Electro-optic subassembly and method of manufacture

Abstract

According to one aspect of the present disclosure, a method is provided for making an electro-optic device. The method including the steps of: creating a prelaminate stacked structure by: providing a first barrier release liner, placing a first laminating inner layer on the first barrier release liner, placing a thin film electro-optic device on the first laminating inner layer, placing a second laminating inner layer on the thin film electro-optic device, and placing a second barrier release liner above the second laminating inner layer; laminating the prelaminate stacked structure to create an electro- optic subassembly; subsequently removing the first and second barrier release liners from the electro-optic subassembly; and securing the electro-optic subassembly between two transparent substrates to create the electro-optic device.

Description

Atty. Docket No. AUTO 05188T (GEN010 FP1422CWO)ELECTRO-OPTIC SUBASSEMBLY AND METHOD OF MANUFACTURECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority under 35 U.S.C. §119(e) upon U.S. Provisional Patent Application No. 63 / 741,540, entitled "ELECTRO-OPTIC SUBASSEMBLY AND METHOD OF MANUFACTURE" filed on January 3, 2025, by Matthew A. Koppey et al., and U.S. Provisional Patent Application No. 63 / 829,848, entitled "ELECTRO-OPTIC SUBASSEMBLY AND METHOD OF MANUFACTURE" filed on June 25, 2025, by Matthew A. Koppey et al., the entire disclosures of which are incorporated herein by reference.TECHNICAL FIELD

[0002] The present disclosure generally relates to an electro-optic subassembly and more particularly to a laminated electro-optic subassembly for an electro-optic device and even more particularly to a laminated electro-optic subassembly for a large area device (LAD) such as a vehicle window or sunroof or an architectural window.SUMMARY

[0003] According to one aspect of the present disclosure, a method is provided for making an electro-optic device. The method including the steps of: creating a prelaminate stacked structure including: a first barrier release liner, a first laminating inner layer disposed adjacent the first barrier release liner, a thin film electro-optic device disposed adjacent the first laminating inner layer, a second laminating inner layer disposed adjacent the thin film electro-optic device, and a second barrier release liner disposed above the second laminating inner layer; laminating the prelaminate stacked structure to create an electro-optic subassembly; subsequently removing the first and second barrier release liners from the electro-optic subassembly; and securing the electro-optic subassembly between two transparent substrates to create the electrooptic LAD.

[0004] According to another aspect of the present disclosure, a method is provided for making an electro-optic subassembly for subsequent use in an electro-optic device. The method including the steps of: creating a prelaminate stacked structure including: a first barrier release liner, a first laminating inner layer disposed adjacent the first barrierrelease liner, a thin film electro-optic device disposed adjacent the first laminating inner layer, a second laminating inner layer disposed adjacent the thin film electro-optic device, a barrier perimeter seal disposed adjacent the first barrier release liner around a periphery of the prelaminate stacked structure, a second barrier release liner disposed above the second laminating inner layer and the barrier perimeter seal; laminating the prelaminate stacked structure to create the electro-optic subassembly, wherein the first and second barrier release liners are configured to be removed from the electro-optic subassembly while leaving the rest of the electro-optic subassembly intact for subsequent use between two transparent substrates of the electro-optic device.

[0005] According to another aspect of the present disclosure, an electro-optic subassembly is provided for subsequent use in an electro-optic device. The electro-optic subassembly including: a prelaminate structure comprising: a thin film electro-optic device, a first laminating inner layer disposed adjacent a first side of the thin film electrooptic device, and a second laminating inner layer disposed adjacent a second side of the thin film electro-optic device that is opposite the first side; a first barrier release liner disposed adjacent the first laminating inner layer opposite the thin film electro-optic device; and a second barrier release liner disposed proximate the second laminating inner layer opposite the thin film electro-optic device, wherein the first and second barrier layers are substantially impervious to oxygen and moisture and are configured for peeling off from the respective first and second laminating inner layers prior to lamination of the prelaminate structure between transparent substrates.

[0006] According to another aspect of the present disclosure, an electro-optic subassembly is provided for subsequent use in a curved electro-optic device between two transparent substrates. The electro-optic subassembly includes: a prelaminate structure including: a thin film electro-optic device, a first laminating inner layer disposed adjacent a first side of the thin film electro-optic device, and a second laminating inner layer disposed adjacent a second side of the thin film electro-optic device that is opposite the first side. At least one of the first and second laminating inner layers are embossed so as to reduce friction between the prelaminate structure and at least one of the two transparent substrates during subsequent lamination of the electro-optic device.

