glass in the embodiment of FIG. 6B includes an additional insulator material 600 provided in a region 506 where the electrostatic force will be altered. This additional insulator can be, for example, an additional transparent polymeric material such as any of the above materials (e.g., PET, PEN, PEEK, PI, etc.). The polymer can be rolled, applied, or otherwise formed thereon over the region 506. Alternatively, or in addition, in a particular exemplary embodiment, a thin film dielectric or other material can also be used for the additional insulator 600. These thin film materials can be formed on the underlying substrate 302 within the region 506 in any suitable manner. It can effectively electrically insulate the TCC 404 on the shutter 312 from the TCC 306 within the component 304'' on the glass of the region 506, or at least increase the electrical resistance therebetween.

[0076] FIG. 7 is a plan view of a third exemplary region 506' that promotes a difference in conductivity, according to a particular exemplary embodiment. The arrows indicate the direction of travel of the shutter, as described above. This region 506' can be considered to include a plurality of segments 702a - 702d on the glass (e.g., as described above in connection with FIG. 6A) separated by regions 704a - 704c where the component on the glass is removed, and / or where additional insulating material is added (e.g., as described above in connection with FIG. 6B).

[0077] In certain exemplary embodiments, segments 702a - 702d on the glass can have the same configuration (e.g., the height and / or width of the entire substrate), although different exemplary embodiments can use different configurations for these segments 702a - 702d on the glass. The example of FIG. 7 uses the former configuration as segments 702a - 702d become progressively smaller as they approach bottom stopper 504. This can be advantageous as a smaller force can be provided by causing a “soft landing” of the shutter on bottom stopper 504, while on the other hand, an “impulse” is provided to facilitate the shutter being continuously extended even as it slows down. In other words, this arrangement can help ensure that the shutter does not stop short of bottom stopper 504 and can also help ensure that the shutter reaches bottom stopper 504 in a more controlled manner.

[0078] In certain exemplary embodiments, segments 702a - 702d on the glass can be evenly spaced or spaced in some other way. The example of FIG. 7 uses the latter configuration as the distance D1 between segment 702a and segment 702b is less than the distance D2 between segment 702b and segment 702c, and the distance D2 between segment 702b and segment 702c is less than the distance D3 between segment 702c and segment 702d. Another way of thinking about this is that regions 704a - 704c can increase in size (e.g., the height and / or width of the entire substrate) as they move towards bottom stopper 504.

[0079] In the exemplary embodiment of FIG. 7, segments 702a-702d and three regions 704a-704c on four glasses are shown, but in certain exemplary embodiments, more or fewer of either or both may be provided. Further, FIG. 7 shows segment 702d on the glass directly adjacent to the upper side of bottom stopper 504 (and implicitly also the lower side), but in different embodiments, electrical contact to bottom stopper 504 can be provided from the bottom side of bottom stopper 504 or in other ways. Thus, segment 702d on the glass can be considered repositionable to the bottom side of bottom stopper 504.

[0080] The exemplary embodiment of FIG. 7 can be manufactured using the techniques described above in connection with FIGS. 6A and / or 6B, which are generally understood to be simply repeated for different segments.

[0081] These segments in embodiments similar to FIG. 7 (e.g., where there are component segments on multiple glasses) can be controlled collectively and / or individually in different exemplary embodiments. For example, a voltage may be provided to all segments at once, or the voltage may be provided to individual segments in a more controlled manner. The former may be advantageous from the perspective of ease of implementation. On the other hand, the latter may be advantageous for more actively controlling (e.g., delaying) speed and reducing power requirements. A timer may be implemented to activate different segments in sequence in certain exemplary embodiments. In certain exemplary embodiments, an imaging device (e.g., a camera, an infrared (IR) sensor, etc.) can be used to track the progress of the shutter when it extends. The controller may receive a signal from the imaging device and selectively activate one or more individual segments of the segments, for example, to ensure that the shutter moves and / or moves at an appropriate speed, based on the position of the shutter determined from that signal.

[0082] Thus, it will be appreciated that the movement of the shutter can be controlled actively and / or passively, particularly as it approaches the bottom stop. Passive control can be provided by defining the characteristics of region 506 according to the exemplary techniques of FIGS. 6A and 6B, and also when the exemplary techniques of FIG. 7 are used in connection with a common voltage “trigger” provided to each segment. Active control can be provided, for example, by individually activating the segments of the example of FIG. 7. In any case, there is sufficient force to drive the shutter, but the force is attenuated as it approaches the bottom stopper in order to avoid a click sound (or to significantly reduce the click sound to at least an imperceptible level and / or a non-intrusive level).

