Method for manufacturing electronic dimming device, electronic component for dimming, and electronic dimming glasses

Abstract

A manufacturing method of an electronic light-adjusting device (10), a light-adjusting electronic component, and electronic light-adjusting glasses, which obtain a light-adjusting effect by supplying electric power to an electronic component (19) overlapping an optical component (30), wherein a laminate (20, 120) in which a pair of electrode layers (22, 24) and a light-adjusting layer (23) between the pair of electrode layers are laminated is formed, an overlapping region (V) in a shape overlapping the optical component is set in a region in which the light-adjusting layer is formed in the laminate, and two or more terminal regions (T1, T2) in which one of the pair of electrode layers and the other of the pair of electrode layers exist separately are set continuously with an outer side of the overlapping region, and the electronic component is formed by cutting out a portion including the overlapping region and the terminal regions from the laminate, thereby improving production efficiency.

Description

Technical Field

[0001] This invention relates to a method for manufacturing an electronic dimming device, electronic components for dimming, and electronic dimming glasses. Background Technology

[0002] Electronic dimming devices exist that superimpose electronic components onto optical elements and achieve dimming effects by supplying electrical energy to the electronic components. As an example, electronic dimming glasses are known to have electronic components on the surface or inside the lens of eyeglasses, and whose optical properties (transmittance, color, etc.) are changed according to changes in the state of the electronic components. Electrochromic elements (EC elements) or liquid crystal elements are known as electronic components used in such electronic dimming glasses.

[0003] Electrochromic elements utilize the phenomenon of reversible optical absorption (electrochromic) caused by electrochemical redox reactions when a charge is applied to a substance. Electrochromic elements used in electronic dimming devices are generally made in a stacked structure with a dimming layer made of a material that displays electrochromic properties sandwiched between a pair of electrode layers for positive and negative electrodes.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent No. 5511997

[0007] Patent Document 2: Japanese Patent No. 6624206

[0008] Previously, when assembling electronic components such as electrochromic elements into eyeglass lenses, it was necessary to prepare a mask that matched the shape of the lens, and to use this mask to pattern the film-forming areas such as electrodes. For example, in the case of electrochromic elements, the mask pattern was typically set such that a light-adjusting area (active area) that changes color when a voltage is applied was formed at the center of the lens, and terminal electrodes divided into two parts were formed at the outer edge of the lens as positive and negative electrodes.

[0009] However, the shapes of eyeglass lenses vary greatly depending on user preferences and frame design. To obtain corresponding electronic components, masks for film deposition need to be prepared on lenses of different shapes to change the film deposition pattern of electrodes, etc. However, the fabrication of these masks is costly and time-consuming. Furthermore, switching to different masks for each lens with different shapes results in poor production efficiency. Conversely, pre-setting the film deposition pattern of the electronic components restricts the freedom of choice in lens shape selection.

[0010] Therefore, in the production of electronic dimming glasses, there is a need to improve productivity by using electronic components that can easily handle a wide variety of lens shapes. This problem is particularly pronounced in electronic dimming glasses with a wide range of lens shape options, but the same issue exists in any custom electronic dimming device that requires electronic components whose shape and size match the optical elements, in addition to electronic dimming glasses. Furthermore, the same challenge exists in electronic dimming devices that use electronic components other than electrochromic elements. Summary of the Invention

[0011] To address the aforementioned problems, the present invention aims to provide a method for manufacturing an electronic dimming device with excellent production efficiency, electronic components for dimming, and electronic dimming glasses.

[0012] The present invention is a method for manufacturing an electronic dimming device that obtains a dimming effect by supplying electrical energy to an electronic element that overlaps with an optical element. The method is characterized by forming a laminate containing a pair of electrode layers and a dimming layer between the pair of electrode layers, setting an overlapping region with an optical element in the dimming layer forming region of the laminate, and setting two or more terminal regions, one on each side of the pair of electrode layers, continuously outside the overlapping region, and cutting out a portion containing the overlapping region and the terminal regions from the laminate to form an electronic element.