[0007] According to another aspect of the present disclosure, a method is provided for making an electro-optic subassembly for subsequent use in a curved electro-optic devicebetween two transparent substrates, the method including the steps of: creating a prelaminate stacked structure including: a first laminating inner layer, a thin film electrooptic device disposed adjacent the first laminating inner layer, and a second laminating inner layer disposed adjacent the thin film electro-optic device; laminating the prelaminate stacked structure to create the electro-optic subassembly; and embossing at least one of the first and second laminating inner layers so as to reduce friction between the prelaminate stacked structure and at least one of the two transparent substrates during subsequent lamination of the electro-optic device.

[0008] These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:

[0010] FIG. 1A is a perspective view of an automobile that incorporates at least one electro-optic element, in accordance with an aspect of the present disclosure;

[0011] FIG. IB is a perspective view of an airplane that incorporates at least one electrooptic element, in accordance with an aspect of the present disclosure;

[0012] FIG. 1C is a perspective view of a building that incorporates at least one electrooptic element, in accordance with an aspect of the present disclosure;

[0013] FIG. 2 is a flowchart illustrating a method of making an electro-optic large area device (LAD);

[0014] FIGS. 3A-3I are side elevational views showing the steps of assembly of an electrooptic LAD constructed according to the method of FIG. 2;

[0015] FIG. 4A is a side elevational view of an electro-optic subassembly according to an alternative embodiment;

[0016] FIG. 4B is a side elevational view of an LAD made using the electro-optic subassembly of FIG. 4A;

[0017] FIG. 5 is a close-up side elevational view of a portion of an electro-optic LAD constructed in accordance with another embodiment;

[0018] FIG. 6 is a flowchart illustrating a method of making an electro-optic subassembly for use in a curved large area device (LAD); and

[0019] FIGS. 7A and 7B are side elevational views showing an alternate prelaminate structure and an alternative electro-optic LAD.DETAILED DESCRIPTION

[0020] The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to an electro-optic subassembly. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

[0021] In this document, relational terms, such as first and second, top and bottom, and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0022] As discussed further below, the present disclosure pertains to an electro-optic subassembly 10 for use in an electro-optic large area device (LAD) such as windows and sunroofs for land vehicles, windows for airplanes, or architectural windows for buildings. As used herein, the term "large area device" or "LAD" shall mean a device having a surface area of about 250 cm2or more. The present disclosure also pertains to a method for manufacturing the electro-optic subassembly 10 and LADs. With reference now to FIGS. 1A-1C, the electro-optic subassembly 10 may be incorporated with one or more structures 36A-36C. For example, FIG. 1A illustrates a vehicle 36A employing the electrooptic subassembly 10. All or some components of the electro-optic subassembly 10 may be located within, or at least partially form, a vehicle window or sunroof 40. The vehicle36A may include a commercial vehicle, an emergency vehicle, a residential vehicle, a train, or the like. FIG. IB illustrates an airplane 36B employing the electro-optic subassembly 10. The electro-optic subassembly 10 may be located within, or at least partially form, an airplane window 42. FIG. 1C illustrates a building 36C employing the electro-optic subassembly 10. The electro-optic subassembly 10 may be located within, or at least partially form, a building window 44. Generally speaking, the electro-optic subassembly 10 may be incorporated into any LAD in any environment wherein changing transmittance and / or reflectivity is beneficial.

[0023] LADs have incorporated electro-optic elements that may be selectively darkened to enhance privacy and to reduce the brightness of light passing therethrough. In a move to make LADs thinner and lighter, a laminated thin film electro-optic subassembly is proposed for subsequent disposition between two substrates, such as glass substrates, to form an electro-optic subassembly used in the LADs. A problem that arises with such laminated thin film electro-optic subassemblies is that they are prone to damage from exposure to environmental elements such as water and oxygen. In final assembly in an LAD, the laminated thin film electro-optic subassemblies are protected from the environment by the glass substrates and a barrier perimeter seal disposed between the glass substrates. This problem was thus previously addressed by assembling the LADs as the laminated thin film electro-optic subassemblies were created. However, this method does not allow for prolonged periods of time before the electro-optic subassemblies are laminated between the glass substrates. Thus, it would not have been possible to ship the electro-optic subassemblies to another facility for subsequent lamination between the glass substrates. The method described below creates electro-optic subassemblies that can withstand shipping without damage from exposure to environmental elements. In this way, final assembly of the LADs including lamination of the electro-optic subassemblies between transparent substrates can occur at another facility.