[0083] Certain exemplary embodiments have been described as creating regions having different electrostatic forces and / or differences in conductivity in relation to components on glass, but it will be understood that the approaches described herein can be used in connection with shutter 312 (including its TCC 404). In order to create the effects of the regions described above, alterations can alternatively or additionally be made to shutter 312 when it is being formed (e.g., prior to rolling), when it is being stretched, etc.

[0084] In certain exemplary embodiments, for regions where a conductive coating (e.g., ITO) is removed, the dimension (either absolute or relative to the bar) can be anywhere between approximately zero and the characteristic width of the shade diameter. In some cases, there is essentially no lower limit to such a dimension because the applied voltage of that region can be lowered to reach a deceleration target. In some cases, for the upper limit of such a dimension, it may be desirable in some cases to ensure that the shade is still affected by the electrostatic field, which can actually impose a limitation.

[0085] The above example helps to decelerate the shutter as it approaches the end stopper. The shutter may come to a complete stop before contacting the bottom stopper, or it may be slowed down to a speed sufficient for the shutter to have a "soft landing" against the bottom stopper. Thus, certain exemplary embodiments can reduce or even eliminate an audible (e.g., click) sound perceptible to humans.

[0086] In certain exemplary embodiments, the shade may be deployed at an initial velocity that decelerates to a final velocity during deployment. The deceleration may be at a constant or non-constant rate. The final velocity may result in a complete or nearly complete stop (e.g., a zero or nearly zero velocity). In this way, the shade may make a "soft landing" on the bottom stop. In certain exemplary embodiments, the shade does not necessarily have to contact the bottom stop during the soft landing. That is, in certain exemplary embodiments, the bottom stop may not be provided. In certain exemplary embodiments where a stop is provided, the stop may be means for providing an electrostatic force to hold the shade in the extended position, in which case the shade may or may not contact the stopper.

[0087] Another problem associated with dynamic shade designs is that the shutter coil may distort or otherwise shift in position during retraction and / or extension. FIG. 8 is a plan view showing how the shutter may distort or be potentially misaligned in some examples. As shown in FIG. 8, the shutter 312 is distorted during deployment and / or retraction because the left side of the coil is "lower" (more extended and less retracted) than the right side of the coil. These distortion / misalignment problems are troublesome and can reduce the comfort of using a dynamic shade. It will be understood that similar top and bottom misalignments can occur in embodiments that deploy horizontally.

[0088] To help address the shutter coil distortion problem, certain exemplary embodiments provide a voltage (or voltages) to one or more portions of the conductive layer on the glass. In certain exemplary embodiments, this can be facilitated by patterning or otherwise dividing the conductive layer on the glass into a plurality of segments. When distortion is detected, or otherwise triggered, the voltage (or voltages) can be provided to one or more portions of the conductive layer on the glass to promote preferential elongation and / or retraction.

[0089] Figure 9A is a plan view of a substrate incorporating a first set of segmented glass components from the example of FIG. 5 according to certain exemplary embodiments. Compared to the component 304 on the glass of FIG. 5, in the example of FIG. 9A, different zones 304a - 304c are created. This can be achieved by partitioning the ITO - coated PET to provide a plurality of partitions, thereby creating the plurality of zones 304a - 304c. The example of FIG. 9A is for vertically - oriented shades, and thus the partitions are likewise oriented substantially vertically. Selective voltage control can be implemented for the plurality of zones 304 - 304c. For example, different voltages can be applied to each of the individual regions, and some regions may not receive a voltage, while some can receive a voltage, for example, to promote selective elongation and / or retraction. As a result, in the vertical arrangement, the left and right sides of the shade, as well as any number of optional intermediate zones, can be individually driven to facilitate correction in the event of coil distortion. In the example of FIG. 9A, independent control of the voltage across the width of the shade is provided. It will be understood that a similar technique can be used in connection with horizontally - arranged shades in that a plurality of substantially horizontal zones can be created and driven independently to facilitate coil correction.

[0090] Patterning can be performed by applying to separate regions of the ITO-coated PET, or other materials on which a conductive coating is formed over that region. In certain exemplary embodiments, laser etching, ablation, photolithographic etching, and / or other techniques can be used to pattern some or all of the components on the glass, thereby creating different zones. In certain exemplary embodiments, different zones of material can be created by applying a plurality of strips or other portions of material over the entire surface of the substrate such that adjacent strips or other portions do not electrically contact or communicate with each other.