[0013] More specifically, the dimming layer in the laminate is approximately circular, and a pair of electrode layers in the laminate are each shaped with a circular portion that overlaps with the dimming layer and an outer diameter portion that is radially disposed outside the circular portion. The laminate is formed in such a way that the outer diameter portions of the pair of electrode layers do not overlap when viewed from the front. Furthermore, overlapping areas are set in two places with the shape of the optical element tangent to the outer periphery of the approximately circular dimming layer, and terminal areas are set with the outer diameter portions of one and the other of the pair of electrode layers located outside the tangent portions at these two locations.

[0014] In the laminate, it is preferable that the diameter of the circular portion of each pair of electrode layers is smaller than the diameter of the dimming layer.

[0015] In the laminate, it is preferable that the outer diameter portions of a pair of electrode layers are each part of a circle with a diameter larger than that of the circular portion, and the outer diameter portions of one and the other are arranged symmetrically with respect to the center of the circular portion when viewed from the front.

[0016] For example, the electronic component can be an electrochromic element that produces a reversible change in the optical physical properties of the dimming layer due to a redox reaction by applying a voltage to the electrode layer.

[0017] This invention is particularly suitable as a method for manufacturing electronic dimming glasses in which electronic components are disposed on the surface or inside of a lens, which is an optical element.

[0018] This invention relates to a dimming electronic component that is superimposed on an optical element and obtains a dimming effect by supplying electrical energy. The component is characterized by having a stacked body comprising a pair of electrode layers and a dimming layer between the electrode layers. The stacked body includes: an overlapping region located in the dimming layer formation area when viewed from the front, which serves as a region overlapping with the optical element; and two or more terminal regions continuously connected to the outer side of the overlapping region, each having a separate electrode layer on one side and the other side. The shape of the overlapping region and the terminal regions can be set relative to multiple optical elements of different shapes.

[0019] More specifically, the dimming layer in the laminate is shaped as a generally circular shape that is inscribed inwards at two points to the outer periphery of the optical element. A pair of electrode layers in the laminate are each shaped as having a circular portion that overlaps with the dimming layer and an outer diameter portion radially disposed outside the circular portion. The outer diameter portions of the pair of electrode layers are arranged without overlapping when viewed from the front. Terminal regions are located on the pair of electrode layers outside the two points where the shape of the optical element is inscribed inwards to the outer periphery of the dimming layer.

[0020] The above-mentioned dimming electronic components are particularly useful in electronic dimming glasses. Specifically, the optical element is a lens, and the dimming electronic component has an overlapping area with a shape corresponding to the lens and two or more terminal areas outside the overlapping area. Furthermore, electronic dimming glasses are constructed from a dimming lens with the dimming electronic component located on or inside the lens surface and a lens frame that holds the dimming lens.

[0021] According to the manufacturing method of the electronic dimming device of the present invention, it is possible to easily obtain an electronic element with electrodes corresponding to optical elements of various shapes from a laminate, and to significantly improve the production efficiency of electronic dimming devices such as electronic dimming glasses and electronic elements for dimming. Attached Figure Description

[0022] Figure 1 This is a diagram showing electronic dimming glasses as one type of electronic dimming device.

[0023] Figure 2 A front view of the electrochromic laminate that forms the basis of the electrochromic element in electronic dimming glasses.

[0024] Figure 3 It is along Figure 2 A cross-sectional view of line III-III.

[0025] Figure 4 This is a front view showing each layer of the electrochromic laminate separately.

[0026] Figure 5 It is a three-dimensional diagram showing each layer of the electrochromic laminate separately.

[0027] Figure 6 It is a three-dimensional diagram of the stacked state of the electrochromic laminate.

[0028] Figure 7 This is a cross-sectional view of a modified electrochromic laminate.

[0029] Figure 8 This is a front view of the electrode layer in a modified example. Detailed Implementation

[0030] Figure 1 This describes an electronic dimming glasses 10 as one embodiment of the electronic dimming device of the present invention. The electronic dimming glasses 10 includes left and right dimming lenses 11 and 12 and a frame 13. The frame 13 includes: annular lens rings 14 and 15 that hold the left and right sides of the dimming lenses 11 and 12; temples 16 and 17 extending from the lens rings 14 and 15; and a bridge (nose bridge) 18 connecting the lens rings 14 and 15. The left-right direction of the electronic dimming glasses 10 is defined as the X-axis direction, and the up-down direction is defined as the Y-axis direction.