[0024] One example of the method 100 will now be described with reference to FIGS. 2 and 3A-3L The method may begin with creating a prelaminate stacked structure 25 (FIG.3F) by: providing a first barrier release liner 12 (step 102) and placing a first laminating inner layer 14 on the first barrier release liner 12 (step 104). FIG. 3A shows the placement of the first laminating inner layer 14 on the first barrier release liner 12. Next, as shown in FIG. 3B, a thin film electro-optic device 16 is placed on the first laminating inner layer 14(step 106). Then, as shown in FIG. 3C, a second laminating inner layer 18 is placed on the thin film electro-optic device 16 (step 108). As shown in FIG. 3D, an optional barrier perimeter seal 20 is disposed on the first barrier release liner 12 around a periphery of the prelaminate stacked structure (step 114). Then, as shown in FIG. 3E, a second barrier release liner 22 is placed above the second laminating inner layer 18 (step 116) to form the prelaminate stacked structure 25 shown in FIG. 3F. In step 118, the prelaminate stacked structure 25 is laminated to form the electro-optic subassembly 10 as shown in FIG. 3G. Note that the order in which the prelaminate stacked structure is assembled may be varied provided the desired components of the prelaminate stacked structure is obtained.

[0025] As apparent from a comparison of FIGS. 3F and 3G, the lamination step heats the inner laminate layers 14 and 18, which become more viscous so as to flow and fill any voids within the structure whereby the thin film electro-optic device 16 is encased by the first and second inner laminating layers 14 and 18. The inner laminating layers 14 and 18 function as a glue that holds the structure together. The inner laminating layers 14 and 18 may be made of a material selected from the group consisting of polyvinyl butyral (PVB), thermoplastic polyurethane (TPU), and ethylene vinyl acetate (EVA).

[0026] If the method were for constructing an electro-optic subassembly 10, the method would be completed at this point. However, if the method is to construct an electro-optic LAD 30 (FIG. 31), the method further includes the step (120) of subsequently removing the first and second barrier release liners 12 and 22 from the electro-optic subassembly 10 as shown in FIG. 3H and the step (122) of securing the electro-optic subassembly 10 between two transparent substrates 24 and 26 to create the electro-optic LAD 30. The barrier perimeter seal 20 is configured to remain around the periphery of the prelaminate structure when the first and second barrier release liners 12 and 22 are removed such that the barrier perimeter seal 20 remains present and functional in the electro-optic LAD 30.

[0027] The first and second barrier release liners 12 and 22 together with the barrier perimeter seal function to prevent air and moisture from reaching the interior of the electro-optic subassembly 10. The first and second barrier release liners 12 and 22 may be made of siliconized polyethylene terephthalate (PET). Such first and second barrier release liners 12 and 22 may be readily peeled from the inner laminating layers 14 and18. In this way, the electro-optic subassemblies 10 may be manufactured at one facility and then shipped to another facility, which may be that of a customer, for subsequent assembly of the electro-optic LAD 30. This is particularly beneficial as the electro-optic subassemblies 10 may be laminated into rigid curved substrates, which are manufactured by the customer.

[0028] The thin film electro-optic device 16 may be a conductive polymer electrochromic (CPEC) thin film device. The electro-optic device 16 may be a solid-state thin film electrooptic device. A seal 17 (FIG. 3B) is optional for such a thin film electro-optic device. The thin film may include cathodic materials, anodic materials, and electrolyte materials. The electro-optic device 16 may be selected such that it exhibits a memory so as to retain a colored state or a non-colored state without application of a voltage.

[0029] The first and second transparent substrates 24 and 26 may be made of a polymer such as polyethylene terephthalate (PET), one or more plastics, or multi-plastic stacks, for example, and may have a thickness of about 125 pm. Alternatively, the transparent substrates 24 and 26 may be made of a flexible glass or a hybrid glass / polymer material.