[0091] In different exemplary embodiments, any suitable pattern may be used. For example, instead of using a vertical pattern as shown in FIG. 9A, the pattern shown in FIG. 9B may be used. FIG. 9B is a plan view of a substrate incorporating a second set of components on segmented glass from the example of FIG. 5 according to a particular exemplary embodiment. In FIG. 9B, a more grid-like pattern is provided where zones 304a - 304i occupy multiple rows and multiple columns. Generally, in embodiments that expand / retract in the vertical direction, at least two vertical zones should be provided and one or more horizontal zones should be provided. Generally, in the case of embodiments that expand / retract horizontally, at least two horizontal zones should be provided and one or more vertical zones should be provided. The zones may have the same size, shape, and dimensions (as shown, for example, in FIG. 9A), or different sizes, shapes, and / or dimensions may be provided (as shown, for example, in FIG. 9B). In certain exemplary embodiments, a separate zone proximate to the lower bar 504 need not necessarily be provided.

[0092] Coil distortion can be detected by any suitable technique. For example, using optical imaging techniques, it can be determined whether the coil appears higher / lower and / or thicker / thinner on one side than on the other. In certain exemplary embodiments, a camera or other imaging means can be positioned at the periphery of the assembly. The imaging means can take a picture of the coil and send the data corresponding to the image to a processing circuit. If the processing circuit "sees" that the coil is distorted (e.g., because the coil appears higher / lower and / or thicker / thinner), the coil can be considered distorted. In a vertical arrangement, it may be advantageous to provide a camera or the like at the top and / or bottom of the assembly, while in a horizontal arrangement, it may be advantageous to provide a camera or the like on the left and / or right side of the assembly. However, different arrangements can be used in different embodiments.

[0093] In certain exemplary embodiments, the correction of the coil can be triggered by the user pressing a button on a window, by a remote control operably connected to the window, or the like.

[0094] In certain exemplary embodiments, coil distortion can be detected by implementing a capacitance sensor. For example, different capacitance sensors can be provided in different respective zones. The capacitance sensor array can cooperate with a power source to selectively introduce a voltage (or voltages) into one or more of the zones to equalize the capacitance of each partitioned zone and thereby assist in correcting the coil distortion. The capacitance sensor utilizes the fact that the electrostatic force helps drive the deployment of the shade and helps "hold" the at least partially deployed shade against the glass. Since a different amount of deployment results in a different capacitive coupling (and thus a different capacitance for each zone), the difference can be measured and determined to reflect a partial or non-uniform deployment.

[0095] For example, assuming that in the example of FIG. 9B, the shutter is largely deployed towards the left side of the window but only slightly deployed towards the right side of the window, at the lower end, it extends from a point approximately at the vertical center of zone 304d to the lower right corner of zone 304c. In this hypothesis, when the shade is evenly spread, the capacitance of zone 304d should match the capacitances of zones 304e and 304f. However, since the shade coil is distorted, the capacitance sensors that measure the capacitances of zones 304d and 304e report different values, and both such values are significantly different from the output of zone 304f (when there is no contact with the distorted coil). When this type of distortion occurs, a difference in capacitance appears in the same way as in zones 304a - 304c of FIG. 9A.

[0096] In different exemplary embodiments, different comparisons can be made. For example, in certain exemplary embodiments, zones at opposite edges of the window can be compared to each other. For example, when a large absolute difference in capacitance is detected, distortion can be estimated. In certain exemplary embodiments, a zone at one edge can be considered as a reference, and the adjacent zone can be considered with respect to the reference. For example, if all, most, or some zones are determined to have a capacitance within a threshold distance from a reference capacitance, a determination of no distortion can be made. The threshold can be constant in certain exemplary embodiments, but in other exemplary embodiments, the threshold can be increased (or decreased) as the distance from the reference zone increases. In certain exemplary embodiments, the capacitance can be measured between adjacent zone pairs. For example, if all, most, or some adjacent zone pairs are within the threshold, a determination of no distortion can be made.

[0097] Since the capacitance can be measured in real time, self-detection and self-correction of coil distortion can also be performed in real time. For example, voltage(s) can be applied to one or more zones to preferentially promote extension and / or retraction. For example, if the shade is extended and the left side is more fully extended than the right side, the voltage can be triggered for the zone with the shortest extension first, the zone with the second shortest extension second, and so on. Alternatively, the voltage can be triggered for all zones, but is maintained for a longer period in the zone(s) with the shortest extension compared to the zone(s) with a large (but not yet complete) extension. Complete extension and lack of distortion can be determined when the capacitance within each sectional zone is balanced, or at least balanced within a threshold.