[0031] like Figure 1 As shown in the cross-sectional view, the dimming lenses 11 and 12 are electronic dimming lenses in which an electrochromic element (EC element) 19, serving as an electronic element for dimming, is superimposed on the surface of the lens 30, which is an optical element. The front side of the lens 30 is convex, and the back side is concave, and the sheet-like electrochromic element 19 is curved along the convex surface of the lens 30. By processing the concave surface of the lens 30, the diopter, etc., can be adjusted. Although Figure 1 Illustrations are omitted, but a coating with specified functions (such as ultraviolet or infrared transmission control, lens protection effect, etc.) can be formed on the surface side of the electrochromic element 19.

[0032] As a method for manufacturing dimming lenses 11 and 12, for example, lens 30 and electrochromic element 19 can be manufactured separately, the electrochromic element 19 can be pre-formed into a curved shape corresponding to the surface of lens 30, and then the electrochromic element 19 and lens 30 can be bonded together. Alternatively, during the forming process of lens 30, the electrochromic element 19 can be integrally formed to obtain dimming lenses 11 and 12.

[0033] The electrochromic element 19 comprises an electrochromic material that reversibly alters its photophysical properties through a redox reaction induced by the application of a voltage. In its normal state without an applied voltage, it is transparent (with the highest transmittance of visible light). By applying a voltage, it is colored to a predetermined color corresponding to the electrochromic material, thereby reducing light transmittance. The structure of the electrochromic element 19 will be described later.

[0034] The frame 13 is equipped with a power supply, control unit, and operation unit (not shown in the diagram). Additionally, a conductive part is provided inside the frame 13 for supplying power to the electrochromic element 19 of the dimming lenses 11 and 12. This conductive part is connected to the terminal areas T1 and T2 of the electrochromic element 19. When the user operates the operation unit, the control unit controls the energization of the electrochromic element 19, thereby achieving the dimming effect of the dimming lenses 11 and 12. The control unit can also adjust the dimming effect (transmittance) of the dimming lenses 11 and 12 in multiple steps according to the operation of the operation unit.

[0035] However, in the electronic dimming glasses 10, various shapes of dimming lenses 11 and 12 can be selected according to the user's preferences and the design of the frame 13. The manufacturing method for efficiently producing electrochromic elements 19 corresponding to different shapes of dimming lenses 11 and 12 will be described below.

[0036] In the production of the electrochromic element 19, an electrochromic laminate 20 is formed as its basis. Then, a portion of the electrochromic laminate 20 is cut into an arbitrary shape corresponding to the lens 30 of each dimming lens 11, 12 to obtain the electrochromic element 19 for dimming lenses 11, 12. Figure 2 , Figure 3 and Figure 6 This indicates the state of each layer after it has been stacked to form the electrochromic laminate 20. Figure 4 and Figure 5 Each layer of the electrochromic laminate 20 is shown separately.

[0037] The electrochromic laminate 20 is constructed by stacking a first electrode layer 22, an electrochromic layer (switching layer) 23, and a second electrode layer 24 on a substrate 21 formed of synthetic resin. The materials and functions of each layer constituting the electrochromic laminate 20 will be briefly explained based on existing electrochromic elements.

[0038] The first electrode layer 22 and the second electrode layer 24 are both transparent conductive films made of transparent and conductive materials. For example, indium tin oxide (ITO), in which tin oxide (Sn2O2) is added to indium oxide (In2O3), is preferably used as the material for the first electrode layer 22 and the second electrode layer 24, but other materials may also be used. The thickness of the first electrode layer 22 and the second electrode layer 24 is set to a predetermined value that is required to obtain the resistance value of the redox reaction in the electrochromic layer 23.