[0030] FIG. 4A shows a second embodiment of an electro-optic subassembly 10a, which differs from the first embodiment shown in FIG. 3G in that it further includes a functional inner layer 28 placed on the second laminating inner layer 18 (step 110) and a third laminating inner layer 32 placed on the functional inner layer 28 (step 112). In this case, the second barrier release liner 22 is placed on the third laminating inner layer 32. FIG.4B shows a second embodiment of an electro-optic LAD 30a, which incorporates the electro-optic subassembly 10a without the release liners 12 and 22. The functional inner layer 28 may be selected from the group consisting of an infrared reflector inner layer and a color filter inner layer. It should be further appreciated that multiple functional inner layers may be added to the electro-optic subassembly 10a. By providing such functional inner layers, a supplier of the electro-optic subassembly 10a may ensue that the end electro-optic LAD 30a may have all the appropriate functions built into the device.

[0031] Although the present embodiments have been described with respect to LADs, it will be appreciated by those skilled in the art that the inventive methods may be employed to make electro-optic devices of any size.

[0032] The above-described method and device works very well for use in flat LADs. However, it was discovered that when used in curved LADs, the smooth flat surface of the inner laminating layers 14 and 18 could not move well along the curved smooth surfaces of the transparent substrates 24 and 26 during the lamination step and this can result in wrinkles in between the inner laminating layers 14 and 18.

[0033] To address this concern pertaining to curved electro-optic devices, the inner laminating layers 14 and 18 may be embossed in such a manner as to reduce or even minimize friction This can be accomplished by reducing or minimizing the contact area between the inner laminating layers 14 and 18 and the transparent substrates 24 and 26. An example of an embossed surface of the second inner laminating layer 18 is shown in a close up view in FIG. 5. As shown in this example, the second inner laminating layer 18 is embossed so as to have a plurality of peaks 18a that contact the surface of the transparent substrate 24 to minimize the area of contact. The first inner laminating layer 14 may be embossed in the same manner. Note that if the third inner laminating layer 32 is present, it would be embossed instead of the second inner laminating layer 18. Upon lamination, the inner laminating layers would melt and flow to fill in all the gaps.

[0034] The inner laminating layers 14 and 18 (or 32) may be embossed with a pattern to provide air channels from the inner part of the LAD to the edges so that air can escape during the lamination process and thereby prevent trapped air pockets and wrinkles in the finished LAD.

[0035] The embossing step may be accomplished by rolling a heated patterned roller along the surfaces of the laminating layers. Alternatively, heated presses may be applied from above and below the prelaminate stack. Yet another alternative is to press the prelaminated stack in a vacuum bag having an embossing pattern on it so that when the vacuum is applied to the bag it compresses the prelaminate stack so as to create an embossing pattern on the laminating layers. The laminating layers may be embossed before or after they are stacked in the prelaminate structure.

[0036] FIG. 6 is a flowchart showing the steps of a method 200 for creating an electrooptic subassembly 10 for subsequent use in a curved electro-optic device 30 between two transparent substrates 24 and 26. The method includes creating a prelaminate stacked structure 25 by providing a first laminating inner layer 14 (step 202), disposing a thin film electro-optic device 16 adjacent the first laminating inner layer 14 (step 204),and placing a second laminating inner layer 18 adjacent the thin film electro-optic device 16 (step 206). The method 200 may optionally include steps 208 and 210 in which an optional functional layer 28 may be placed on the second laminating inner layer 18 and a third laminating inner layer 32 may be placed on the functional layer 28. The prelaminate stacked structure 25 is then laminated to create the electro-optic subassembly (step 212). The method 200 further includes embossing (step 214) at least one of the first, second, and third laminating inner layers so as to reduce friction between the prelaminate stacked structure 25 and at least one of the two transparent substrates 24 and 26 during subsequent lamination of the electro-optic device 30.

[0037] FIG. 7A shows an alternate prelaminate structure 25b according to a third embodiment and FIG. 7B shows the resulting alternate electro-optic subassembly 10b. Prelaminate structure 25b differs in that one of the first laminating inner layer 14 and the second laminating inner layer 18 is wider than the other to provide a ledge 14b. The ledge 14b is provided to provide better adhesion of the seal 20. Both the first laminating inner layer 14 and the second laminating inner layer 18 may be extended relative to the thin film electro-optic device 16.