[0098] The capacitance can be measured, for example, using one or more sensing circuits between the coil and each section within the ITO-coated PET. The comparator compares the measured capacitance in two or more sections and controls the voltage controller to increase and / or reduce the voltages V1, V2, V3, and / or V n provided to various zones.

[0099] FIG. 10 is a schematic diagram showing an example of FIG. 9A having a plurality of detection circuits 1002a-1002n and a voltage controller 1006 for correcting coil distortion according to a particular exemplary embodiment. In the example of FIG. 10, the detection circuits 1002a-1002n can monitor a change in frequency within an oscillation circuit coupled to a section when the coil extends and / or retracts. In the example of FIG. 10, the number of detection circuits matches the number of zones (however, this is not necessarily the case in different embodiments). In the example of FIG. 10, the first detection circuit 1002a is connected to the first zone 304a to provide a left reference, the second detection circuit 1002b is connected to the first zone 304a and the second zone 304b to provide a difference calculation, the nth detection circuit 1002n is connected to the nth zone 304n to provide a right reference, and the third sensing circuit 1002c is connected to the nth zone 304n and the third zone 304c, etc.

[0100] In this example, when the coil extends or retracts, the capacitance formed between the coil and the section changes. The capacitance formed between the coil and the section can be connected in parallel with capacitor C and in series with resistor R. The overall capacitance of the resistor and the two capacitors determines the frequency at which the RC oscillator oscillates. When the overall capacitance of the two capacitors connected in parallel changes, the oscillation frequency also changes (e.g., the higher the capacitance, the lower the frequency). The comparator circuit 1004 can compare the oscillation frequency with one reference frequency or a plurality of reference frequencies of other zones to determine whether the section increases and / or decreases the applied voltage.

[0101] FIG. 11 is a first exemplary comparator circuit that can be used in a particular exemplary embodiment, and FIG. 12 is a second exemplary comparator circuit that can be used in a particular exemplary embodiment. In a particular exemplary embodiment, a frequency-voltage converter can receive an oscillation signal and generate a voltage value representing the oscillation frequency. The voltage value can be compared with one reference voltage or a plurality of reference voltages corresponding to oscillation signals in other sections to determine whether the section increases and / or decreases the applied voltage.

[0102] In different exemplary embodiments, different circuit designs may be used, and it will be understood that the comparison techniques described above and / or other comparison techniques may be used in different exemplary embodiments. For example, in certain exemplary embodiments, changes to the circuit design may be made such that the rate at which the oscillation frequency increases or decreases can be measured and compared.

[0103] As noted above, the zones can have the same or different sizes, shapes, and / or dimensions in different exemplary embodiments. The comparison can be easier to perform and / or the results can be more accurate in exemplary embodiments where the zones have at least the same surface area.

[0104] It will be understood that the capacitance should be the same if the coil is "straight" or not distorted (or at least not significantly distorted). However, some variations can still exist, for example, caused by non-uniform thickness of the shade, non-uniform charges on the substrate and shade surfaces, non-uniform friction during shade movement, non-perfect levels of the shade, debris on the charged surface, arcs on the conductive surface, etc. Thus, certain exemplary embodiments can take these and / or other variables into account by applying thresholding techniques whereby results are considered equal if they are known beforehand and / or differ below a predefined threshold.

[0105] Voltage(s) can be measured before, during, and / or after elongation and / or retraction to identify strain in different exemplary embodiments. Similarly, voltage(s) can be provided before, during, and / or after elongation and / or retraction to correct strain in different exemplary embodiments. As described above, for example, techniques that actively promote retraction using electrostatic forces may be employed, and these techniques can be applied to correct strain (e.g., to promote retraction in one zone while holding the shade in place in another zone, to promote elongation in one zone while promoting retraction in another zone, etc.).

