WO2009002556A1 - Electrochromic device having an improved fill port plug - Google Patents

Electrochromic device having an improved fill port plug Download PDF

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Publication number
WO2009002556A1
WO2009002556A1 PCT/US2008/008064 US2008008064W WO2009002556A1 WO 2009002556 A1 WO2009002556 A1 WO 2009002556A1 US 2008008064 W US2008008064 W US 2008008064W WO 2009002556 A1 WO2009002556 A1 WO 2009002556A1
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WO
WIPO (PCT)
Prior art keywords
electrochromic
electrochromic device
antimonate
substrate
anodic
Prior art date
Application number
PCT/US2008/008064
Other languages
French (fr)
Inventor
William L. Tonar
Joel A. Stray
Steven J. Veenman
Leroy J. Kloeppner
David L. Poll
Gary J. Dozeman
Nalini C. Menon
Original Assignee
Gentex Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Gentex Corporation filed Critical Gentex Corporation
Publication of WO2009002556A1 publication Critical patent/WO2009002556A1/en

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Classifications

    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/15—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on an electrochromic effect
    • G02F1/153—Constructional details
    • G02F1/161—Gaskets; Spacers; Sealing of cells; Filling or closing of cells
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F2202/00—Materials and properties
    • G02F2202/02—Materials and properties organic material
    • G02F2202/022—Materials and properties organic material polymeric
    • G02F2202/023—Materials and properties organic material polymeric curable

Definitions

  • the present invention relates in general to electrochromic devices and, more particularly, to an electrochromic device having a first substrate, a second substrate, a seal member and/or a chamber which comprises a plug associated with a fill port, wherein the plug comprises an antimonate and/or is at least partially cured with an antimonate photo initiator.
  • the present invention further relates to a one- or two-part plug as is disclosed herein, wherein the plug comprises a resin or mixture of resins that are substantially insoluble and/or substantially immiscible with an associated electrochromic medium while in the uncured state.
  • Electrochromic (EC) devices have been known in the art for several years.
  • electrochromic devices having plugs associated with fill ports are likewise well known.
  • a plug material is formulated using these resins there is little or no intermixing of the uncured plug material and the EC media prior to plug cure. If the insoluble plug material in the cured form does not have all of the attributes that are required of a plug material (such as low oxygen and moisture permeability, good adhesion, high temperature stability, etcetera) this material can be backed up with a secondary plug material of choice that has all these attributes without concern for its interaction with the EC media.
  • the present invention is preferably directed to an electrochromic device, comprising: (a) a first substantially transparent substrate having an electrically conductive material associated therewith; (b) a second substrate having an electrically conductive material associated therewith; (c) an electrochromic medium contained within a chamber positioned between the first and second substrates which comprises: (1) at least one solvent; (2) at least one anodic material; and (3) at least one cathodic material, wherein both of the anodic and cathodic materials are electroactive and at least one of the anodic and cathodic materials is electrochromic; (d) wherein at least one of a seal member, the first substrate, the second substrate, and the chamber comprises a plug associated with a fill port; and (e) wherein the plug is at least partially cured
  • At least one of the first substrate and the second substrate preferably comprises a plug associated with a fill port.
  • the plug preferably comprises an epoxy resin.
  • the plug is preferably at least partially cured with cationic photoinitiating antimonate salt.
  • the antimonate salt may comprise a sulfonium antimonate, an iodonium antimonate, an arylsulfonium antimonate, an aryliodonium antimonate, a triarylsulfonium antimonate, a biaryliodonium antimonate, a triarylsulfonium hexafluoroantimonate, a mixed triarylsulfonium hexafluoroantimonate, and/or a biaryliodonium hexafluoroantimonate.
  • the antimonate preferably comprises at least one of the following formulae:
  • Ri-Ru are the same or different and comprise H, a hydroxyl group, a straight or branched alkyl, cycloalkyl, polycycloalkyl, heterocycloalkyl, alkaryl, alkoxy, aryl, aralkyl, alkenyl, alkynyl, or carbonyl group containing approximately 1 to approximately 50 carbon atom(s) and combinations thereof.
  • the antimonate preferably comprises at least one of the following chemical structures:
  • the antimonate preferably comprises the following formula:
  • RpR 2 are the same or different and comprise H, a hydroxyl group, a straight or branched alkyl, cycloalkyl, polycycloalkyl, heterocycloalkyl, alkaryl, alkoxy, aryl, aralkyl, alkenyl, alkynyl, or carbonyl group containing approximately 1 to approximately 50 carbon atom(s) and combinations thereof.
  • the antimonate preferably comprises one or more of the following chemical structures:
  • the cathodic material preferably comprises a viologen, a ferrocinium species, etcetera and/or the anodic material preferably comprises phenazine, such as a substituted phenazine.
  • the concentration of the anodic and/or cathodic material preferably ranges from approximately 1 mM to approximately 500 mM, and more preferably from approximately 2 mM to approximately 100 mM.
  • the electrochromic medium preferably further comprises a cross-linked polymer matrix, a free-standing gel, and/or a substantially non-weeping gel.
  • the electrochromic medium preferably further comprises a redox buffer.
  • the electrochromic device preferably comprises an electrochromic window, electrochromic aircraft transparency, and/or an electrochromic mirror.
  • the present invention is also preferably directed to an electrochromic device, comprising: (a) a first substantially transparent substrate having an electrically conductive material associated therewith; (b) a second substrate having an electrically conductive material associated therewith; (c) an electrochromic medium contained within a chamber positioned between the first and second substrates which comprises: (1) at least one solvent; (2) at least one anodic material; and (3) at least one cathodic material, wherein both of the anodic and cathodic materials are electroactive and at least one of the anodic and cathodic materials is electrochromic; and (d) wherein at least one of a seal member, the first substrate, the second substrate, and the chamber comprises a one- or two-part plug associated with a fill port, as is disclosed herein, wherein the plug comprises a resin or mixture of resins that are substantially insoluble and/or substantially immiscible with an associated electrochromic medium while in the uncured state.
  • the two-part plug comprises a resin or mixture of resins that are substantially in
  • the fill port plug preferably comprises additives, such as tougheners, flexibilizers/crosslinkers, surface active agents, and/or cure indicators as are disclosed herein.
  • Fig. 1 of the drawings is a cross-sectional schematic representation of an electrochromic device fabricated in accordance with the present invention showing, among other things, a plug associated with a fill port of a conventional seal member;
  • Fig. 2 of the drawings is a cross-sectional schematic representation of an electrochromic device fabricated in accordance with the present invention showing, among other things, a two-part plug associated with a fill port of a conventional seal member;
  • FIG. 3 of the drawings is a cross-sectional schematic representation of an electrochromic device fabricated in accordance with the present invention showing, among other things, a plug associated with a fill port of a substrate;
  • FIG. 4 of the drawings is a cross-sectional schematic representation of an electrochromic device fabricated in accordance with the present invention showing, among other things, a two-part plug associated with a fill port of a substrate;
  • Fig. 5 of the drawings is a cross-sectional schematic representation of an electrochromic device fabricated in accordance with the present invention showing, among other things, a plug associated with a fill port of a first substrate, a second substrate, and a seal member;
  • Fig. 5 of the drawings is a cross-sectional schematic representation of an electrochromic device fabricated in accordance with the present invention showing, among other things, a plug associated with a fill port of a first substrate, a second substrate, and a seal member;
  • FIG. 6 of the drawings is a cross-sectional schematic representation of an electrochromic device fabricated in accordance with the present invention showing, among other things, a two-part plug associated with a fill port of a first substrate, a second substrate, and a seal member; and [0029] Fig. 7 of the drawings is a cross-sectional schematic representation of an electrochromic device fabricated in accordance with the present invention showing, among other things, a plug associated with a fill port.
  • electrochromic devices 100 which generally comprise first substrate 112 having front surface 1 12A and rear surface 1 12B, second substrate 114 having front surface 114A and rear surface 1 14B, chamber 116 for containing electrochromic medium 124, and one or more plugs 126 associated with one or more fill ports 128.
  • electrochromic devices 100 may comprise, for illustrative purposes only, a window, an aircraft transparency, a mirror, a display device, and the like. It will be understood that like or analogous elements and/or components, and/or methods referred to herein, may be identified throughout the drawings with like reference characters.
  • FIGs. 1-7 are merely schematic representations of electrochromic devices 100. As such, some of the components have been distorted from their actual scale for pictorial clarity. Indeed, numerous other electrochromic device configurations are contemplated for use, including those disclosed in U.S. Patent No. 5,818,625 entitled “Electrochromic Rearview Mirror Incorporating A Third Surface Metal Reflector," U.S. Patent No. 6,597,489 entitled “Electrode Design For Electrochromic Devices," and U.S. Patent No.
  • First substrate 112 may be fabricated from any one of a number of materials that are transparent or substantially transparent in the visible region of the electromagnetic spectrum, such as, for example, borosilicate glass, soda lime glass, natural and synthetic polymeric resins, plastics, and/or composites including polyesters (e.g.
  • First substrate 112 is preferably fabricated from a sheet of glass having a thickness ranging from approximately 0.10 millimeters (mm) to approximately 12.7 mm, more preferably from approximately 0.50 mm to approximately 1.50 mm, and yet more preferably from approximately 0.75 mm to approximately 1.00 mm.
  • mm millimeters
  • the thickness of the substrate will depend largely upon the particular application of the electrochromic device.
  • first substrate 112 and/or second substrate 114 may comprise a UV absorbing layer and/or contain a UV absorbing material to help protect the substrate(s) and/or the electrochromic media from UV damage.