[0038] Although the thin film electro-optic device 16 is described above as possibly being a CPEC thin film device, it may also be any other electro-optic device such as polymer dispersed liquid crystal (PDLC), suspended particle device (SPD), etc.

[0039] In this document, relational terms, such as "first," "second," and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions.

[0040] As used herein, the term "and / or" when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and / or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.

[0041] For purposes of this disclosure, the term "associated" generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achievedwith the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

[0042] The term "substantially," and variations thereof, will be understood by persons of ordinary skill in the art as describing a feature that is equal or approximately equal to a value or description. For example, a "substantially planar" surface is intended to denote a surface that is planar or approximately planar. Moreover, "substantially" is intended to denote that two values are equal or approximately equal. If there are uses of the term which are not clear to persons of ordinary skill in the art, given the context in which it is used, "substantially" may denote values within 10% of each other, such as within 5% of each other, or within 2% of each other.

[0043] The term "transparent" is applied in the relative sense. "Transparent" refers to an optical element or material that is substantially transmissive at wavelengths of interest and thus generally allows light at such wavelengths to pass therethrough. The wavelengths in question will vary based on the context. However, in the event the wavelengths in question are not readily apparent, the wavelengths in question shall generally refer to visible light.

[0044] According to a first aspect of the present disclosure, a method is provided for making an electro-optic device. The method including the steps of: creating a prelaminate stacked structure comprising: a first barrier release liner, a first laminating inner layer disposed adjacent the first barrier release liner, a thin film electro-optic device disposed adjacent the first laminating inner layer, a second laminating inner layer disposed adjacent the thin film electro-optic device, and a second barrier release liner disposed above the second laminating inner layer; laminating the prelaminate stacked structure to create an electro-optic subassembly; subsequently removing the first and second barrier release liners from the electro-optic subassembly; and securing the electro-optic subassembly between two transparent substrates to create the electrooptic device.

[0045] The above first aspect may further include the prelaminate stacked structure further comprises a barrier perimeter seal disposed between the first and second barrier release liners around a periphery of the prelaminate stacked structure, wherein thebarrier perimeter seal is configured to remain around the periphery of the prelaminate structure when the first and second barrier release liners are removed such that the barrier perimeter seal remains present and functional in the electro-optic LAD.

[0046] The above first aspect may further include the prelaminate stacked structure further comprising: a functional inner layer disposed adjacent the second laminating inner layer; and a third laminating inner layer disposed adjacent the functional inner layer, wherein the second barrier release liner is disposed adjacent the third laminating inner layer. The functional inner layer may be selected from the group consisting of an infrared reflector inner layer and a color filter inner layer.

[0047] In the above first aspect, the first and second barrier release liners may include siliconized polyethylene terephthalate (PET).

[0048] According to the above first aspect, the first and second laminating inner layers may include a material selected from the group consisting of polyvinyl butyral (PVB), thermoplastic polyurethane (TPU), and ethylene vinyl acetate (EVA).

[0049] According to the above first aspect, the thin film electro-optic device is encased by the first and second laminating inner layers.

[0050] Also according to the above first aspect, the thin film electro-optic device is a conductive polymer electrochromic thin film device.

[0051] An electro-optic large area device (LAD) may be constructed in accordance with the method of the above first aspect.

[0052] According to a second aspect of the present disclosure, a method is provided for making an electro-optic subassembly for subsequent use in an electro-optic device. The method including the steps of: creating a prelaminate stacked structure comprising: a first barrier release liner, a first laminating inner layer disposed adjacent the first barrier release liner, a thin film electro-optic device disposed adjacent the first laminating inner layer, a second laminating inner layer disposed adjacent the thin film electro-optic device, a barrier perimeter seal disposed adjacent the first barrier release liner around a periphery of the prelaminate stacked structure, a second barrier release liner disposed above the second laminating inner layer and the barrier perimeter seal; laminating the prelaminate stacked structure to create the electro-optic subassembly, wherein the first and second barrier release liners are configured to be removed from the electro-opticsubassembly while leaving the rest of the electro-optic subassembly intact for subsequent use between two transparent substrates of the electro-optic device.