[0106] The IG units described herein may incorporate a low-E coating on any one or more of surfaces 1, 2, 3, and 4. As described above, for example, such a low-E coating may function as a conductive layer for shading. In other exemplary embodiments, in addition to or separate from serving as a shading and a conductive layer for shading, a low-E coating may be provided on another inner surface. For example, a low-E coating may be provided on surface 2, and a shade may be provided for surface 3. In another example, the positions of the shade and the low-E coating may be reversed. In any case, a separate low-E coating may or may not be used to assist in manipulating the shade provided for surface 3. In certain exemplary embodiments, the low-E coatings provided on surfaces 2 and 3 may be silver-based low-E coatings. Examples of low-E coatings are specified in U.S. Patent Nos. 9,802,860, 8,557,391, 7,998,320, 7,771,830, 7,198,851, 7,189,458, 7,056,588, and 6,887,575, and the entire contents of each of the above documents are incorporated herein by reference. Low-E coatings based on ITO or the like may be used on the inner and / or outer surfaces. For example, reference is made to U.S. Patent Nos. 9,695,085 and 9,670,092, and the entire contents of each of the above documents are incorporated herein by reference. These low-E coatings may be used in connection with certain exemplary embodiments.

[0107] An anti-reflection coating may be provided on the major surfaces of the IG unit. In certain exemplary embodiments, an AR coating may be provided on each major surface where a low-E coating and a shade are not provided. Exemplary AR coatings are described, for example, in U.S. Patent Nos. 9,796,619 and 8,668,990, and U.S. Patent Application Publication No. 2014 / 0272314, the entire contents of each of the above documents being incorporated herein by reference. See also U.S. Patent No. 9,556,066, the entire contents of which are incorporated herein by reference. These AR coatings may be used in connection with certain exemplary embodiments.

[0108] The exemplary embodiments described herein can be incorporated into a wide variety of applications, including, for example, interior and exterior windows, skylights, doors, display shelves (e.g., for their doors and / or "walls") such as refrigerators / freezers, vehicle applications, etc. for commercial and / or residential use.

[0109] Certain exemplary embodiments are described in connection with an IG unit including two substrates, but it will be understood that the techniques described herein can be applied with respect to so-called triple IG units. In such units, a first substrate, a second substrate, and a third substrate that are substantially parallel and spaced apart are separated by a first spacer system and a second spacer system, and a shade may be provided adjacent to any one or more of the inner surfaces of the innermost substrate and the outermost substrate and / or adjacent to one or both of the surfaces of the intermediate substrate.

[0110] While specific exemplary embodiments are described as incorporating a glass substrate (e.g., for use in the inner and outer panes of the IG units described herein), it will be understood that other exemplary embodiments may incorporate a non-glass substrate for one or both of such panes. For example, plastics, composites, etc. may be used. When a glass substrate is used, such a substrate may be heat treated (e.g., heat strengthened and / or heat tempered), chemically heat tempered, left in an annealed state, etc. In certain exemplary embodiments, the inner substrate or the outer substrate may be laminated to another substrate of the same or different material.

[0111] As used herein, terms such as "on" and "supported by" should not be construed to mean that two elements are in direct adjacency to each other unless explicitly stated otherwise. In other words, a first layer may be said to be "on" or "supported by" a second layer even if there is one or more layers between the first layer and the second layer.

[0112] In certain exemplary embodiments, an insulating glass (IG) unit is provided. The first substrate and the second substrate each have an inner major surface and an outer major surface, and the inner major surface of the first substrate faces the inner major surface of the second substrate. A spacer system serves to maintain the first substrate and the second substrate in a spaced-apart relationship substantially parallel to each other and to define a gap therebetween. A dynamically controllable shade is inserted between the first substrate and the second substrate. The shade includes a first conductive coating provided directly or indirectly on the inner major surface of the first substrate, the first conductive coating being divided into a plurality of zones electrically insulated from each other, a dielectric film or an insulator film provided directly or indirectly on the first conductive coating, and a shutter including a polymer substrate supporting a second conductive coating, the polymer substrate being extendable to a shutter closed position and retractable to a shutter open position, and the first conductive coating and / or the second conductive coating being electrically connectable to a power source controllable to set a potential difference and generate an electrostatic force to drive the polymer substrate to the shutter closed position.

[0113] In addition to the features of the previous paragraph, in certain exemplary embodiments, the power source may be electrically connected to the zones, and the IG unit may further include a controller configured to enable the power source to deliver voltage(s) to the zones independently of each other.

[0114] In addition to the features of any of the previous two paragraphs, in certain exemplary embodiments, the polymer substrate may be configured to preferentially extend closer to the zones receiving voltage(s) compared to other zones that do not receive voltage(s).

[0115] In addition to the features of any of the previous three paragraphs, in certain exemplary embodiments, the first conductive coating may be divided into at least three zones.