  • Second substrate 114 may be fabricated from similar materials as that of first substrate 112. However, if the electrochromic device is a mirror or comprises a mirrored surface, then the requisite of substantial transparency is not necessary. As such, second substrate 114 may, alternatively, comprise polymers, metals, glass, and ceramics - to name a few. Second substrate 114 is preferably fabricated from a sheet of glass or plastic having a thickness ranging from approximately 0.10 mm to approximately 12.7 mm, more preferably from approximately 0.50 mm to approximately 1.50 mm, and yet more preferably from approximately 0.75 mm to approximately 1.00 mm.
  • first and second substrates 112 and 114 are fabricated from sheets of glass, then the glass can optionally be tempered, heat strengthened, chemically strengthened, and/or laminated prior to or subsequent to being coated with layers of electrically conductive material (118 and 120).
  • One or more layers of electrically conductive material 118 are associated with rear surface 112B of first substrate 112. These layers serve as an electrode for the electrochromic device.
  • Electrically conductive material 1 18 is desirably a material that: (a) is substantially transparent in the visible region of the electromagnetic spectrum; (b) bonds reasonably well to first substrate 112; (c) maintains this bond when associated with a sealing member; (d) is generally resistant to corrosion from materials contained within the electrochromic device or the atmosphere; and (e) exhibits minimal diffuse or specular reflectance as well as sufficient electrical conductance.
  • electrically conductive material 118 may be fabricated from fluorine doped tin oxide (FTO), for example TEC glass, which is commercially available from Libbey Owens-Ford-Co., of Toledo, Ohio, indium/tin oxide (ITO), doped zinc oxide, indium zinc oxide, metal oxide / Ag / metal oxide, or other materials known to those having ordinary skill in the art.
  • FTO fluorine doped tin oxide
  • ITO indium/tin oxide
  • Electrically conductive material 120 is preferably associated with front surface 1 14A of second substrate 114, and is preferably operatively bonded to electrically conductive material 1 18 by sealing member 122. As can be seen in Figs.
  • sealing member 122, plug 126 and/or the juxtaposed portions of electrically conductive materials 1 18 and 120 serve to generally define an inner peripheral geometry of chamber 116.
  • edge sealing techniques may be utilized which are disclosed in U.S. Patent No. 7,372,611 entitled "Vehicular Rearview Mirror Elements
  • Electrically conductive material 120 may vary depending upon the intended use of the electrochromic device. For example, if the electrochromic device is a mirror, then the material may comprise a transparent conductive coating similar to electrically conductive material 118 (in which case a reflector is associated with rear surface 114B of second substrate 114). Alternatively, electrically conductive material 120 may comprise a layer of reflective material in accordance with the teachings of previously referenced and incorporated U.S. Patent No. 5,818,625. In this case, electrically conductive material 120 is associated with front surface 1 14A of second substrate 1 14. Typical coatings for this type of reflector include chromium, rhodium, ruthenium, silver, silver alloys, and combinations thereof.
  • the cell spacing between inner surfaces of substrates 112 and 114 preferably ranges from approximately 10 microns ( ⁇ m) to approximately 750 ⁇ m, and more preferably from approximately 20 ⁇ m to approximately 600 ⁇ m.
  • the thickness of the cell spacing will depend largely upon the particular application of the electrochromic device.
  • Sealing member 122 may comprise any material that is capable of being adhesively bonded to the electrically conductive materials 118 and 120 to, in turn, seal chamber 116, (in certain embodiments in cooperation with plug 126 and fill port 128, see Figs. 1, 2, 5, and 6) so that electrochromic medium 124 does not inadvertently leak out of the chamber. As is shown in dashed lines in Figs. 1-7, it is also contemplated that the sealing member extend all the way to rear surface 112B and front surface 114A of their respective substrates. In such an embodiment, the layers of electrically conductive material 118 and 120 may be partially removed where the sealing member 122 is positioned.
  • sealing member 122 preferably bonds well to glass. It will be understood that sealing member 122 can be fabricated from any one of a number of materials including, for example, those disclosed in U.S. Patent No. 4,297,401 entitled
  • electrochromic medium 124 typically comprises at least one solvent, at least one anodic material, and at least one cathodic material.
  • Electrochromic medium 124 is preferably chosen from one of the following categories:
  • the electrochromic medium may comprise a single-layer of material which may include small non-homogenous regions and includes solution-phase devices where a material may be contained in solution in an ionically conducting electrolyte which remains in solution in the electrolyte when electrochemically oxidized or reduced.
  • Solution phase electroactive materials may be contained in the continuous solution-phase of a gel medium in accordance with the teachings of U.S. Patent No. 5,928,572 entitled "Electrochromic Layer And Devices
  • the anodic and cathodic materials may also be combined or linked by a bridging unit as described in U.S. Patent No. 6,241,916 entitled “Electrochromic System” and/or U.S. Patent Publication No. 2002/0015214 Al entitled “Electrochromic Device,” which are hereby incorporated herein by reference in their entirety.
  • the electrochromic materials may also include near-infrared (NIR) absorbing compounds as described in U.S. Patent No. 6,193,912 entitled “Near Infrared-Absorbing Electrochromic Compounds And Devices Comprising Same," which is hereby incorporated herein by reference in its entirety.
  • NIR near-infrared
  • the anodic and cathodic electrochromic materials can also include coupled materials as described in U.S. Patent No. 6,249,369 entitled “Coupled Electrochromic Compounds With Photostable Dication Oxidation States,” which is hereby incorporated herein by reference in its entirety.
  • the concentration of the electrochromic materials can be selected as taught in U.S. Patent No. 6,137,620 entitled “Electrochromic Media With Concentration Enhanced Stability, Process For The Preparation Thereof and Use In Electrochromic Devices," the entirety of which is hereby incorporated herein by reference.
  • a single-layer, single-phase medium may include a medium where the anodic and cathodic materials are incorporated into a polymer matrix as is described in International Patent Application Serial No. PCT/EP98/03862 entitled “Electrochromic Polymer System,” and International Patent Application Serial No. PCT/US98/05570 entitled “Electrochromic Polymeric Solid Films, Manufacturing Electrochromic Devices Using Such Solid Films, And Processes For Making Such Solid Films And Devices,” which is hereby incorporated herein by reference in its entirety.
  • the medium may be made up in layers and includes a material attached directly to an electrically conducting electrode or confined in close proximity thereto which remains attached or confined when electrochemically oxidized /-
  • Multi-phase - One or more materials in the medium undergoes a change in phase during the operation of the device, for example a material contained in solution in the ionically conducting electrolyte forms a layer on the electrically conducting electrode when electrochemically oxidized or reduced.
  • electrochromic medium 124 may comprise other materials, such as light absorbers, light stabilizers, thermal stabilizers, antioxidants, thickeners, viscosity modifiers, tint providing agents, redox buffers, and mixtures thereof.
  • Suitable redox buffers include, among others, those disclosed in U.S. Patent No. 6,188,505 Bl entitled “Color-Stabilized Electrochromic Devices,” which is hereby incorporated herein by reference in its entirety - including all continuing applications/patents claiming priority therefrom.
  • Suitable UV-stabilizers may include: the material 2-ethyl-2-cyano- 3,3-diphenyl acrylate, sold by BASF of Parsippany, NY, under the trademark Uvinul N- 35 and by Aceto Corp., of Flushing, NY, under the trademark Viosorb 910; the material (2-ethylhexyl)-2-cyano-3,3-diphenyl acrylate, sold by BASF under the trademark Uvinul
  • anodic materials may include any one of a number of materials including ferrocene, substituted ferrocenes, substituted ferrocenyl salts, phenazine, substituted phenazines, phenothiazine, substituted phenothiazines including substituted dithiazines, thianthrene, and substituted thianthrenes.
  • Examples of anodic materials may include di-tert-butyl-diethylferrocene, 5,10-dimethyl-5,10-dihydrophenazine (DMP), 3,7,10-trimethylphenothiazine, 2,3,7,8- tetramethoxy-thianthrene, 10-methylphenothiazine, tetramethylphenazine (TMP) - see U.S. Patent No.
  • the anodic material may comprise a polymer film, such as polyaniline, polythiophenes, polymeric metallocenes, or a solid transition metal oxide, including, but not limited to, oxides of vanadium, nickel, iridium, as well as numerous heterocyclic compounds, etcetera.
  • a polymer film such as polyaniline, polythiophenes, polymeric metallocenes, or a solid transition metal oxide, including, but not limited to, oxides of vanadium, nickel, iridium, as well as numerous heterocyclic compounds, etcetera.
  • numerous other anodic materials are contemplated for use including those disclosed in U.S. Patent No. 4,902,108 entitled “Single-Compartment, Self-Erasing, Solution-Phase Electrochromic Devices, Solutions For Use Therein, And Uses Thereof," as well as U.S. Patent No.
  • Cathodic materials may include, for example, viologens, such as methyl viologen tetrafluoroborate, octyl viologen tetrafluoroborate (octylviologen), or benzyl viologen tetrafluoroborate, ferrocinium salts, such as (6-(tri-tert- butylferrocinium)hexyl)triethylammonium di-tetrafluoroborate (TTBFc + ) — see U.S. Patent No. 7,046,418 entitled "Reversible Electrodeposition Devices And Associated Electrochemical Media” for synthesis which is hereby incorporated herein by reference in its entirety. It will be understood that the preparation and/or commercial availability for each of the above-identified cathodic materials is well known in the art. See, for example,
  • the cathodic material may comprise a polymer film, such as various substituted polythiophenes, polymeric viologens, an inorganic film, or a solid transition metal oxide, including, but not limited to, tungsten oxide.
