Electrochromic polymeric solid films, manufacturing electrochromic devices using such solid films, and processes for making such solid films and devices

Claim 2

A segmented electrochromic device comprising: (a) a first transparent substrate having a transparent conductive layer on a surface thereof; (b) a second substrate having a conductive layer on a surface thereof, said conductive layer of said first substrate opposing said conductive layer of said second substrate in a spaced-apart relationship, thereby forming an interpane distance between said substrates of at least about 10 microns; (c) an electrochromic medium disposed between said spaced-apart substrates, said medium comprising a cross-linked polymeric solid film formed by curing a monomer composition that includes at least one of (A) a monofunctional monomer and a cross-linking agent and (B) a polyfunctional monomer capable of cross-linking, said cross-linked polymeric solid film plasticized with a plasticizer; and (d) at least one break in electrical continuity in at least one of said conductive layer of said first substrate and said conductive layer of said second substrate, said at least one break in electrical continuity of said conductive layer defining a selected portion of the electrochromic device in order that upon application of a potential thereto, said selected portion colors in preference to an adjacent portion.

Claim 3

The segmented electrochromic device of claim 1, wherein said device comprises an electrochromic rearview mirror and wherein said selected portion colors to assist in reducing locally reflected glare.

Claim 4

The segmented electrochromic device of claim 2, wherein said mirror comprises a multi-radius mirror having an inboard less curved region and an outboard more curved region, said selected portion comprising one of said inboard region and said outboard region.

Claim 5

The segmented electrochromic device of claim 1, wherein said device comprises a segmented sunvisor.

Claim 6

The segmented electrochromic device of claim 4, wherein said segmented sunvisor comprises segments addressable by at least one of a switch, a photosensor, a touch sensor, a voice activated sensor and an RF activated sensor.

Claim 7

The segmented electrochromic device of claim 4, wherein said segmented sunvisor comprises one of horizontal segments and vertical segments.

Claim 8

The segmented electrochromic device of claim 1, wherein said device comprises one of a mirror and a glazing.

Claim 9

The segmented electrochromic device of claim 7, wherein said device comprises a vehicular mirror.

Claim 10

The segmented electrochromic device of claim 7, wherein said device comprises one of a vehicular glazing, an aeronautical glazing and an architectural glazing.

Claim 11

The segmented electrochromic device of claim 1, wherein said break is formed by at least one of chemical etching, mechanical scribing, laser etching, scoring and sand blasting.

Claim 12

The segmented electrochromic device of claim 1, wherein said break in electrical continuity is in both of said conductive layer of said first substrate and said conductive layer of said second substrate layer.

Claim 13

The segmented electrochromic device according to claim 1, wherein said interpane distance is from about 10 μm to about 1000 μm.

Claim 14

The segmented electrochromic device according to claim 12, wherein said interpane distance is from about 20 μm to about 200 μm.

Claim 15

The segmented electrochromic device according to claim 12, wherein said interpane distance is from about 37 μm to about 74 μm.

Claim 16

The segmented electrochromic device according to claim 1, wherein said electrochromic monomer composition includes a monomer component selected from the group consisting of urethane forming material, derivatized urethane forming material, acrylate forming material, epoxy forming material, and vinyl forming material.

Claim 17

The segmented electrochromic device according to claim 1, wherein said electrochromic monomer composition further comprises a component selected from the group consisting of cross-linking agents, photoinitiators, photosensitizers, ultraviolet stabilizing agents, electrolytic materials, coloring agents, spacers, anti-oxidizing agents, flame retarding agents, heat stabilizing agents, compatibilizing agents, humectants, lubricating agents, adhesion promoting agents, coupling agents and combinations thereof.

Claim 18

The segmented electrochromic device according to claim 1, wherein said electrochromic monomer composition comprises a cross-linking agent.

Claim 19

The segmented electrochromic device according to claim 17, wherein said cross-linking agent is selected from the group consisting of polyfunctional hydroxy compounds, polyfunctional primary or secondary amino compounds, polyfunctional mercapto compounds and combinations thereof.