[0039] The electrochromic layer 23 is a three-layer film consisting of an electrochromic electrode layer, a solid electrolyte layer, and a counter electrode layer. For example, a tungsten oxide (WO3) film is preferred as the electrochromic electrode layer, a tantalum pentoxide (Ta2O5) film is preferred as the solid electrolyte layer, and an iridium oxide (Ir2O2) film or an indium oxide (In2O3) film is preferred as the counter electrode layer, but other materials may also be used.

[0040] The formation methods of the first electrode layer 22, the second electrode layer 24, and the electrochromic layer 23 can be arbitrarily selected from known film formation methods (various coating film formation methods or vacuum film formation methods, etc.) according to the material or purpose.

[0041] The substrate 21 in the electrochromic laminate 20 is Figure 2 The film-forming center C is shown as an approximately circular shape. The electrochromic layer 23 is also approximately circular, centered on the film-forming center C. Figure 2 and Figure 4 From such a frontal view, the annular outer periphery 23a surrounding the film-forming center C forms its shape. The diameter D2 of the electrochromic layer 23 ( Figure 4 The diameter D1 of the substrate 21 is smaller than that of the small-diameter substrate 21. Figure 4 A portion near the outer edge of the electrochromic layer 23 becomes an extension 23b that extends along the thickness direction of the electrochromic layer stack 20 and is in contact with the substrate 21.

[0042] Under frontal observation of the electrochromic laminate 20 ( Figure 2 , Figure 4 The first electrode layer 22 and the second electrode layer 24 are symmetrical about each other with respect to a centerline extending in the Y-axis direction through the film-forming center C. That is, when viewed from the front, the first electrode layer 22 and the second electrode layer 24 are symmetrical about the left and right sides with respect to the film-forming center C. Specifically, the first electrode layer 22 and the second electrode layer 24 have the shapes described below.

[0043] like Figure 4 As shown, the first electrode layer 22 has a central circular portion 22a and an outer diameter portion 22b that is radially continuous with respect to the outer side of the central circular portion 22a. The central circular portion 22a is a generally circular portion centered on the film formation center C, and the diameter D3 of the central circular portion 22a is... Figure 4 The diameter D2 of the electrochromic layer 23 is set to be greater than that of the electrochromic layer 23. Figure 4 Slightly smaller.

[0044] The outer diameter portion 22b is a part of a circle with a diameter larger than that of the central circular portion 22a. More specifically, it is a part of a circle having the same outer peripheral shape (radius size) as the substrate 21. When viewed from the front, the outer diameter portion 22b is formed in the region to the left of the film-forming center C in the X-axis direction.

[0045] The first electrode layer 22 has an external shape consisting of a semi-circular outer periphery 22c in the central circular portion 22a, an arc portion 22d in the outer diameter portion 22b, a pair of straight portions 22e extending from both ends of the arc portion 22d along the Y-axis, and a pair of straight portions 22f extending from the pair of straight portions 22e along the X-axis and connecting with the semi-circular outer periphery 22c. The arc portion 22d has a shape that is approximately consistent with a portion of the outer periphery of the substrate 21.

[0046] like Figure 4 As shown, the second electrode layer 24 has a central circular portion 24a and an outer diameter portion 24b radially disposed outside the central circular portion 24a. The central circular portion 24a is a generally circular portion centered on the film formation center C, and the diameter D4 of the central circular portion 24a is... Figure 4 The diameter D2 of the electrochromic layer 23 is set to be greater than that of the electrochromic layer 23. Figure 4 Slightly smaller. The diameter D3 of the central circular portion 22a of the first electrode layer 22 is the same as the diameter D4 of the central circular portion 24a of the second electrode layer 24.

[0047] The outer diameter portion 24b is a part of a circle with a diameter larger than that of the central circular portion 24a; more specifically, it is a part of a circle having the same outer peripheral shape (radius size) as the substrate 21. When the electrochromic laminate 20 is viewed from the front, the outer diameter portion 24b is formed in a region to the right of the film-forming center C in the X-axis direction. Figure 5 As shown, the central circular portion 24a and the outer diameter portion 24b are positioned differently in the thickness direction of the electrochromic laminate 20, and the connecting portion 24g connects the outer edge portion of the central circular portion 24a and the inner edge portion of the outer diameter portion 24b.