  • concentration of the anodic and/or cathodic materials can range from approximately 1 millimolar (mM) to approximately
  • a solvent of electrochromic medium 124 may comprise any one of a number of common, commercially available solvents including 3-methylsulfolane, dimethyl sulfoxide, dimethyl formamide, tetraglyme and other poly ethers; alcohols such as ethoxyethanol; nitriles, such as acetonitrile, glutaronitrile, 3-hydroxypropionitrile, and 2-methylglutaronitrile; ketones including 2-acetylbutyrolactone, and cyclopentanone; cyclic esters including beta- propiolactone, gamma-butyrolactone, and gamma-valerolactone; propylene carbonate (PC), ethylene carbonate; and homogenous mixtures of the same. While specific solvents have been disclosed as being associated with the electrochromic medium, numerous other solvents that would be known to those having ordinary skill in the art having the present disclosure before them are likewise contemplated for use.
  • plug 126 is associated with fill port
  • electrochromic medium 124 which preferably comprises an epoxy resin or mixture of resins (or other resins provided herein) and which is at least partially cured with a cationic photoinitiating antimonate salt and/or comprises an antimonate toward enhancing durability of plug 126 and/or compatibility of the same with electrochromic medium 124 and/or external atmospheric conditions.
  • Such enhanced durability and/or compatibility preferably reduces the likelihood of any materials within electrochromic medium 124 being compositionally compromised and/or from inadvertently leaking out of chamber 116 through fill port 128.
  • fill port 128 is utilized to introduce electrochromic medium 124 into chamber 116 of electrochromic device 100.
  • partially fabricated electrochromic device 100 is placed with fill port 128 downward in an empty container or trough in a vacuum vessel and evacuated.
  • Electrochromic medium 124 is introduced into the trough or container in a manner such that fill port 128 is submerged. The vacuum vessel is then backfilled, which forces electrochromic medium 124 through fill port 128 and, ultimately, into chamber 116.
  • electrochromic device 100 is placed with fill port 128 upward in a vacuum vessel and evacuated.
  • Electrochromic medium 124 is introduced into the container via conventional conduit in a manner such that fill port 128 is not submerged.
  • Fill port 128 is then plugged preferably with a photo curing epoxy resin, (e.g. plug 126) which is at least partially cured with a cationic photoinitiating antimonate salt and/or comprises an antimonate.
  • a photo curing epoxy resin e.g. plug 1266
  • a cationic photoinitiating antimonate salt and/or comprises an antimonate Such curing is preferably accomplished via a UV lamp.
  • the formulation of plug 126 preferably comprises an epoxy resin or mixture of resins (e.g. cycloaliphatic epoxy resins including, for example, Omnilane OCl 005, which is available from IGM Resins Inc., Bartlett, IL, aromatic epoxy resins including, for example, Bis-F, Bis-A, and/or epoxy novolac resins including, for example, DER 354, DER 332, and DEN 431, which are all available from the Dow Chemical Company - all of which may be optionally filled with fumed silica or other fillers such as glass beads, calcium carbonate, aluminum oxide, calcium fluoride, or other fillers as desired) which are at least partially cured using one or more antimonate photo initiators, such as, for example, a sulfonium antimonate, an arylsulfonium antimonate, a triarylsulfonium antimonate, a triarylsulfonium hexafluoroantimon
  • an epoxy resin or mixture of resins
  • Ri-Rn are the same or different and comprise H, a hydroxy 1 group, a straight or branched alkyl, cycloalkyl, polycycloalkyl, heterocycloalkyl, alkaryl, alkoxy, aryl, aralkyl, alkenyl, alkynyl, or carbonyl group containing approximately 1 to approximately 50 carbon atom(s) and combinations thereof.
  • sulfonium antimonates which are commercially available from Union Carbide Corporation which is a wholly owned subsidiary of Dow Chemical Company include, for example:
  • an epoxy resin which is at least partially cured using one or more antimonate photo initiators, such as, for example, an iodonium antimonate, an aryliodonium antimonate, a biaryliodonium antimonate, a biaryliodonium hexafluoroantimonate, and mixtures thereof.
  • antimonate photo initiators such as, for example, an iodonium antimonate, an aryliodonium antimonate, a biaryliodonium antimonate, a biaryliodonium hexafluoroantimonate, and mixtures thereof.
  • the iodonium antimonate may be represented by one or more of the following formula: r
  • R)-R 2 are the same or different and comprise H, a hydroxyl group, a straight or branched alkyl, cycloalkyl, polycycloalkyl, heterocycloalkyl, alkaryl, alkoxy, aryl, aralkyl, alkenyl, alkynyl, or carbonyl group containing approximately 1 to approximately 50 carbon atom(s) and combinations thereof.
  • iodonium antimonates which are commercially available from Gelest Inc. include, for example:
  • antimonate photo initiators While specific antimonate photo initiators have been disclosed, for illustrative purposes only, it will be understood that any one of a number of antimonate initiators are contemplated for use in accordance with the present invention.
  • antimonate photo initiators While specific anionic salts of photo initiators have been disclosed, for illustrative purposes only, it will be understood that any one of a number of other anions are contemplated for use in accordance with the present invention, including, for example, AsF 6 , Ga(C 6 F 5 ) 4j etcetera.
  • the antimonate facilitates better cross-linked density within plug 126, thereby enhancing at least durability of the same. It is further believed that the antimonate is a stronger acid than conventional counter ions, such as hexafluorophosphate, tetrafluoroborate, etcetera. [0065] In another embodiment of the present invention, the formulation of plug
  • 126 comprises a resin or mixture of resins (e.g. epoxy resins, such as epoxidized polybutadienes, epoxidized castor oil, epoxidized cashew nut oil, acrylated butadiene resins, among other provided herein) that are substantially insoluble and/or substantially immiscible with an associated electrochromic medium (i.e. 124) while in the uncured state.
  • resins e.g. epoxy resins, such as epoxidized polybutadienes, epoxidized castor oil, epoxidized cashew nut oil, acrylated butadiene resins, among other provided herein
  • the resin or mixture of resins may comprise Sartomer CN-301, Sartomer CN-304, Rhan BR-643.
  • resins other than acrylated (Sartomer CN-301), methacrylated (Sartomer CN-304) or epoxidized polybutabiene can be used in a plug formulation that are at least substantially insoluble and/or at least substantially immiscible in the EC media.
  • insoluble monomers or oligomers available from Sartomer include CN-986 (aliphatic urethane acrylate), CN- 2252 (polyester acrylate), CN-934 (aliphatic urethane acrylate), CN-975 (hexafunctional urethane acrylate), CN-965 (aliphatic urethane acrylate), CN-981 (aliphatic urethane acrylate) CN-973 (aromatic urethane acrylate), SR-489 (tridecyl acrylate) and SR-335 (lauryl acrylate) -just to name a few.
  • the formulation of plug 126 comprises two-parts, namely; a first sub-component comprising a resin or mixture of resins (e.g. epoxy resins, acrylated butadiene resins, among other provided supra and infra) that are substantially insoluble and/or substantially immiscible with an associated electrochromic medium (i.e. 124) while in the uncured state, and a second- subcomponent comprising a resin or mixture of resins (e.g.
  • the permeability of the second- subcomponent will preferably protect electrochromic medium 124 from air and/or moisture if the first- subcomponents exhibits permeability to air and/or moisture.
  • the second-subcomponent will preferably adhere to at least the first- subcomponent toward maintaining device integrity over long periods of time - including one or more decades depending upon the application of the particular electrochromic device.
  • Additional non-limiting examples of resins that are suitable for use as second-subcomponent resins and/or resins cured with an antimonate photo initiator include conventional aliphatic amines, cycloaliphatic amines, amidoamines, mercaptans, cycloaliphatic epoxy resins such as Omnilane OCl 005, which is available from IGM Resins Inc., Bartlett, IL, aromatic epoxy resins such as Bis-F, Bis-A, and/or epoxy novolac resins such as DER 354, DER 332, and DEN 431, which are all available from the Dow Chemical Company, as well as thermal and/or photoinitiators, and optionally filled with fumed silica or other fillers such as glass beads, calcium carbonate, aluminum oxide, etcetera, using conventional techniques.
  • conventional aliphatic amines such as Omnilane OCl 005, which is available from IGM Resins Inc., Bartlett, IL, aromatic epoxy resins such as Bis-F, Bis-
  • the first sub-component of plug 126 can be introduced into fill port 128 which is generally compatible with the components of electrochromic medium 124 and subsequently cured.
  • the outer surface of the first sub-component and surrounding area can be cleaned, or cleaned and etched, if desired, prior (to association of the second sub-component. Etching can be accomplished by several methods including mechanical etching such as sandblasting, sandpaper, and chemical etching - just to name a few etching techniques.
  • the second sub-component of plug 126 can be associated with the outer surface area the first sub-component and the surrounding area which is generally compatible with external atmospheric conditions/parameters.
  • plug 126 may also optionally comprise one or more cure indicators which provide optical and/or measurable indication of the degree of plug curing.
  • a first class of cure indicators preferably includes pH based cure indicators, such as phenolphthalein (0.25-0.5 parts per hundred resin "phr") and thymolphthalein (0.25-0.5 phr), which are available from Aldrich Chemical Company.
  • a second class of cure indicators preferably includes free radical/reactive cure indicators such as Crystal Violet (0.25-0.5 phr), which is available from Aldrich Chemical Company.