[0053] The above second aspect may further include the prelaminate stacked structure further comprising: a functional inner layer disposed adjacent the second laminating inner layer; and a third laminating inner layer disposed adjacent the functional inner layer, wherein the second barrier release liner is disposed adjacent the third laminating inner layer.

[0054] An electro-optic LAD may be constructed in accordance with the method of the above second aspect.

[0055] According to a third aspect of the present disclosure, an electro-optic subassembly is provided for subsequent use in an electro-optic device. The electro-optic subassembly including: a prelaminate structure comprising: a thin film electro-optic device, a first laminating inner layer disposed adjacent a first side of the thin film electrooptic device, and a second laminating inner layer disposed adjacent a second side of the thin film electro-optic device that is opposite the first side; a first barrier release liner disposed adjacent the first laminating inner layer opposite the thin film electro-optic device; and a second barrier release liner disposed proximate the second laminating inner layer opposite the thin film electro-optic device, wherein the first and second barrier layers are substantially impervious to oxygen and moisture and are configured for peeling off from the respective first and second laminating inner layers prior to lamination of the prelaminate structure between transparent substrates.

[0056] In the third aspect of the present disclosure, the electro-optic subassembly may further include a barrier perimeter seal disposed around the periphery of the prelaminate structure between the first and second barrier release liners, wherein the barrier perimeter seal is configured to remain around the periphery of the prelaminate structure when the first and second barrier release liners are removed.

[0057] In the third aspect of the present disclosure, the first and second barrier release liners may include siliconized polyethylene terephthalate (PET).

[0058] In the third aspect, the first and second laminating inner layers comprise a material selected from the group consisting of polyvinyl butyral (PVB), thermoplastic polyurethane (TPU), and ethylene vinyl acetate (EVA).

[0059] In the third aspect, the thin film electro-optic device is encased by the first and second laminating inner layers.

[0060] In the third aspect of the present disclosure, the prelaminate structure may further include one or more functional inner layers and a third laminating inner layer both disposed between the second laminating inner layer and the second barrier release liner. The one or more functional inner layers are selected from the group consisting of one or more of an infrared reflector inner layer and a color filter inner layer.

[0061] In the third aspect, the thin film electro-optic device is a conductive polymer electrochromic (CPEC) thin film device.

[0062] According to a fourth aspect of the present disclosure, an electro-optic subassembly is provided for subsequent use in a curved electro-optic device between two transparent substrates. The electro-optic subassembly includes: a prelaminate structure including: a thin film electro-optic device, a first laminating inner layer disposed adjacent a first side of the thin film electro-optic device, and a second laminating inner layer disposed adjacent a second side of the thin film electro-optic device that is opposite the first side. At least one of the first and second laminating inner layers are embossed so as to reduce friction between the prelaminate structure and at least one of the two transparent substrates during subsequent lamination of the electro-optic device.

[0063] According to a fifth aspect of the present disclosure, a method is provided for making an electro-optic subassembly for subsequent use in a curved electro-optic device between two transparent substrates, the method including the steps of: creating a prelaminate stacked structure including: a first laminating inner layer, a thin film electrooptic device disposed adjacent the first laminating inner layer, and a second laminating inner layer disposed adjacent the thin film electro-optic device; laminating the prelaminate stacked structure to create the electro-optic subassembly; and embossing at least one of the first and second laminating inner layers so as to reduce friction between the prelaminate stacked structure and at least one of the two transparent substrates during subsequent lamination of the electro-optic device.

[0064] It should be appreciated by those skilled in the art that the above-described components may be combined in additional or alternative ways not explicitly described herein. Modifications of the various implementations of the disclosure will occur to those skilled in the art and to those who apply the teachings of the disclosure.Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and not intended to limit the scope of the disclosure, which is defined by the following claims as interpreted according to the principles of patent law, including the doctrine of equivalents.

Claims

CLAIMSWhat is claimed is:

1. A method of making an electro-optic device comprising the steps of:creating a prelaminate stacked structure comprising:a first barrier release liner,a first laminating inner layer disposed adjacent the first barrier release liner,a thin film electro-optic device disposed adjacent the first laminating inner layer,a second laminating inner layer disposed adjacent the thin film electrooptic device, anda second barrier release liner disposed above the second laminating inner layer;laminating the prelaminate stacked structure to create an electro-optic subassembly;subsequently removing the first and second barrier release liners from the electro-optic subassembly; andsecuring the electro-optic subassembly between two transparent substrates to create the electro-optic device.