[0048] The shape of the second electrode layer 24, viewed from the front, consists of a semi-circular outer periphery 24c in the central circular portion 24a, an arc portion 24d in the outer diameter portion 24b, a pair of straight portions 24e extending from both ends of the arc portion 24d along the Y-axis, and a pair of straight portions 24f extending from the pair of straight portions 24e along the X-axis and connected to the semi-circular outer periphery 24c. The arc portion 24d has a shape that is approximately consistent with a portion of the outer periphery of the substrate 21. Furthermore, because there is a step formed by the connecting portion 24g between the central circular portion 24a and the outer diameter portion 24b, the pair of straight portions 24e and the pair of straight portions 24f are not directly connected. Figure 5 Reference).

[0049] The first electrode layer 22 and the second electrode layer 24 are formed and arranged such that the centers of their respective central circular portions 22a and 24a are located at the film-forming center C, and the outer diameter portions 22b and 24b are symmetrical about the film-forming center C when viewed from the front. Figure 3As shown, regarding the first electrode layer 22, both the central circular portion 22a and the outer diameter portion 22b are in contact with the substrate 21, and regarding the second electrode layer 24, the outer diameter portion 24b is in contact with the substrate 21.

[0050] In the thickness direction of the electrochromic laminate 20, the area where the first electrode layer 22 (central circular portion 22a), the electrochromic layer 23, and the second electrode layer 24 (central circular portion 24a) completely overlap becomes the dimming region E, which produces a color change (transmittance change) by applying voltage. Figure 2 and Figure 3 When viewed from the front, the circular area enclosed by the semicircular outer periphery 22c of the central circular portion 22a and the semicircular outer periphery 24c of the central circular portion 24a is the dimming area E. Figure 2 Reference).

[0051] Outside the dimming region E, the outer diameter portions 22b of the first electrode layer 22 and 24b of the second electrode layer 24 are separated in the X-axis direction without overlapping. When the electrochromic stack 20 is viewed from the front, a gap exists in the X-axis direction between a pair of straight portions 22e of the outer diameter portion 22b and a pair of straight portions 24e of the outer diameter portion 24b. (As shown...) Figure 6 As shown, the outer diameter portions 22b and 24b are positioned differently in the thickness direction of the electrochromic stack 20.

[0052] The dimensions (particularly diameters D1 to D4) of each part in the electrochromic laminate 20 are set such that the shapes of the lenses 30 of the various (different shapes and sizes) dimming lenses 11 and 12 used in the electronic dimming glasses 10 converge to the inner side of the outer periphery 23a of the electrochromic layer 23. For example, the diameter D1 of the substrate 21 is 40 mm, the diameter D2 of the electrochromic layer 23 is 30 mm, and the diameters D3 and D4 of the central circular portion 22a and central circular portion 24a are both 28 mm. In this case, the circular region with a diameter of 28 mm centered on the film formation center C becomes the dimming region E.

[0053] The diameter D2 of the electrochromic layer 23 is larger than the diameters D3 and D4 of the central circular portions 22a and 24a, and has a margin of approximately 1 mm in the radial direction centered on the film formation center C. Furthermore, the outer diameter portions 22b and 24b are separately arranged in the X-axis direction. Therefore, there is no portion in the thickness direction of the electrochromic layer stack 20 where the first electrode layer 22 and the second electrode layer 24 directly face each other, preventing short circuits between the first electrode layer 22 and the second electrode layer 24.

[0054] A shape corresponding to the outline of the dimming lenses 11 and 12 is cut from the electrochromic laminate 20 constructed as described above to form an electrochromic element 19 customized for the lens. As a condition setting for obtaining the electrochromic element 19 from the electrochromic laminate 20, firstly, when viewed from the front, an overlap region V (shaped overlapping with the outline of the lens 30) is set in the forming area of ​​the electrochromic layer 23 (inside the outer periphery 23a). Figure 2 In addition, two or more terminal regions T1 and T2, which are independently formed without overlapping with the first electrode layer 22 (outer diameter portion 22b) and the second electrode layer 24 (outer diameter portion 24b), are continuously provided on the outer side of the overlapping region V. Figure 2 Then, the overlapping region V and the portion where the terminal regions T1 and T2 are combined are cut out from the electrochromic laminate 20 to obtain the electrochromic element 19.