  • a third class of cure indicators preferably includes UV cure indicators such as
  • Plug 126 may further optionally comprise one or more additives, such as, but not limited to, tougheners (e.g. Fortegra 100 (1-5 wt%) available from The Dow Chemical Company and MXl 36 core-shell toughener (25 wt% in Bis-F epoxy) available from Kaneka Corporation, Pasedena, TX), flexibilizers/crosslinkers (e.g. H2003 dendritic polymer (1-20 wt%) or CAPA polyols (1-20 wt%) available from Perstorp Polyols, Inc,
  • tougheners e.g. Fortegra 100 (1-5 wt%) available from The Dow Chemical Company and MXl 36 core-shell toughener (25 wt% in Bis-F epoxy) available from Kaneka Corporation, Pasedena, TX
  • flexibilizers/crosslinkers e.g. H2003 dendritic polymer (1-20 wt%) or CAPA polyols (1-20 wt%) available from Perstorp Polyols, Inc,
  • Electrochromic devices of the present invention can be used in a wide variety of applications wherein the transmitted or reflected light/heat can be modulated.
  • Such devices include mirrors; aircraft transparencies; windows for the exterior of a building, home or vehicle; skylights for buildings including tubular light filters; windows in office or room partitions; and light filters for photographic devices and light sensors.

Abstract

An electrochromic device including: (a) a first substantially transparent substrate having an electrically conductive material associated therewith; (b) a second substrate having an electrically conductive material associated therewith; (c) an electrochromic medium contained within a chamber positioned between the first and second substrates which includes: (1) a solvent; (2) an anodic material; and (3) a cathodic material, wherein both of the anodic and cathodic materials are electroactive and at least one of the anodic and cathodic materials is electrochromic; (d) wherein a seal member, the first substrate, the second substrate, and/or the chamber includes a plug associated with a fill port; and (e) wherein the plug is at least partially cured with an antimonate photo initiator and/or is one- or two-part plug which comprises a resin or mixture of resins that are substantially insoluble and/or substantially immiscible with an associated electrochromic medium while in the uncured state.

Description

TITLE OF THE INVENTION
ELECTROCHROMIC DEVICE HAVING AN IMPROVED FILL PORT PLUG CROSS-REFERENCE TO RELATED APPLICATION(S)
[0000] This application claims the benefit of U.S. Provisional Application No. 60/937,354, filed June 27, 2007 - which is hereby incorporated herein by reference in its entirety. BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates in general to electrochromic devices and, more particularly, to an electrochromic device having a first substrate, a second substrate, a seal member and/or a chamber which comprises a plug associated with a fill port, wherein the plug comprises an antimonate and/or is at least partially cured with an antimonate photo initiator. The present invention further relates to a one- or two-part plug as is disclosed herein, wherein the plug comprises a resin or mixture of resins that are substantially insoluble and/or substantially immiscible with an associated electrochromic medium while in the uncured state.
2. Background Art
[0002] Electrochromic (EC) devices have been known in the art for several years.
Furthermore, electrochromic devices having plugs associated with fill ports are likewise well known.
[0003] Although such fill port plugs have been readily utilized, issues relative to plug compatibility, curability and/or reliability remain paramount to the commercialized success of electrochromic devices such as, for example, electrochromic mirrors, electrochromic windows, and electrochromic aircraft transparencies. Indeed, incomplete plug curing and/or failure can not only render an associated electrochromic device inoperable, but leakage of the electrochromic medium contained within the electrochromic device can also substantially damage the interior of, for example, an automobile, building, and/or aircraft - the owners and/or manufacturers of which can be completely intolerable of such an occurrence. In addition, gas permeability and/or barrier properties of a plug can compromise the longevity and/or functionality of an associated device. [0004] It has now been surprisingly discovered that selective incorporation of one or more antimonate photo initiators into the fill port plug formulation facilitates a more complete cure of the same, which, in turn, increases plug compatibility, curability and/or reliability towards minimization and/or elimination of plug failure. It has further been discovered that such a plug configuration is particularly compatible with not only a conventional seal member, but also a first substrate, a second substrate, and/or a chamber. [0005] Another aspect of the present invention deals with selecting liquid resin monomers or oligomers to use in a plug formulation that are generally not miscible and/or soluble with associated electrochromic media. The solvents used in a typical solution phase electrochromic device are usually very polar in nature. Many uncured resins such as Bis A or Bis F epoxy resins are completely soluble in the liquid or un- gelled electrochromic media. This means that as the uncured plug material is injected into the fill opening some of the plug material can dissolve into the electrochromic (EC) media before the plug can be cured. Generally, the larger the cell gap the more this intermixing occurs. The uncured plug material that dissolves into the electrochromic media is there for the life of the device and can cause premature device failure. These failure modes include electrode passivation, instability in UV, visible hazing of the EC media and/or color change. In accordance with the present invention, resins have been uncovered that are generally not miscible and/or soluble in the polar EC media. If a plug material is formulated using these resins there is little or no intermixing of the uncured plug material and the EC media prior to plug cure. If the insoluble plug material in the cured form does not have all of the attributes that are required of a plug material (such as low oxygen and moisture permeability, good adhesion, high temperature stability, etcetera) this material can be backed up with a secondary plug material of choice that has all these attributes without concern for its interaction with the EC media.
[0006] It is therefore an object of the present invention, among other objects, to provide an electrochromic device that remedies the aforementioned detriments and/or complications associated with the use of conventional fill port plugs. SUMMARY OF THE INVENTION [0007] The present invention is preferably directed to an electrochromic device, comprising: (a) a first substantially transparent substrate having an electrically conductive material associated therewith; (b) a second substrate having an electrically conductive material associated therewith; (c) an electrochromic medium contained within a chamber positioned between the first and second substrates which comprises: (1) at least one solvent; (2) at least one anodic material; and (3) at least one cathodic material, wherein both of the anodic and cathodic materials are electroactive and at least one of the anodic and cathodic materials is electrochromic; (d) wherein at least one of a seal member, the first substrate, the second substrate, and the chamber comprises a plug associated with a fill port; and (e) wherein the plug is at least partially cured with an antimonate photo initiator.
[0008] In one embodiment of the present invention, at least one of the first substrate and the second substrate preferably comprises a plug associated with a fill port. [0009] In another embodiment of the present invention, the plug preferably comprises an epoxy resin.
[0010] In yet another embodiment of the present invention, the plug is preferably at least partially cured with cationic photoinitiating antimonate salt. In this embodiment the antimonate salt may comprise a sulfonium antimonate, an iodonium antimonate, an arylsulfonium antimonate, an aryliodonium antimonate, a triarylsulfonium antimonate, a biaryliodonium antimonate, a triarylsulfonium hexafluoroantimonate, a mixed triarylsulfonium hexafluoroantimonate, and/or a biaryliodonium hexafluoroantimonate.
[0011] In one aspect of the present invention, the antimonate preferably comprises at least one of the following formulae:
Figure imgf000006_0001
[SbF6]"
(I)
Figure imgf000006_0002
[SbF6]" [SbF6]- (II)
Figure imgf000006_0003
wherein Ri-Ru are the same or different and comprise H, a hydroxyl group, a straight or branched alkyl, cycloalkyl, polycycloalkyl, heterocycloalkyl, alkaryl, alkoxy, aryl, aralkyl, alkenyl, alkynyl, or carbonyl group containing approximately 1 to approximately 50 carbon atom(s) and combinations thereof. In this embodiment, the antimonate preferably comprises at least one of the following chemical structures:
Figure imgf000007_0001
Figure imgf000007_0002
[0012] In another aspect of the present invention, the antimonate preferably comprises the following formula:
Ri R2
[SbF6]-
(HI) wherein RpR2 are the same or different and comprise H, a hydroxyl group, a straight or branched alkyl, cycloalkyl, polycycloalkyl, heterocycloalkyl, alkaryl, alkoxy, aryl, aralkyl, alkenyl, alkynyl, or carbonyl group containing approximately 1 to approximately 50 carbon atom(s) and combinations thereof. In this embodiment, the antimonate preferably comprises one or more of the following chemical structures:
Figure imgf000008_0001
[0013] In one embodiment of the present invention, the cathodic material preferably comprises a viologen, a ferrocinium species, etcetera and/or the anodic material preferably comprises phenazine, such as a substituted phenazine. [0014] In yet another preferred embodiment of the present invention, the concentration of the anodic and/or cathodic material preferably ranges from approximately 1 mM to approximately 500 mM, and more preferably from approximately 2 mM to approximately 100 mM.
[0015] In accordance with the present invention, the electrochromic medium preferably further comprises a cross-linked polymer matrix, a free-standing gel, and/or a substantially non-weeping gel.
[0016] In one embodiment of the present invention, the electrochromic medium preferably further comprises a redox buffer.
[0017] • In another embodiment of the present invention, the electrochromic device preferably comprises an electrochromic window, electrochromic aircraft transparency, and/or an electrochromic mirror.
[0018] The present invention is also preferably directed to an electrochromic device, comprising: (a) a first substantially transparent substrate having an electrically conductive material associated therewith; (b) a second substrate having an electrically conductive material associated therewith; (c) an electrochromic medium contained within a chamber positioned between the first and second substrates which comprises: (1) at least one solvent; (2) at least one anodic material; and (3) at least one cathodic material, wherein both of the anodic and cathodic materials are electroactive and at least one of the anodic and cathodic materials is electrochromic; and (d) wherein at least one of a seal member, the first substrate, the second substrate, and the chamber comprises a one- or two-part plug associated with a fill port, as is disclosed herein, wherein the plug comprises a resin or mixture of resins that are substantially insoluble and/or substantially immiscible with an associated electrochromic medium while in the uncured state. [0019] In one embodiment of the present invention, the two-part plug comprises a first sub-component comprising an epoxy resin, an acrylated butadiene, and mixtures thereof, and a second sub-component comprising an epoxy resin.