2. The method of claim 1, wherein, prior to placing the second barrier release liner, the prelaminate stacked structure further comprises a barrier perimeter seal disposed between the first and second barrier release liners around a periphery of the prelaminate stacked structure, wherein the barrier perimeter seal is configured to remain around the periphery of the prelaminate structure when the first and second barrier release liners are removed such that the barrier perimeter seal remains present and functional in the electro-optic device.

3. The method of any one of claims 1 and 2, wherein the prelaminate stacked structure further comprises:a functional inner layer disposed adjacent the second laminating inner layer; and a third laminating inner layer disposed adjacent the functional inner layer, wherein the second barrier release liner is disposed adjacent the third laminating inner layer.

4. The method of claim 3, wherein the functional inner layer is selected from the group consisting of an infrared reflector inner layer and a color filter inner layer.

5. The method of any one of claims 1-4, wherein the first and second barrier release liners comprise siliconized polyethylene terephthalate (PET).

6. The method of any one of claims 1-5, wherein the first and second laminating inner layers comprise a material selected from the group consisting of polyvinyl butyral (PVB), thermoplastic polyurethane (TPU), and ethylene vinyl acetate (EVA).

7. The method of any one of claims 1-6, wherein the thin film electro-optic device is encased by the first and second laminating inner layers.

8. The method of any one of claims 1-7, wherein the thin film electro-optic device is a conductive polymer electrochromic thin film device.

9. An electro-optic large area (LAD) constructed in accordance with the method of any one of claims 1-8.

10. A method of making an electro-optic subassembly for subsequent use in an electro-optic device, the method comprising the steps of:creating a prelaminate stacked structure comprising:a first barrier release liner,a first laminating inner layer disposed adjacent the first barrier release liner,a thin film electro-optic device disposed adjacent the first laminating inner layer,a second laminating inner layer disposed adjacent the thin film electro-optic device,a barrier perimeter seal disposed adjacent the first barrier release liner around a periphery of the prelaminate stacked structure, a second barrier release liner disposed above the second laminating inner layer and the barrier perimeter seal;laminating the prelaminate stacked structure to create the electro-optic subassembly,wherein the first and second barrier release liners are configured to be removed from the electro-optic subassembly while leaving the rest of the electro-optic subassembly intact for subsequent use between two transparent substrates of the electro-optic device.

11. The method of claim 10, wherein the prelaminate stacked structure further comprises:a functional inner layer disposed adjacent the second laminating inner layer; and a third laminating inner layer disposed adjacent the functional inner layer, wherein the second barrier release liner is disposed adjacent to the third laminating inner layer.

12. An electro-optic subassembly constructed in accordance with the method of any one of claims 10 and 11.

13. An electro-optic subassembly for subsequent use in an electro-optic device, the electro-optic subassembly comprising:a prelaminate structure comprising:a thin film electro-optic device,a first laminating inner layer disposed adjacent a first side of the thin film electro-optic device, anda second laminating inner layer disposed adjacent a second side of the thin film electro-optic device that is opposite the first side;a first barrier release liner disposed adjacent the first laminating inner layer opposite the thin film electro-optic device; anda second barrier release liner disposed proximate the second laminating inner layer opposite the thin film electro-optic device,wherein the first and second barrier layers are substantially impervious to oxygen and moisture and are configured for peeling off from the respective first and second laminating inner layers prior to lamination of the prelaminate structure between transparent substrates.

14. The electro-optic subassembly of claim 13, and further comprising a barrier perimeter seal disposed around the periphery of the prelaminate structure between the first and second barrier release liners, wherein the barrier perimeter seal is configured to remain around the periphery of the prelaminate structure when the first and second barrier release liners are removed.

15. The electro-optic subassembly of any one of claims 13 and 14, wherein the first and second barrier release liners comprise siliconized polyethylene terephthalate (PET).

16. The electro-optic subassembly of any one of claims 13-15, wherein the first and second laminating inner layers comprise a material selected from the group consisting of polyvinyl butyral (PVB), thermoplastic polyurethane (TPU), and ethylene vinyl acetate (EVA).

17. The electro-optic subassembly of any one of claims 13-16, wherein the thin film electro-optic device is encased by the first and second laminating inner layers.