[0116] In addition to the features of any of the previous four paragraphs, in certain exemplary embodiments, the zones may be arranged in rows and / or columns.

[0117] In addition to the features of any of the previous five paragraphs, in certain exemplary embodiments, the zones may be of the same size and shape.

[0118] In addition to the features of any of the previous six paragraphs, in certain exemplary embodiments, the sensing circuit may be configured to measure capacitance in different zones.

[0119] In addition to the features of any of the previous seven paragraphs, in certain exemplary embodiments, the polymeric substrate may be structured to coil up upon retraction and unwind upon extension, and the IG unit may further comprise a controller configured to estimate whether the coil of the polymeric substrate is distorted during extension and / or retraction based on the measured capacitance.

[0120] In addition to the features of any of the previous eight paragraphs, in certain exemplary embodiments, the distortion of the coil of the polymeric substrate may be estimated based on different zones having measured capacitances that differ from the measured capacitances of one or more reference zones by more than a predetermined threshold (e.g., if one or more reference zones are the outermost zones (s) of the IG unit), etc., based on different zones having measured capacitances that differ from each other by more than a predetermined threshold.

[0121] In addition to the features of any of the previous nine paragraphs, in certain exemplary embodiments, the controller may be further configured to control the power supply to selectively deliver voltage (s) to the zones to correct the estimated distortion of the coil of the polymeric substrate.

[0122] In addition to the features of any of the previous 10 paragraphs, in certain exemplary embodiments, the polymeric substrate may be configured to extend preferentially closer to the zone(s) that receive the voltage(s) as compared to other zones that do not receive the voltage(s).

[0123] In certain exemplary embodiments, the glass substrate includes a dynamically controllable shade disposed on the glass substrate. The shade includes a first conductive coating disposed directly or indirectly on a major surface of the substrate, the first conductive coating being divided into a plurality of zones electrically insulated from each other, a dielectric / insulator film disposed directly or indirectly on the first conductive coating, and a shutter including a polymeric substrate that supports a second conductive coating. The polymeric substrate is extensible to a shutter closed position and retractable to a shutter open position. The first conductive coating and / or the second conductive coating are electrically connectable to a power source controllable to set a potential difference and generate an electrostatic force to drive the polymeric substrate to the shutter closed position.

[0124] In addition to the features of the previous paragraph, in certain exemplary embodiments, the polymeric substrate may be structured to coil up upon retraction and unwind upon extension, and the coil strain of the polymeric substrate can be estimated from the capacitance measured in the zones.

[0125] In addition to the features of any of the previous two paragraphs, in certain exemplary embodiments, the power source may be controllable to selectively deliver a voltage(s) to the zones to correct for the estimated strain of the coil of the polymeric substrate.

[0126] In addition to the features of any of the previous three paragraphs, in certain exemplary embodiments, the polymeric substrate may be configured to extend preferentially closer to the zone(s) that receive the voltage(s) as compared to other zones that do not receive the voltage(s).

[0127] In certain exemplary embodiments, a method of manufacturing an insulating glass (IG) unit is provided. The method comprises having a first substrate and a second substrate, each having an inner major surface and an outer major surface, wherein the inner major surface of the first substrate faces the inner major surface of the second substrate, and providing a dynamically controllable shade on the first substrate and / or the second substrate. The shade includes a first conductive coating provided directly or indirectly on the inner major surface of the first substrate, the first conductive coating being divided into a plurality of zones electrically insulated from each other, a dielectric film or an insulator film provided directly or indirectly on the first conductive coating, and a shutter including a polymer substrate supporting a second conductive coating, the polymer substrate being extendable to a shutter closed position and retractable to a shutter open position. The first substrate and the second substrate are connected to each other in a substantially parallel and spaced relationship such that a gap is defined therebetween and the dynamically controllable shade is positioned in the gap. The first conductive coating and / or the second conductive coating are electrically connectable to a power source controllable to set a potential difference and generate an electrostatic force to drive the polymer substrate to the shutter closed position.

[0128] In addition to the features of the preceding paragraph, in certain exemplary embodiments, the zones may be arranged in rows and / or columns.

[0129] In addition to the features of any of the preceding two paragraphs, in certain exemplary embodiments, the zones may be of the same size and shape.

[0130] In addition to the features of any of the preceding three paragraphs, in certain exemplary embodiments, a sensing circuit may be electrically connected to the zones, the sensing circuit being configured to measure capacitance in different zones.