[0020] In another embodiment of the present invention, the fill port plug preferably comprises additives, such as tougheners, flexibilizers/crosslinkers, surface active agents, and/or cure indicators as are disclosed herein.
[0021] These and other objectives of the present invention will become apparent in light of the present specification, claims, and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The invention will now be described with reference to the drawings wherein:
[0023] Fig. 1 of the drawings is a cross-sectional schematic representation of an electrochromic device fabricated in accordance with the present invention showing, among other things, a plug associated with a fill port of a conventional seal member; [0024] Fig. 2 of the drawings is a cross-sectional schematic representation of an electrochromic device fabricated in accordance with the present invention showing, among other things, a two-part plug associated with a fill port of a conventional seal member;
[0025] Fig. 3 of the drawings is a cross-sectional schematic representation of an electrochromic device fabricated in accordance with the present invention showing, among other things, a plug associated with a fill port of a substrate;
[0026] ' Fig. 4 of the drawings is a cross-sectional schematic representation of an electrochromic device fabricated in accordance with the present invention showing, among other things, a two-part plug associated with a fill port of a substrate; [0027] Fig. 5 of the drawings is a cross-sectional schematic representation of an electrochromic device fabricated in accordance with the present invention showing, among other things, a plug associated with a fill port of a first substrate, a second substrate, and a seal member; [0028] Fig. 6 of the drawings is a cross-sectional schematic representation of an electrochromic device fabricated in accordance with the present invention showing, among other things, a two-part plug associated with a fill port of a first substrate, a second substrate, and a seal member; and [0029] Fig. 7 of the drawings is a cross-sectional schematic representation of an electrochromic device fabricated in accordance with the present invention showing, among other things, a plug associated with a fill port. DETAILED DESCRIPTION OF THE INVENTION
[0030] Referring now to the drawings and to Figs. 1-7 in particular, cross- sectional schematic representations of electrochromic devices 100 are shown, which generally comprise first substrate 112 having front surface 1 12A and rear surface 1 12B, second substrate 114 having front surface 114A and rear surface 1 14B, chamber 116 for containing electrochromic medium 124, and one or more plugs 126 associated with one or more fill ports 128. In accordance with the present invention, electrochromic devices 100 may comprise, for illustrative purposes only, a window, an aircraft transparency, a mirror, a display device, and the like. It will be understood that like or analogous elements and/or components, and/or methods referred to herein, may be identified throughout the drawings with like reference characters. It will be further understood that Figs. 1-7 are merely schematic representations of electrochromic devices 100. As such, some of the components have been distorted from their actual scale for pictorial clarity. Indeed, numerous other electrochromic device configurations are contemplated for use, including those disclosed in U.S. Patent No. 5,818,625 entitled "Electrochromic Rearview Mirror Incorporating A Third Surface Metal Reflector," U.S. Patent No. 6,597,489 entitled "Electrode Design For Electrochromic Devices," and U.S. Patent No.
6,700,692 entitled "Electrochromic Rearview Mirror Assembly Incorporating A Display /Signal Light," all of which are hereby incorporated herein by reference in their entirety including all references incorporated therein. [0031] First substrate 112 may be fabricated from any one of a number of materials that are transparent or substantially transparent in the visible region of the electromagnetic spectrum, such as, for example, borosilicate glass, soda lime glass, natural and synthetic polymeric resins, plastics, and/or composites including polyesters (e.g. PET), polyimides (PI), polycarbonates, polysulfones, polyethylene naphthalate (PEN), ethylene vinyl acetate (EVA), acrylate polymers, as well as Topas®, which is commercially available from Ticona of Summit, New Jersey. First substrate 112 is preferably fabricated from a sheet of glass having a thickness ranging from approximately 0.10 millimeters (mm) to approximately 12.7 mm, more preferably from approximately 0.50 mm to approximately 1.50 mm, and yet more preferably from approximately 0.75 mm to approximately 1.00 mm. Of course, the thickness of the substrate will depend largely upon the particular application of the electrochromic device.
While particular substrate materials have been disclosed, for illustrative purposes only, it will be understood that numerous other substrate materials are likewise contemplated for use - so long as the materials are at least substantially transparent and exhibit appropriate physical properties, such as strength, to be able to operate effectively in conditions of intended use. Indeed, electrochromic devices in accordance with the present invention can be, during normal operation, exposed to extreme temperature variation as well as substantial UV radiation, emanating primarily from the sun. It will be further understood that first substrate 112 and/or second substrate 114 may comprise a UV absorbing layer and/or contain a UV absorbing material to help protect the substrate(s) and/or the electrochromic media from UV damage.
[0032] Second substrate 114 may be fabricated from similar materials as that of first substrate 112. However, if the electrochromic device is a mirror or comprises a mirrored surface, then the requisite of substantial transparency is not necessary. As such, second substrate 114 may, alternatively, comprise polymers, metals, glass, and ceramics - to name a few. Second substrate 114 is preferably fabricated from a sheet of glass or plastic having a thickness ranging from approximately 0.10 mm to approximately 12.7 mm, more preferably from approximately 0.50 mm to approximately 1.50 mm, and yet more preferably from approximately 0.75 mm to approximately 1.00 mm. If first and second substrates 112 and 114, respectively, are fabricated from sheets of glass, then the glass can optionally be tempered, heat strengthened, chemically strengthened, and/or laminated prior to or subsequent to being coated with layers of electrically conductive material (118 and 120). [0033] One or more layers of electrically conductive material 118 are associated with rear surface 112B of first substrate 112. These layers serve as an electrode for the electrochromic device. Electrically conductive material 1 18 is desirably a material that: (a) is substantially transparent in the visible region of the electromagnetic spectrum; (b) bonds reasonably well to first substrate 112; (c) maintains this bond when associated with a sealing member; (d) is generally resistant to corrosion from materials contained within the electrochromic device or the atmosphere; and (e) exhibits minimal diffuse or specular reflectance as well as sufficient electrical conductance. It is contemplated that electrically conductive material 118 may be fabricated from fluorine doped tin oxide (FTO), for example TEC glass, which is commercially available from Libbey Owens-Ford-Co., of Toledo, Ohio, indium/tin oxide (ITO), doped zinc oxide, indium zinc oxide, metal oxide / Ag / metal oxide, or other materials known to those having ordinary skill in the art. [0034] Electrically conductive material 120 is preferably associated with front surface 1 14A of second substrate 114, and is preferably operatively bonded to electrically conductive material 1 18 by sealing member 122. As can be seen in Figs. 1-7, once bonded, sealing member 122, plug 126 and/or the juxtaposed portions of electrically conductive materials 1 18 and 120 serve to generally define an inner peripheral geometry of chamber 116. Alternatively, edge sealing techniques may be utilized which are disclosed in U.S. Patent No. 7,372,611 entitled "Vehicular Rearview Mirror Elements
And Assemblies Incorporating These Elements," filed on February 25, 2005, which is hereby incorporated herein by reference in its entirety — including the associated priority documents. [0035] Electrically conductive material 120 may vary depending upon the intended use of the electrochromic device. For example, if the electrochromic device is a mirror, then the material may comprise a transparent conductive coating similar to electrically conductive material 118 (in which case a reflector is associated with rear surface 114B of second substrate 114). Alternatively, electrically conductive material 120 may comprise a layer of reflective material in accordance with the teachings of previously referenced and incorporated U.S. Patent No. 5,818,625. In this case, electrically conductive material 120 is associated with front surface 1 14A of second substrate 1 14. Typical coatings for this type of reflector include chromium, rhodium, ruthenium, silver, silver alloys, and combinations thereof.
[0036] In accordance with the present invention, the cell spacing between inner surfaces of substrates 112 and 114 preferably ranges from approximately 10 microns (μm) to approximately 750 μm, and more preferably from approximately 20 μm to approximately 600 μm. However, it will be understood that the thickness of the cell spacing will depend largely upon the particular application of the electrochromic device.
[0037] Sealing member 122 may comprise any material that is capable of being adhesively bonded to the electrically conductive materials 118 and 120 to, in turn, seal chamber 116, (in certain embodiments in cooperation with plug 126 and fill port 128, see Figs. 1, 2, 5, and 6) so that electrochromic medium 124 does not inadvertently leak out of the chamber. As is shown in dashed lines in Figs. 1-7, it is also contemplated that the sealing member extend all the way to rear surface 112B and front surface 114A of their respective substrates. In such an embodiment, the layers of electrically conductive material 118 and 120 may be partially removed where the sealing member 122 is positioned. If electrically conductive materials 118 and 120 are not associated with their respective substrates, then sealing member 122 preferably bonds well to glass. It will be understood that sealing member 122 can be fabricated from any one of a number of materials including, for example, those disclosed in U.S. Patent No. 4,297,401 entitled
"Liquid Crystal Display And Photopolymerizable Sealant Therefor," U.S. Patent No. 4,418,102 entitled "Liquid Crystal Displays Having Improved Hermetic Seal," U.S. Patent No. 4,695,490 entitled "Seal For Liquid Crystal Display," U.S. Patent No. 5,596,023 entitled "Sealing Material For Liquid Crystal Display Panel, And Liquid Crystal Display Panel Using It," U.S. Patent No. 5,596,024 entitled "Sealing Composition For Liquid Crystal," U.S. Patent No. 6,157,480 entitled "Seal For Electrochromic
Devices," and U.S. Patent No. 6,714,334, entitled "Electrochromic Device Having A Seal Including An Epoxy Resin Cured With A Cycloaliphatic Amine," all of which are hereby incorporated herein by reference in their entirety. [0038] For purposes of the present disclosure, and as will be explained in greater detail herein below, electrochromic medium 124 typically comprises at least one solvent, at least one anodic material, and at least one cathodic material.