Claim 20

The segmented electrochromic device according to claim 18, wherein said cross-linking agent comprises a polyfunctional hydroxy compound.

Claim 21

The segmented electrochromic device according to claim 19, wherein said polyfunctional hydroxy compound comprises a polyol.

Claim 22

The segmented electrochromic device according to claim 20, wherein said polyol comprises a glycol or a glycerol.

Claim 23

The segmented electrochromic device according to claim 17, wherein said cross-linking agent is selected from the group consisting of pentaerythritol, 2-ethyl-2-(hydroxymethyl)-1,3-propanediol, caprolactone triols, and combinations thereof.

Claim 24

The segmented electrochromic device according to claim 1, wherein said monomer composition comprises a monomer component selected from the group consisting of a monofunctional monomer, a difunctional monomer, a trifunctional monomer, a polyfunctional monomer or mixtures thereof.

Claim 25

The segmented electrochromic device according to claim 23, wherein said monomer component is selected from the group of monomers consisting of 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, methylene glycol monoacrylate, diethylene glycol monomethacrylate, 2-hydroxypropyl acrylate, 2-hydroxypropyl methacrylate, 3-hydroxypropyl acrylate, 3-hydroxypropyl methacrylate, dipropylene glycol monomethacrylate, 2,3-dihydroxypropyl methacrylate, methyl acrylate, ethyl acrylate, n-propyl acrylate, i-propyl acrylate, n-butyl acrylate, s-butyl acrylate, n-pentyl acrylate, 2-ethylhexyl acrylate, methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, i-propyl methacrylate, n-butyl methacrylate, s-butyl methacrylate, n-pentyl methacrylate, s-pentyl methacrylate, methoxyethyl acrylate, methoxyethyl methacrylate, triethylene glycol monoacrylate, glycerol monoacrylate, glycerol monomethacrylate, benzyl acrylate, caprolactone acrylate, cyclohexyl acrylate, cyclohexyl methacrylate, 2-ethoxyethyl acrylate, 2-ethoxyethyl methacrylate, 2-(2-ethoxyethoxy)-ethylacrylate, glycidyl methacrylate, n-hexyl acrylate, n-hexyl methacrylate, isobornyl acrylate, isobornyl methacrylate, i-decyl acrylate, i-decyl methacrylate, i-octyl acrylate, lauryl acrylate, lauryl methacrylate, 2-methoxyethyl acrylate, n-octyl acrylate, 2-phenoxyethyl acrylate, 2-phenoxyethyl methacrylate, stearyl acrylate, stearyl methacrylate, tetrahydrofurfuryl acrylate, tetrahydrofurfuryl methacrylate, tridecyl methacrylate, 1,4-butanediol diacrylate, 1,4-butanediol dimethacrylate, 1,3-butylene glycol diacrylate, 1,3-butylene glycol dimethacrylate, diethylene glycol diacrylate, diethylene glycol dimethacrylate, ethylene glycol diacrylate, ethoxylated bisphenol A dimethacrylate, ethylene glycol dimethacrylate, 1,6-hexanediol diacrylate, 1,6-hexanediol dimethacrylate, neopentyl glycol diacrylate, neopentyl glycol dimethacrylate, polyethylene glycol diacrylate, polyethylene glycol dimethacrylate, tetraethylene glycol diacrylate, tetraethylene glycol dimethacrylate, triethylene glycol diacrylate, triethylene glycol dimethacrylate, tripropylene glycol diacrylate, dipentaerythritol pentaacrylate, ethoxylated pentaerythritol triacrylate, pentaerythritol tetraacrylate, trimethylolpropane triacrylate, pentaerythritol triacrylate, trimethylolpropane trimethacrylate, tris(2-hydroxyethyl)-isocyanurate triacrylate, tris(2-hydroxyethyl)-isocyanurate trimethacrylate, polyethylene glycol monoacrylate, polyethylene glycol monomethacrylate, polypropylene glycol monoacrylate, polypropylene glycol monomethacrylate, hydroxyethyl cellulose acrylate, hydroxyethyl cellulose methacrylate, methoxy poly(ethyleneoxy) ethylacrylate, methoxy poly(ethyleneoxy) ethylmethacrylate, ethylene glycol diacrylate, ethylene glycol dimethacrylate, 1,2-butylene dimethacrylate, 1,3-butylene dimethacrylate, 1,4-butylene dimethacrylate, propylene glycol diacrylate, propylene glycol dimethacrylate, dipropylene glycol diacrylate, divinyl benzene, divinyl toluene, diallyl tartrate, allyl maleate, divinyl tartrate, triallyl melamine, glycerine trimethacrylate, diallyl maleate, divinyl ether, diallyl monomethylene glycol citrate, ethylene glycol vinyl allyl citrate, allyl vinyl maleate, diallyl itaconate, ethylene glycol diester of itaconic acid, polyester of maleic anhydride with triethylene glycol, polyallyl glucoses, polyallyl sucroses, glucose dimethacrylate, pentaerythritol tetraacrylate, sorbitol dimethacrylate, diallyl aconitate, divinyl citrasonate, diallyl fumarate, allyl methacrylate, 1,3-bis-(4-benzoyl-3-hydroxyphenoxy)-2-propylacrylate, 2-hydroxy-4-acryloxyethoxybenzophenone, 4-methacryloxy-2-hydroxybenzophenone, cyclohexene oxide, cyclopentene oxide, glycidyl i-propyl ether, glycidyl acrylate, furfuryl glycidyl ether, styrene oxide, ethyl-3-phenyl glycidate, 1,4-butanediol glycidyl ether, 2,3-epoxypropyl-4-(2,3-epoxypropoxy) benzoate, 4,4'-bis-(2,3-epoxypropoxy)biphenyl and combinations thereof.