[0055] More specifically, such as Figure 2 As shown, the overlapping region V is configured such that the shape of the lens 30 in the dimming lenses 11 and 12 is internally tangent to the outer periphery 23a of the approximately circular electrochromic layer 23 at two points (internal tangency points P1 and P2).

[0056] Furthermore, one internal tangent point P1 is located in the circumferential direction centered on the film formation center C within the formation range of the outer diameter portion 22b of the first electrode layer 22 (inner diameter side of the arc portion 22d), and another internal tangent point P2 is located in the circumferential direction centered on the film formation center C within the formation range of the outer diameter portion 24b of the second electrode layer 24 (inner diameter side of the arc portion 24d).

[0057] Since the formation ranges of the outer diameter portions 22b and 24b are respectively divided into one side and the other side of the X-axis direction relative to the film formation center C, the inner tangent points P1 and P2 are at least at least in the X-axis direction, their relative positions are different. Furthermore, in Figure 2 In the setup shown, the inner tangent point P1 and the inner tangent point P2 are located at approximately the same position in the Y-axis direction. However, depending on the shape of the lens 30 or the configuration of the overlapping area V, there are also cases where the positions of the inner tangent point P1 and the inner tangent point P2 in the Y-axis direction are different from each other.

[0058] Furthermore, a portion of the outer diameter portion 22b is designated as terminal region T1, continuous with the overlapping region V, outside the inner tangent point P1, and a portion of the outer diameter portion 24b is designated as terminal region T2, continuous with the overlapping region V, outside the inner tangent point P2. Additionally, in the second electrode layer 24, a connecting portion 24g exists at the boundary between the central circular portion 24a and the outer diameter portion 24b. Therefore, for terminal region T2, a condition can be added such that it extends from the inner tangent point P2 to the outer diameter side by at least an amount exceeding the thickness of the connecting portion 24g as viewed from the front. With this configuration, terminal region T2 can be reliably positioned on the outer diameter portion 24b.

[0059] By setting the overlapping area V and terminal areas T1 and T2 in this way and cutting them out from the electrochromic laminate 20, it is possible to easily produce an electrochromic element 19 that has a dimming effect on approximately the entire area of ​​the lens 30 and has multiple terminal portions (terminal areas T1 and T2) for power supply.

[0060] As an advantage of the above manufacturing method, as long as the above-mentioned setting conditions regarding the configuration of the overlapping region V and the terminal regions T1, T2 are met, an electrochromic element 19 that can correspond to a lens 30 of any shape can be obtained from an electrochromic laminate 20. Therefore, it is possible to produce electrochromic elements 19 with electrode configurations customized for each lens in less time and at a lower cost without performing film deposition processing using individual mask patterns corresponding to various lens shapes.

[0061] The electrochromic layer 23 in the electrochromic stack 20 is a very simple circle when viewed from the front. Furthermore, the first electrode layer 22 and the second electrode layer 24 are relatively simple shapes obtained by removing a portion from the circular shape of the substrate 21 when viewed from the front. Therefore, each layer of the electrochromic stack 20 can be easily formed without using complex mask patterns. Compared to film deposition processes using complex mask patterns that match individual lens shapes, the electrochromic stack 20 can be fabricated inexpensively and efficiently.

[0062] When the dimming lenses 11 and 12 are assembled into the frame 13, the terminal regions T1 and T2 of the electrochromic element 19 are in a conductive state and contact the conductive parts disposed within the frame 13. The contact points between the terminal regions T1 and T2 and the conductive parts are covered by the lens rims 14 and 15 of the frame 13 and are not exposed to the appearance of the electronic dimming glasses 10. Figure 1 Reference).

[0063] In addition, Figure 2 In the example shown, a portion of the terminal regions T1 and T2 (internal tangent points P1 and P2) in the overlapping region V is not included in the dimming region E. However, when the dimming lenses 11 and 12 are assembled into the frame 13, this portion is covered by the lens rings 14 and 15. Therefore, in the completed state of the electronic dimming glasses 10, the dimming effect of the dimming lenses 11 and 12 can be obtained in the entire area inside the lens rings 14 and 15.