[0039] Typically both of the anodic and cathodic materials are electroactive and at least one of them is electrochromic. It will be understood that regardless of its ordinary meaning, the term "electroactive" will be defined herein as a material that undergoes a modification in its oxidation state upon exposure to a particular electrical potential difference. Additionally, it will be understood that the term "electrochromic" will be defined herein, regardless of its ordinary meaning, as a material that exhibits a change in its extinction coefficient at one or more wavelengths upon exposure to a particular electrical potential difference. [0040] Electrochromic medium 124 is preferably chosen from one of the following categories:
[0041] (1) Single-layer, single-phase - The electrochromic medium may comprise a single-layer of material which may include small non-homogenous regions and includes solution-phase devices where a material may be contained in solution in an ionically conducting electrolyte which remains in solution in the electrolyte when electrochemically oxidized or reduced. Solution phase electroactive materials may be contained in the continuous solution-phase of a gel medium in accordance with the teachings of U.S. Patent No. 5,928,572 entitled "Electrochromic Layer And Devices
Comprising Same," and International Patent Application Serial No. PCT/US98/05570 entitled "Electrochromic Polymeric Solid Films, Manufacturing Electrochromic Devices Using Such Solid Films, And Processes For Making Such Solid Films And Devices," both of which are hereby incorporated herein by reference in their entirety. [0042] More than one anodic and cathodic material can be combined to give a pre-selected color as described in U.S. Patent No. 5,998,617 entitled "Electrochromic Compounds," U.S. Patent No. 6,020,987 entitled "Electrochromic Medium Capable Of Producing A Pre-selected Color," U.S. Patent No. 6,037,471 entitled "Electrochromic Compounds," and U.S. Patent No. 6,141,137 entitled "Electrochromic Media For Producing A Pre-selected Color," all of which are hereby incorporated herein by reference in their entirety.
[0043] The anodic and cathodic materials may also be combined or linked by a bridging unit as described in U.S. Patent No. 6,241,916 entitled "Electrochromic System" and/or U.S. Patent Publication No. 2002/0015214 Al entitled "Electrochromic Device," which are hereby incorporated herein by reference in their entirety. The electrochromic materials may also include near-infrared (NIR) absorbing compounds as described in U.S. Patent No. 6,193,912 entitled "Near Infrared-Absorbing Electrochromic Compounds And Devices Comprising Same," which is hereby incorporated herein by reference in its entirety.
[0044] It is also possible to link anodic materials or cathodic materials by similar methods. The concepts described in these patents can further be combined to yield a variety of electroactive materials that are linked or coupled, including linking of a redox buffer such as linking of a color-stabilizing moiety to an anodic and/or cathodic material.
[0045] The anodic and cathodic electrochromic materials can also include coupled materials as described in U.S. Patent No. 6,249,369 entitled "Coupled Electrochromic Compounds With Photostable Dication Oxidation States," which is hereby incorporated herein by reference in its entirety. [0046] The concentration of the electrochromic materials can be selected as taught in U.S. Patent No. 6,137,620 entitled "Electrochromic Media With Concentration Enhanced Stability, Process For The Preparation Thereof and Use In Electrochromic Devices," the entirety of which is hereby incorporated herein by reference. [0047] Additionally, a single-layer, single-phase medium may include a medium where the anodic and cathodic materials are incorporated into a polymer matrix as is described in International Patent Application Serial No. PCT/EP98/03862 entitled "Electrochromic Polymer System," and International Patent Application Serial No. PCT/US98/05570 entitled "Electrochromic Polymeric Solid Films, Manufacturing Electrochromic Devices Using Such Solid Films, And Processes For Making Such Solid Films And Devices," which is hereby incorporated herein by reference in its entirety.
[0048] (2) Multi-layer - The medium may be made up in layers and includes a material attached directly to an electrically conducting electrode or confined in close proximity thereto which remains attached or confined when electrochemically oxidized /-
or reduced.
[0049] (3) Multi-phase - One or more materials in the medium undergoes a change in phase during the operation of the device, for example a material contained in solution in the ionically conducting electrolyte forms a layer on the electrically conducting electrode when electrochemically oxidized or reduced.
[0050] In addition, electrochromic medium 124 may comprise other materials, such as light absorbers, light stabilizers, thermal stabilizers, antioxidants, thickeners, viscosity modifiers, tint providing agents, redox buffers, and mixtures thereof. Suitable redox buffers include, among others, those disclosed in U.S. Patent No. 6,188,505 Bl entitled "Color-Stabilized Electrochromic Devices," which is hereby incorporated herein by reference in its entirety - including all continuing applications/patents claiming priority therefrom. Suitable UV-stabilizers may include: the material 2-ethyl-2-cyano- 3,3-diphenyl acrylate, sold by BASF of Parsippany, NY, under the trademark Uvinul N- 35 and by Aceto Corp., of Flushing, NY, under the trademark Viosorb 910; the material (2-ethylhexyl)-2-cyano-3,3-diphenyl acrylate, sold by BASF under the trademark Uvinul
N-539; the material 2-(2'-hydroxy-4'-methylphenyl)benzotriazole, sold by Ciba-Geigy Corp. under the trademark Tinuvin P; the material 3-[3-(2H-benzotriazole-2-yl)-5-(l,l- dimethylethyl)-4-hydroxyphenyl]propionic acid pentyl ester prepared from Tinuvin 213, sold by Ciba-Geigy Corp., via conventional hydrolysis followed by conventional esterification (hereinafter "Tinuvin PE"); the material 2,4-dihydroxybenzophenone sold by, among many others, Aldrich Chemical Co.; the material 2-hydroxy-4- methoxybenzophenone sold by American Cyanamid under the trademark Cyasorb UV 9; and the material 2-ethyl-2'-ethoxyalanilide sold by Sandoz Color & Chemicals under the trademark Sanduvor VSU - to name a few.
[0051] For purposes of the present invention, anodic materials may include any one of a number of materials including ferrocene, substituted ferrocenes, substituted ferrocenyl salts, phenazine, substituted phenazines, phenothiazine, substituted phenothiazines including substituted dithiazines, thianthrene, and substituted thianthrenes. Examples of anodic materials may include di-tert-butyl-diethylferrocene, 5,10-dimethyl-5,10-dihydrophenazine (DMP), 3,7,10-trimethylphenothiazine, 2,3,7,8- tetramethoxy-thianthrene, 10-methylphenothiazine, tetramethylphenazine (TMP) - see U.S. Patent No. 6,242,602 Bl for synthesis, which is hereby incorporated herein by reference in its entirety, and bis(butyltriethylammonium)-para-methoxytriphenodithiazine (TPDT) - see synthesis of 3,10-dimethoxy-7,14-(triethylarnmoniumbutyl)- triphenodithazinebis(tetrafluoroborate) in U.S. Patent No. 6,710,906 B2, which is hereby incorporated herein by reference in its entirety. It is also contemplated that the anodic material may comprise a polymer film, such as polyaniline, polythiophenes, polymeric metallocenes, or a solid transition metal oxide, including, but not limited to, oxides of vanadium, nickel, iridium, as well as numerous heterocyclic compounds, etcetera. It will be understood that numerous other anodic materials are contemplated for use including those disclosed in U.S. Patent No. 4,902,108 entitled "Single-Compartment, Self-Erasing, Solution-Phase Electrochromic Devices, Solutions For Use Therein, And Uses Thereof," as well as U.S. Patent No. 6,188,505 Bl entitled "Color-Stabilized Electrochromic Devices," and U.S. Patent No. 6,710,906 B2 entitled "Controlled Diffusion Coefficient Electrochromic Materials For Use In Electrochromic Mediums And Associated Electrochromic Devices," all of which are hereby incorporated herein by reference in their entirety.
[0052] Cathodic materials may include, for example, viologens, such as methyl viologen tetrafluoroborate, octyl viologen tetrafluoroborate (octylviologen), or benzyl viologen tetrafluoroborate, ferrocinium salts, such as (6-(tri-tert- butylferrocinium)hexyl)triethylammonium di-tetrafluoroborate (TTBFc+) — see U.S. Patent No. 7,046,418 entitled "Reversible Electrodeposition Devices And Associated Electrochemical Media" for synthesis which is hereby incorporated herein by reference in its entirety. It will be understood that the preparation and/or commercial availability for each of the above-identified cathodic materials is well known in the art. See, for example,
"The Bipyridinium Herbicides" by L. A. Summers (Academic Press 1980). While specific cathodic materials have been provided for illustrative purposes only, numerous other conventional cathodic materials are likewise contemplated for use including, but by no means limited to, those disclosed in previously referenced and incorporated U.S. Patent No. 4,902,108, U.S. Patent No. 6,188,505, and U.S. Patent No. 6,710,906 B2. Moreover, it is contemplated that the cathodic material may comprise a polymer film, such as various substituted polythiophenes, polymeric viologens, an inorganic film, or a solid transition metal oxide, including, but not limited to, tungsten oxide. [0053] For illustrative purposes only, the concentration of the anodic and/or cathodic materials can range from approximately 1 millimolar (mM) to approximately
500 mM and more preferably from approximately 2 mM to approximately 100 mM. While particular concentrations of the anodic as well as cathodic materials have been provided, it will be understood that the desired concentration may vary greatly depending upon the geometric configuration of the chamber containing electrochromic medium 124. [0054] For purposes of the present disclosure, a solvent of electrochromic medium 124 may comprise any one of a number of common, commercially available solvents including 3-methylsulfolane, dimethyl sulfoxide, dimethyl formamide, tetraglyme and other poly ethers; alcohols such as ethoxyethanol; nitriles, such as acetonitrile, glutaronitrile, 3-hydroxypropionitrile, and 2-methylglutaronitrile; ketones including 2-acetylbutyrolactone, and cyclopentanone; cyclic esters including beta- propiolactone, gamma-butyrolactone, and gamma-valerolactone; propylene carbonate (PC), ethylene carbonate; and homogenous mixtures of the same. While specific solvents have been disclosed as being associated with the electrochromic medium, numerous other solvents that would be known to those having ordinary skill in the art having the present disclosure before them are likewise contemplated for use.