[0131] In addition to the features of any of the previous four paragraphs, in certain exemplary embodiments, the polymeric substrate may be structured to coil up upon retraction and unwind upon extension, and the method may further include providing a controller configured to estimate whether the coils of the polymeric substrate are distorted during extension and / or retraction based on the measured capacitance.

[0132] In addition to the features of any of the previous four paragraphs, in certain exemplary embodiments, the distortion of the coils of the polymeric substrate may be estimated based on (a) different zones having measured capacitances that differ from each other by more than a predetermined threshold, and / or (b) different zones having measured capacitances that differ from the measured capacitance(s) of one or more reference zones by more than a predetermined threshold, where the one or more reference zones are the outermost zone(s) of the IG unit.

[0133] In addition to the features of any of the previous five paragraphs, in certain exemplary embodiments, the controller may be further configured to control the power supply to selectively deliver voltage(s) to the zones to assist in correcting the estimated distortion of the coils of the polymeric substrate.

[0134] In addition to the features of any of the previous six paragraphs, in certain exemplary embodiments, the polymeric substrate may be configured to extend preferentially closer to the zone(s) receiving voltage(s) compared to other zones that do not receive voltage(s).

[0135] In certain exemplary embodiments, a method of operating a dynamic shade within an insulating glass (IG) unit is provided. The method includes having an IG unit fabricated according to the techniques disclosed herein and providing voltage(s) to one or more zones to assist in correcting the distortion of the shutter. For example, the method may include selectively activating the power supply, moving the polymeric substrate between a shade open position and a closed position, and supplying power to the zones to selectively correct the distortion of the coils of the polymeric substrate.

[0136] The present invention has been described in connection with what is presently considered to be practical and preferred embodiments, but the present invention is not limited to the disclosed embodiments and / or vapor deposition techniques. Rather, it is intended to cover various modifications and equivalent configurations included within the spirit and scope of the appended claims.

Claims

1. An insulating glass (IG) unit, comprising: a first substrate and a second substrate, each having an inner major surface and an outer major surface, wherein the inner major surface of the first substrate faces the inner major surface of the second substrate; a spacer system configured to maintain the first substrate and the second substrate in a spaced-apart relationship substantially parallel to each other and contributing to defining at least one gap between the first substrate and the second substrate; a dynamically controllable shade inserted at least between the first substrate and the second substrate, the shade comprising: a first conductive coating provided directly or indirectly on the inner major surface of the first substrate, the first conductive coating being divided into a plurality of zones electrically insulated from each other; a dielectric film provided directly or indirectly on the first conductive coating; a shutter comprising a polymer substrate supporting a second conductive coating, the polymer substrate being extendable to a shutter closed position and retractable to a shutter open position, and when the polymer substrate extends to the shutter closed position, the first conductive coating extends across the plurality of zones and the shutter contacts a stopper provided at the shutter closed position; The insulating glass (IG) unit, wherein at least one of the first conductive coating and / or the second conductive coating is electrically connectable to a power source configured to set a potential difference and generate an electrostatic force to drive the polymer substrate to the shutter closed position.

2. The power source is electrically connected to at least some of the plurality of zones, and the IG unit further comprises a controller configured to enable the power source to deliver a voltage (s) to the zones independent of each other. The IG unit according to claim 1.

3. The IG unit according to claim 1 or 2, wherein the polymer substrate is configured to extend preferentially closer to zones receiving a voltage (s) compared to other zones not receiving a voltage (s).

4. The IG unit according to any one of claims 1 to 3, wherein the first conductive coating is divided into at least three zones.

5. The IG unit according to any one of claims 1 to 4, wherein the zones are arranged in rows and / or columns.

6. The IG unit according to any one of claims 1 to 5, wherein the zones each have the same size and shape.

7. The IG unit according to any one of claims 1 to 6, further comprising a detection circuit configured to measure capacitance in different zones.

8. The polymer substrate is structured to coil when retracted and unwind when extended, and the IG unit further comprises a controller configured to estimate whether the coil of the polymer substrate is distorted during extension and / or retraction based on the measured capacitance. The IG unit according to claim 7.

9. The IG unit according to claim 8, wherein the distortion of the coil of the polymer substrate is estimated based on different zones having measured capacitances that differ from each other by more than a predetermined threshold value.

10. The distortion of the coil of the polymer substrate is estimated based on different zones having measured capacitances that differ from the measured capacitance(s) of one or more reference zones by more than a predetermined threshold value, and the one or more reference zones are the outermost zone(s) within the IG unit. The IG unit according to claim 8 or 9.