[0064] The outer periphery of the electrochromic element 19, after being cut from the electrochromic laminate 20, can be sealed with a sealing material. This improves the durability of the electrochromic element 19.

[0065] like Figure 2As shown, in the electrochromic laminate 20 of this embodiment, the first electrode layer 22 and the second electrode layer 24 cover most of the substrate 21 except for the space between the straight portions 22e and 24e. In this way, by forming the first electrode layer 22 (especially the outer diameter portion 22b) and the second electrode layer 24 (especially the outer diameter portion 24b) in a shape that covers the outer edge shape of the substrate 21 as much as possible, the range of selectable overlapping regions V and terminal regions T1 and T2 is widened, and the range of lens shape changes that can be accommodated is widened.

[0066] Furthermore, when the first electrode layer 22 (particularly the outer diameter portion 22b) and the second electrode layer 24 (particularly the outer diameter portion 24b) are formed in a manner that covers the outer edge shape of the substrate 21 as much as possible, the degree of freedom in selecting the arrangement of the overlapping region V and the terminal regions T1 and T2 for the same lens shape increases. For example, in the electrochromic laminate 20 of this embodiment, even if the overlapping region V is from Figure 2 The tilted configuration shown allows the lens 30 to be tangent to the outer periphery 23a of the electrochromic layer 23 at two locations, and the terminal regions T1 and T2 to be positioned at the outer diameter portions 22b and 24b. Therefore, when film formation defects occur in a portion of the electrochromic layer stack 20, the flexibility to avoid these defective areas in setting the overlapping region V and terminal regions T1 and T2 increases, thereby improving the yield rate of the electrochromic element 19.

[0067] However, if the formation range of the first electrode layer 22 and the second electrode layer 24 on the substrate 21 is too wide, the risk of contact or short circuit between the electrode layers 22 and 24 increases. Therefore, in the first electrode layer 22 and the second electrode layer 24, the outer diameter portions 22b and 24b, which are located further outward than the central circular portions 22a and 24a, are arranged so that they do not overlap when viewed from the front. In the electrochromic stack 20 of this embodiment, the straight portion 22e, which is the edge portion of the outer diameter portion 22b, and the straight portion 24e, which is the edge portion of the outer diameter portion 24b, have a gap between them in a manner that separates them from each other by a predetermined distance or more in the X-axis direction.

[0068] exist Figure 1 In the frame 13 of the electronic dimming glasses 10 shown, the temples 16 and 17 and the bridge 18 are connected to the upper edges of the left and right lens rings 14 and 15. Therefore, it is easy to arrange a conductive portion along the upper edge of the frame 13 to supply power to the electrochromic elements 19 of the left and right dimming lenses 11 and 12. That is, it is envisioned that a conductive portion extending approximately in the X-axis direction along the upper edge of the frame 13 is used. In this case, as... Figure 1 and Figure 2As shown, as a terminal configuration on the electrochromic element 19 side that is easily connected to the conductive portion, terminal regions T1 and T2 are suitable to be provided near the upper edge of the electrochromic element 19 and separated on both sides in the X-axis direction. For this reason, in the electrochromic laminate 20, the outer diameter portions 22b and 24b, which will form the basis of the terminal regions T1 and T2, are separately arranged on both sides in the X-axis direction.

[0069] However, the arrangement of the outer diameter portions of the two electrode layers can also differ from the embodiment described above. For example, it could be that... Figure 2 The electrochromic laminate 20 shown is rotated 90 degrees, and the outer diameter portions 22b and 24b are separated in the Y-axis direction. In this case, the angle and position of the overlapping area are changed so that the shape of the lens 30 is separated from the two incision points of the outer periphery 23a of the electrochromic layer 23 on the upper and lower sides in the Y-axis direction sandwiching the film formation center C. Correspondingly, the two terminal regions provided outside the two incision points are also configured to be on the upper and lower sides in the Y-axis direction.