[0055] In one aspect of the present invention plug 126 is associated with fill port
128, which preferably comprises an epoxy resin or mixture of resins (or other resins provided herein) and which is at least partially cured with a cationic photoinitiating antimonate salt and/or comprises an antimonate toward enhancing durability of plug 126 and/or compatibility of the same with electrochromic medium 124 and/or external atmospheric conditions. Such enhanced durability and/or compatibility preferably reduces the likelihood of any materials within electrochromic medium 124 being compositionally compromised and/or from inadvertently leaking out of chamber 116 through fill port 128.
[0056] It will be understood that during normal fabrication of electrochromic device 100, fill port 128 is utilized to introduce electrochromic medium 124 into chamber 116 of electrochromic device 100. In certain embodiments (e.g. Figs. 1 , 2) partially fabricated electrochromic device 100 is placed with fill port 128 downward in an empty container or trough in a vacuum vessel and evacuated. Electrochromic medium 124 is introduced into the trough or container in a manner such that fill port 128 is submerged. The vacuum vessel is then backfilled, which forces electrochromic medium 124 through fill port 128 and, ultimately, into chamber 116. In certain other embodiments, (e.g. Figs. 3, 4) such as an aircraft transparency, partially fabricated electrochromic device 100 is placed with fill port 128 upward in a vacuum vessel and evacuated. Electrochromic medium 124 is introduced into the container via conventional conduit in a manner such that fill port 128 is not submerged. Fill port 128 is then plugged preferably with a photo curing epoxy resin, (e.g. plug 126) which is at least partially cured with a cationic photoinitiating antimonate salt and/or comprises an antimonate. Such curing is preferably accomplished via a UV lamp. Additional discussions relative to the fabrication process of certain embodiments of electrochromic devices 100 are disclosed in U.S. Patent No. 6,700,692, B2, which has been previously referenced and incorporated herein.
[0057] In one embodiment of the present invention, the formulation of plug 126 preferably comprises an epoxy resin or mixture of resins (e.g. cycloaliphatic epoxy resins including, for example, Omnilane OCl 005, which is available from IGM Resins Inc., Bartlett, IL, aromatic epoxy resins including, for example, Bis-F, Bis-A, and/or epoxy novolac resins including, for example, DER 354, DER 332, and DEN 431, which are all available from the Dow Chemical Company - all of which may be optionally filled with fumed silica or other fillers such as glass beads, calcium carbonate, aluminum oxide, calcium fluoride, or other fillers as desired) which are at least partially cured using one or more antimonate photo initiators, such as, for example, a sulfonium antimonate, an arylsulfonium antimonate, a triarylsulfonium antimonate, a triarylsulfonium hexafluoroantimonate, and a mixed triarylsulfonium hexafluoroantimonate, and combinations thereof. For purposes of the present disclosure, the sulfonium antimonate may be represented by one or more of the following formulae:
Figure imgf000024_0001
[SbF6]-
(I)
R6 R9
R5 R7 1 Rio
[SbF6]" [SbF6]" (π)
Figure imgf000024_0002
wherein Ri-Rn are the same or different and comprise H, a hydroxy 1 group, a straight or branched alkyl, cycloalkyl, polycycloalkyl, heterocycloalkyl, alkaryl, alkoxy, aryl, aralkyl, alkenyl, alkynyl, or carbonyl group containing approximately 1 to approximately 50 carbon atom(s) and combinations thereof.
[0058] Specific examples of sulfonium antimonates which are commercially available from Union Carbide Corporation which is a wholly owned subsidiary of Dow Chemical Company include, for example:
Figure imgf000025_0001
Figure imgf000025_0002
[0059] In another embodiment of the present invention, the formulation of plug
126 comprises an epoxy resin which is at least partially cured using one or more antimonate photo initiators, such as, for example, an iodonium antimonate, an aryliodonium antimonate, a biaryliodonium antimonate, a biaryliodonium hexafluoroantimonate, and mixtures thereof.
[0060] For purposes of the present disclosure, the iodonium antimonate may be represented by one or more of the following formula: r
R1- ^ R2
[SbF6]"
(III) wherein R)-R2 are the same or different and comprise H, a hydroxyl group, a straight or branched alkyl, cycloalkyl, polycycloalkyl, heterocycloalkyl, alkaryl, alkoxy, aryl, aralkyl, alkenyl, alkynyl, or carbonyl group containing approximately 1 to approximately 50 carbon atom(s) and combinations thereof.
[0061] Specific examples of iodonium antimonates which are commercially available from Gelest Inc. include, for example:
Figure imgf000026_0001
[0062] While specific antimonate photo initiators have been disclosed, for illustrative purposes only, it will be understood that any one of a number of antimonate initiators are contemplated for use in accordance with the present invention. [0063] While specific anionic salts of photo initiators have been disclosed, for illustrative purposes only, it will be understood that any one of a number of other anions are contemplated for use in accordance with the present invention, including, for example, AsF6, Ga(C6F5)4j etcetera.
[0064] Without being bound to any one particular theory, it is believed that the antimonate facilitates better cross-linked density within plug 126, thereby enhancing at least durability of the same. It is further believed that the antimonate is a stronger acid than conventional counter ions, such as hexafluorophosphate, tetrafluoroborate, etcetera. [0065] In another embodiment of the present invention, the formulation of plug
126 comprises a resin or mixture of resins (e.g. epoxy resins, such as epoxidized polybutadienes, epoxidized castor oil, epoxidized cashew nut oil, acrylated butadiene resins, among other provided herein) that are substantially insoluble and/or substantially immiscible with an associated electrochromic medium (i.e. 124) while in the uncured state. By way of supporting example, the resin or mixture of resins may comprise Sartomer CN-301, Sartomer CN-304, Rhan BR-643. [0066] For purposes of the present invention it will be understood that resins other than acrylated (Sartomer CN-301), methacrylated (Sartomer CN-304) or epoxidized polybutabiene can be used in a plug formulation that are at least substantially insoluble and/or at least substantially immiscible in the EC media. Other insoluble monomers or oligomers available from Sartomer include CN-986 (aliphatic urethane acrylate), CN- 2252 (polyester acrylate), CN-934 (aliphatic urethane acrylate), CN-975 (hexafunctional urethane acrylate), CN-965 (aliphatic urethane acrylate), CN-981 (aliphatic urethane acrylate) CN-973 (aromatic urethane acrylate), SR-489 (tridecyl acrylate) and SR-335 (lauryl acrylate) -just to name a few. [0067] In yet another embodiment of the present invention, the formulation of plug 126 comprises two-parts, namely; a first sub-component comprising a resin or mixture of resins (e.g. epoxy resins, acrylated butadiene resins, among other provided supra and infra) that are substantially insoluble and/or substantially immiscible with an associated electrochromic medium (i.e. 124) while in the uncured state, and a second- subcomponent comprising a resin or mixture of resins (e.g. epoxy resins, urethane resins, phenolic resins, acrylic resins, cured at room temperature, thermally and/or with radiation, among other provided supra and infra) that exhibit desired permeability, adhesion, and/or stability characteristics. In particular, the permeability of the second- subcomponent will preferably protect electrochromic medium 124 from air and/or moisture if the first- subcomponents exhibits permeability to air and/or moisture. Furthermore, the second-subcomponent will preferably adhere to at least the first- subcomponent toward maintaining device integrity over long periods of time - including one or more decades depending upon the application of the particular electrochromic device.
[0068] Additional non-limiting examples of resins that are suitable for use as second-subcomponent resins and/or resins cured with an antimonate photo initiator include conventional aliphatic amines, cycloaliphatic amines, amidoamines, mercaptans, cycloaliphatic epoxy resins such as Omnilane OCl 005, which is available from IGM Resins Inc., Bartlett, IL, aromatic epoxy resins such as Bis-F, Bis-A, and/or epoxy novolac resins such as DER 354, DER 332, and DEN 431, which are all available from the Dow Chemical Company, as well as thermal and/or photoinitiators, and optionally filled with fumed silica or other fillers such as glass beads, calcium carbonate, aluminum oxide, etcetera, using conventional techniques.
[0069] It will be understood that the first sub-component of plug 126 can be introduced into fill port 128 which is generally compatible with the components of electrochromic medium 124 and subsequently cured. Next, the outer surface of the first sub-component and surrounding area can be cleaned, or cleaned and etched, if desired, prior (to association of the second sub-component. Etching can be accomplished by several methods including mechanical etching such as sandblasting, sandpaper, and chemical etching - just to name a few etching techniques. After optionally etching, the second sub-component of plug 126 can be associated with the outer surface area the first sub-component and the surrounding area which is generally compatible with external atmospheric conditions/parameters.