Claim 26

The segmented electrochromic device according to claim 1, wherein said plasticizer is selected from the group consisting of acetonitrile, benzylacetone, 3-hydroxypropionitrile, methoxypropionitrile, 3-ethoxypropionitrile, propylene carbonate, ethylene carbonate, glycerine carbonate, 2-acetylbutyrolactone, cyanoethyl sucrose, y-butyrolactone, 2-methylglutaronitrile, N,N'-dimethylformamide, 3-methylsulfolane, methylethyl ketone, cyclopentanone, cyclohexanone, 4-hydroxy-4-methyl-2-pentanone, acetophenone, glutaronitrile, 3,3'-oxydipropionitrile, 2-methoxyethyl ether, triethylene glycol dimethyl ether and combinations thereof.

Claim 27

The segmented electrochromic device according to claim 1, wherein said electrochromic medium comprises at least one of a cathodic compound and an anordic electrochromic compound.

Claim 28

The segmented electrochromic device according to claim 26, wherein said cathodic electrochromic compound comprises a viologen or an anthraquinone.

Claim 29

The segmented electrochromic device according to claim 27, wherein said cathodic electrochromic compound comprises one of a ethylviologen, heptylviologen, distyrylmethylviologen, ethylhydroxypropylviologen or combinations thereof.

Claim 30

The segmented electrochromic device according to claim 26, wherein said anodic electrochromic compound is selected from the group consisting of phenothiazines, phenazines, metallocenes and combinations thereof.

Claim 31

The segmented electrochromic device according to claim 29, wherein said anodic electrochromic compound is selected from the group consisting of 2-methyl-phenothiazine-3-one having been previously contacted with a redox agent, 5,10-dihydro-5,10-dimethylphenazine, a ferrocene and combinations thereof.

Claim 32

The segmented electrochromic device according to claim 1, wherein said electrochromic cross-linked polymeric solid film comprises a cross-linked urethane, a cross-linked epoxy, a cross-linked acrylate, a cross-linked vinyl or a combination thereof.