11. The IG unit according to any one of claims 8 to 10, wherein the controller is further configured to control the power supply so as to selectively deliver a voltage(s) to the zones to correct the estimated distortion of the coil of the polymer substrate.

12. The IG unit according to claim 11, wherein the polymer substrate is configured to extend preferentially closer to the zone(s) receiving the voltage(s) compared to other zones that do not receive the voltage(s).

13. A glass substrate, comprising a dynamically controllable shade system provided on the glass substrate, the shade system comprising: a first conductive coating provided directly or indirectly on the main surface of the substrate, the first conductive coating being divided into a plurality of zones electrically insulated from each other; a first conductive coating A dielectric film provided directly or indirectly on the first conductive coating; A shutter including a polymer substrate that supports a second conductive coating, the polymer substrate being extendable to a shutter closed position and retractable to a shutter open position, and when the polymer substrate is extended to the shutter closed position, the first conductive coating extends across the plurality of zones, and the shutter contacts a stopper provided at the shutter closed position; A glass substrate, at least one of the first conductive coating and / or the second conductive coating being electrically connectable to a power source controllable to set a potential difference and generate an electrostatic force to drive the polymer substrate to the shutter closed position.

14. The polymer substrate according to claim 13, wherein the polymer substrate is structured to coil up when retracting and unwind when extending, and the coil strain of the polymer substrate is determinable based on at least the capacitance measured in the zone.

15. The substrate according to claim 14, wherein the power source is controllable to selectively deliver a voltage(s) to the zone to correct an estimated and / or determined strain of the coil of the polymer substrate.

16. The substrate according to claim 15, wherein the polymer substrate is configured to extend preferentially closer to a zone that receives a voltage(s) compared to other zones that do not receive a voltage(s).

17. A method for manufacturing an insulating glass (IG) unit, the method comprising: Having a first substrate and a second substrate; Providing a dynamically controllable shade on the first substrate and / or the second substrate, the shade comprising: A first conductive coating provided directly or indirectly on an inner main surface of the first substrate, the first conductive coating being divided into a plurality of zones that are electrically insulated from each other; A dielectric film provided directly or indirectly on the first conductive coating; A shutter including a polymer substrate that supports a second conductive coating, wherein the polymer substrate is extendable to a shutter closed position and retractable to a shutter open position, and when the polymer substrate is extended to the shutter closed position, the first conductive coating extends across the plurality of zones, and the shutter contacts a stopper provided at the shutter closed position. Connecting the first substrate and the second substrate in a substantially parallel and spaced relationship such that at least one gap is defined between the first substrate and the second substrate and the at least dynamically controllable shade is disposed within the gap. At least one of the first conductive coating and / or the second conductive coating is electrically connectable to a power source controllable to set a potential difference and generate an electrostatic force to drive the polymer substrate to the shutter closed position.

18. The method according to claim 17, wherein the zones are arranged in rows and / or columns.

19. The method according to claim 17 or 18, wherein the zones have the same size and shape.

20. The method according to any one of claims 17 to 19, further comprising a detection circuit configured to measure capacitance in different ones of the zones.

21. The polymer substrate is structured to coil when retracted and unwind when extended, and the method further includes providing a controller configured to estimate and / or determine whether the coil of the polymer substrate is distorted during extension and / or retraction based on the measured capacitance. The method according to any one of claims 17 to 20.

22. The distortion of the coil of the polymer substrate is estimated and / or measured based on (a) different zones having measured capacitances that differ from each other by more than a predetermined threshold, and / or (b) measured capacitances of one or more reference zones that differ from the measured capacitances of different zones by more than a predetermined threshold, and the one or more reference zones are the outermost zones (plural) of the IG unit. The method according to claim 21.

23. The method according to claim 21 or 22, wherein the controller is further configured to control the power supply to selectively deliver voltage(s) to the zone to correct the estimated strain of the coil of the polymer substrate.

24. The method according to claim 23, wherein the polymer substrate is configured to extend preferentially closer to the zone that receives voltage compared to other zones that do not receive voltage(s).

25. A method of operating a dynamic shade within an insulating glass (IG) unit, the method comprising: having an IG unit fabricated according to the method according to any one of claims 17 to 24; selectively activating the power supply to move the polymer substrate between the shutter open position and the shutter closed position; and selectively providing power to the zone to correct the strain of the coil of the polymer substrate.

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