[0070] In accordance with the present invention, plug 126 may also optionally comprise one or more cure indicators which provide optical and/or measurable indication of the degree of plug curing. A first class of cure indicators preferably includes pH based cure indicators, such as phenolphthalein (0.25-0.5 parts per hundred resin "phr") and thymolphthalein (0.25-0.5 phr), which are available from Aldrich Chemical Company. A second class of cure indicators preferably includes free radical/reactive cure indicators such as Crystal Violet (0.25-0.5 phr), which is available from Aldrich Chemical Company. A third class of cure indicators preferably includes UV cure indicators such as
Blue 55 (1-5 phr), which is available from Spectra Group Limited, Inc., Millbury, OH. It will be understood that the concentrations of cure indicators provided above are merely preferred operative concentrations, but are, in no way, limiting. To be sure, other concentrations that would be known to those having ordinary skill in the art are likewise contemplated or use in accordance with the present invention. It will be further understood that utilization of plug cure indicators to the formulation is advantageous in a production setting to insure that plug 126 has been exposed to UV light and/or is in a properly cured state.
[0071] Plug 126 may further optionally comprise one or more additives, such as, but not limited to, tougheners (e.g. Fortegra 100 (1-5 wt%) available from The Dow Chemical Company and MXl 36 core-shell toughener (25 wt% in Bis-F epoxy) available from Kaneka Corporation, Pasedena, TX), flexibilizers/crosslinkers (e.g. H2003 dendritic polymer (1-20 wt%) or CAPA polyols (1-20 wt%) available from Perstorp Polyols, Inc,
Toledo, OH), and/or surface active agents (e.g. UV3570 (0.5-2.5 wt%) available from BYK-Chemie, Germany). It will be understood that plug tougheners and flexibilizers/crosslinkers are functionally self-explanatory, and that surface active agents can reduce the surface tension of the plug formulation and help repel the electrochromic medium during the plugging operation and reduce intermixing.
[0072] Electrochromic devices of the present invention can be used in a wide variety of applications wherein the transmitted or reflected light/heat can be modulated. Such devices include mirrors; aircraft transparencies; windows for the exterior of a building, home or vehicle; skylights for buildings including tubular light filters; windows in office or room partitions; and light filters for photographic devices and light sensors.
[0073] While the invention has been described in detail herein in accordance with certain preferred embodiments thereof, many modifications and changes therein may be effected by those skilled in the art. Accordingly, it is our intent to be limited only by the scope of the appending claims and not by way of details and instrumentalities describing the embodiments shown herein.

Claims

WHAT IS CLAIMED IS:
1. An electrochromic device, comprising:
- a first substantially transparent substrate having an electrically conductive material associated therewith; - a second substrate having an electrically conductive material associated therewith;
- an electrochromic medium contained within a chamber positioned between the first and second substrates which comprises:
- at least one solvent; - at least one anodic material; and
- at least one cathodic material, wherein both of the anodic and cathodic materials are electroactive and at least one of the anodic and cathodic materials is electrochromic;
- wherein at least one of a seal member, the first substrate, the second substrate, and the chamber comprises a plug associated with a fill port; and
- wherein the plug is at least partially cured with an antimonate photo initiator.
2. The electrochromic device according to claim 1, wherein at least one of the first substrate, and the second substrate comprises a plug associated with a fill port.
3. The electrochromic device according to claim 1, wherein the plug comprises an epoxy resin.
4. The electrochromic device according to claim 1 , wherein the plug is at least partially cured with cationic photoinitiating antimonate salt.
5. The electrochromic device according to claim 1, wherein the antimonate comprises a sulfonium antimonate.
6. The electrochromic device according to claim 1, wherein the antimonate comprises an arylsulfonium antimonate.
7. The electrochromic device according to claim 1, wherein the antimonate comprises a triarylsulfonium antimonate.
8. The electrochromic device according to claim 1, wherein the antimonate comprises a triarylsulfonium hexafluoroantimonate.
9. The electrochromic device according to claim 1, wherein the antimonate comprises a mixed triarylsulfonium hexafluoroantimonate.
10. The electrochromic device according to claim 1, wherein the antimonate comprises an iodonium antimonate.
1 1. The electrochromic device according to claim 1 , wherein the antimonate comprises an aryliodonium antimonate.
12. The electrochromic device according to claim 1, wherein the antimonate comprises a biaryliodonium antimonate.
13. The electrochromic device according to claim 1, wherein the antimonate comprises a biaryliodonium hexafluoroantimonate.
14. The electrochromic device according to claim 1, wherein the antimonate comprises at least one of the following formulae:
R3
R1 R2 R4
[SbF6]" (I)
R6 R9
.S s,
+ +
Rs R- R; R10
[SbF6]- [SbF6]" (π)
Rn
. S,
R12^ R|3
[SbF6]- (πi)
wherein R1-R13 are the same or different and comprise H, a hydroxyl group, a straight or branched alkyl, cycloalkyl, polycycloalkyl, heterocycloalkyl, alkaryl, alkoxy, aryl, aralkyl, alkenyl, alkynyl, or carbonyl group containing approximately 1 to approximately 50 carbon atom(s) and combinations thereof.
15. The electrochromic device according to claim 1, wherein the antimonate comprises at least one of the following chemical structures:
Figure imgf000035_0001
Figure imgf000035_0002
16. The electrochromic device according to claim 1, wherein the antimonate comprises the following formula:
R1" R2
[SbF6]-
(III) wherein Ri-R2 are the same or different and comprise H, a hydroxy 1 group, a straight or branched alkyl, cycloalkyl, polycycloalkyl, heterocycloalkyl, alkaryl, alkoxy, aryl, aralkyl, alkenyl, alkynyl, or carbonyl group containing approximately 1 to approximately 50 carbon atom(s) and combinations thereof.
17. The electrochromic device according to claim 1, wherein the antimonate comprises the following chemical structure:
Figure imgf000036_0001
18. The electrochromic device according to claim 1, wherein the antimonate comprises the following chemical structure:
Figure imgf000037_0001
19. The electrochromic device according to claim 1, wherein the electrochromic medium further comprises at least one of a cross-linked polymer matrix, a free-standing gel, and a substantially non- weeping gel.
20. The electrochromic device according to claim 1 , wherein the electrochromic medium further comprises a redox buffer.
21. The electrochromic device according to claim 1, wherein the device is an electrochromic window.
22. The electrochromic device according to claim 1, wherein the device is an electrochromic aircraft transparency.
23. The electrochromic device according to claim 1, wherein the second substrate is coated with a reflective material.
24. The electrochromic device according to claim 23, wherein the reflective material is selected from the group comprising chromium, ruthenium, rhodium, silver, alloys and/or combinations of the same, and stacked layers thereof.
25. The electrochromic device according to claim 24, wherein the device is an electrochromic mirror.
26. An electrochromic device, comprising:
- a first substantially transparent substrate having an electrically conductive material associated therewith;
- a second substrate having an electrically conductive material associated therewith;
- an electrochromic medium contained within a chamber positioned between the first and second substrates which comprises:
- at least one solvent;
- at least one anodic material; and - at least one cathodic material, wherein both of the anodic and cathodic materials are electroactive and at least one of the anodic and cathodic materials is electrochromic;
- wherein at least one of a seal member, the first substrate, the second substrate, and the chamber comprises a plug associated with a fill port; and
- wherein the plug comprises an antimonate.
27. An electrochromic device, comprising: - a first substantially transparent substrate having an electrically conductive material associated therewith;
- a second substrate having an electrically conductive material associated therewith;
- an electrochromic medium contained within a chamber positioned between the first and second substrates which comprises:
- at least one solvent;
- at least one anodic material; and
- at least one cathodic material, wherein both of the anodic and cathodic materials are electroactive and at least one of the anodic and cathodic materials is electrochromic;
- wherein at least one of a seal member, the first substrate, the second substrate, and the chamber comprises a plug associated with a fill port; and
- wherein the plug comprises a resin or mixture of resins that are at least one of substantially insoluble and substantially immiscible with the electrochromic medium while in the uncured state.
28. The electrochromic device according to claim 27, further comprising a cure indicator.
29. The electrochromic device according to claim 27, further comprising at least one of a toughener, a flexibilizer, and a surface active agent.
30. An electrochromic device, comprising:
- a first substantially transparent substrate having an electrically conductive material associated therewith;
- a second substrate having an electrically conductive material associated therewith;
- an electrochromic medium contained within a chamber positioned between the first and second substrates which comprises:
- at least one solvent;
- at least one anodic material; and - at least one cathodic material, wherein both of the anodic and cathodic materials are electroactive and at least one of the anodic and cathodic materials is electrochromic;
- wherein at least one of a seal member, the first substrate, the second substrate, and the chamber comprises a two-part plug associated with a fill port; and - wherein the two-part plug comprises a first sub-component comprising a resin or mixture of resins that are at least one of substantially insoluble and substantially immiscible with the electrochromic medium while in the uncured state, and a second- subcomponent comprising a resin or mixture of resins that exhibit at least one of desired permeability, adhesion, and stability characteristics.
31. An electrochromic device, comprising:
- a first substantially transparent substrate having an electrically conductive material associated therewith;
- a second substrate having an electrically conductive material associated therewith;
- an electrochromic medium contained within a chamber positioned between the first and second substrates which comprises: - at least one solvent;
- at least one anodic material; and
- at least one cathodic material, wherein both of the anodic and cathodic materials are electroactive and at least one of the anodic and cathodic materials is electrochromic; - wherein at least one of a seal member, the first substrate, the second substrate, and the chamber comprises a two-part plug associated with a fill port; and
- wherein the two-part plug comprises a first sub-component comprising an epoxy resin, an acrylated butadiene, and mixtures thereof, and a second sub-component comprising an epoxy resin.
32. The electrochromic device according to claim 29, wherein a surface of the first subcomponent has been at least one of mechanically etched and chemically etched.
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