18. The electro-optic subassembly of any one of claims 13-17, wherein the prelaminate structure further comprises one or more functional inner layers and a third laminating inner layer both disposed between the second laminating inner layer and the second barrier release liner.

19. The electro-optic subassembly of claim 18, wherein the one or more functional inner layers are selected from the group consisting of one or more of an infrared reflector inner layer and a color filter inner layer.

20. The electro-optic subassembly of any one of claims 13-19, wherein the thin film electro-optic device is a conductive polymer electrochromic (CPEC) thin film device.

21. An electro-optic subassembly for subsequent use in a curved electro-optic device between two transparent substrates, the electro-optic subassembly comprising:a prelaminate structure comprising:a thin film electro-optic device,a first laminating inner layer disposed adjacent a first side of the thin film electro-optic device, anda second laminating inner layer disposed adjacent a second side of the thin film electro-optic device that is opposite the first side, wherein at least one of the first and second laminating inner layers are embossed so as to reduce friction between the prelaminate structure and at least one of the two transparent substrates during subsequent lamination of the electro-optic device.

22. The electro-optic subassembly of claim 21, wherein the prelaminate structure further comprises:a first barrier release liner disposed adjacent the first laminating inner layer; and a second barrier release liner disposed above the second laminating inner layer, wherein the first and second barrier release liners are configured to be removed from the electro-optic subassembly while leaving the rest of the electro-optic subassembly intact for subsequent use between the two transparent substrates of the electro-optic device.

23. The electro-optic subassembly of any one of claims 21 and 22, wherein the prelaminate structure further comprises:a functional inner layer disposed adjacent the second laminating inner layer; and a third laminating inner layer disposed adjacent the functional inner layer, wherein the first and third laminating layers are embossed.

24. The electro-optic subassembly of any one of claims 21-23, wherein the first and second laminating inner layers comprise a material selected from the group consisting of polyvinyl butyral (PVB), thermoplastic polyurethane (TPU), and ethylene vinyl acetate (EVA).

25. The electro-optic subassembly of any one of claims 21-24, wherein the thin film electro-optic device is a conductive polymer electrochromic thin film device.

26. A method of making an electro-optic subassembly for subsequent use in a curved electro-optic device between two transparent substrates, the method comprising the steps of:creating a prelaminate stacked structure comprising:a first laminating inner layer,a thin film electro-optic device disposed adjacent the first laminating inner layer, anda second laminating inner layer disposed adjacent the thin film electro-optic device;laminating the prelaminate stacked structure to create the electro-optic subassembly; andembossing at least one of the first and second laminating inner layers so as to reduce friction between the prelaminate stacked structure and at least one of the two transparent substrates during subsequent lamination of the electro-optic device.

27. The method of claim 26, wherein the step of embossing is performed by rolling a heated patterned roller across the at least one of the first and second laminating inner layers.

28. The method of any one of claims 26 and 27, wherein the prelaminate stacked structure further comprises:a first barrier release liner disposed adjacent the first laminating inner layer; and a second barrier release liner disposed above the second laminating inner layer,wherein the first and second barrier release liners are configured to be removed from the electro-optic subassembly while leaving the rest of the electro-optic subassembly intact for subsequent use between the two transparent substrates of the electro-optic device.

29. The method of any one of claims 26-28, wherein the prelaminate stacked structure further comprises:a functional inner layer disposed adjacent the second laminating inner layer; and a third laminating inner layer disposed adjacent the functional inner layer, wherein the first and third laminating layers are embossed.

30. The method of any one of claims 26-29, wherein the first and second laminating inner layers comprise a material selected from the group consisting of polyvinyl butyral (PVB), thermoplastic polyurethane (TPU), and ethylene vinyl acetate (EVA).

31. The method of any one of claims 26-30, wherein the thin film electro-optic device is a conductive polymer electrochromic thin film device.

32. An electro-optic large area (LAD) constructed in accordance with the method of any one of claims 26-31.

33. The method of any one of claims 1-8, 10, 11, and 26-31, wherein one or more of the first and second laminating inner layers extends beyond the thin film electro-optic device to provide at least one ledge.

34. The electro-optic subassembly of any one of claims 12-25, wherein one or more of the first and second laminating inner layers extends beyond the thin film electro-optic device to provide at least one ledge.

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