[0070] The above describes one type of electrochromic laminate 20, but various electrochromic laminates with different diameters of the dimming region E can also be prepared. This allows for the further fabrication of electrochromic elements corresponding to lenses of various shapes and sizes. The diameter of the dimming region E can be appropriately set according to the diameters D2 to D4 of the electrochromic layer 23, the central circular portion 22a of the first electrode layer 22, and the central circular portion 24a of the second electrode layer 24, with only slight variations such as changes in the diameter of the circular portions. Therefore, even if multiple electrochromic laminates are prepared, compared to the case where different film patterns are used for each lens shape, the processing time and cost can be kept lower.

[0071] When using the manufacturing method of this embodiment, the lens center may deviate from the film-forming center C of the electrochromic laminate 20, but this can be addressed by considering the optical design of the off-center lens. Such an approach can be achieved, for example, by... Figure 1 The lens 30 shown is achieved by machining the back (concave surface) during the finishing process to form its final shape.

[0072] Figure 7 This refers to an electrochromic laminate 120 as a modified example. The electrochromic laminate 20 described above is formed by stacking a first electrode layer 22, an electrochromic layer 23, and a second electrode layer 24 on a substrate 21. Figure 3 (Refer to). In contrast, Figure 7 The electrochromic laminate 120 is a substrate 25 containing a synthetic resin in addition to the substrate 21, and a first electrode layer 22, an electrochromic layer 23 and a second electrode layer 24 are sandwiched between the substrate 21 and the substrate 25.

[0073] Substrate 25 is Figure 2 The film-forming center C shown is a roughly circular shape with approximately the same diameter as the substrate 21. A first electrode layer 22 is formed on the substrate 21, and a second electrode layer 24 is formed on the substrate 25. An electrochromic layer 23 is disposed between the opposing first electrode layer 22 and second electrode layer 24 to form an electrochromic laminate 120.

[0074] Substrates 21 and 25 are positioned with their centers (film formation centers C) aligned. The shape and arrangement of the first electrode layer 22 on substrate 21 are the same as those of the electrochromic laminate 20. For the second electrode layer 24, the outer diameter portion 24h of the central circular portion 24a is located at the same position as the central circular portion 24a in the thickness direction of the electrochromic laminate 120, and both the central circular portion 24a and the outer diameter portion 24h are in contact with substrate 25. That is, unlike the electrochromic laminate 20 of the previous embodiment, the second electrode layer 24 of the electrochromic laminate 120 is a flat structure in which the central circular portion 24a and the outer diameter portion 24h are continuous without a connecting portion. The arc portion 24i, which is the outer edge of the outer diameter portion 24h, has a shape that is approximately consistent with a part of the outer peripheral shape of substrate 25. When viewed from the front, the shape and positional relationship of the first electrode layer 22, the electrochromic layer 23, and the second electrode layer 24 are the same as those of the electrochromic stack 20 described above. Therefore, the manufacturing method of the electrochromic stack 120 can achieve the same effect as the manufacturing method of the electrochromic stack 20.

[0075] Figure 2 and Figure 4 The outer diameter portion 22b of the first electrode layer 22 and the outer diameter portion 24b of the second electrode layer 24 shown are optimized shapes to cover the outer edge shape of the substrate 21 to a greater extent, but the shape of the outer diameter portion of each electrode layer 22, 24 can also be changed.

[0076] in addition, Figure 2 and Figure 4 In the first electrode layer 22 and the second electrode layer 24 shown, the outer diameter portions 22b and 24b are symmetrical about the left and right with respect to the film formation center C when viewed from the front. However, the shape of the outer diameter portions of each electrode layer 22 and 24 can also be asymmetrical when viewed from the front.

[0077] Figure 8 This illustrates a modified example of the first electrode layer 22 having a changed outer diameter portion 22g. In this modified example, the outer diameter portion 22g has an edge portion replacing the previously described straight portion 22e. Figure 4 (Referencing) The straight portion 22h is designed to extend in the radial direction centered on the film-forming center C. That is, the outer diameter portion 22g is formed as a fan shape centered on the film-forming center C. Figure 8The outer diameter portion 24b of the second electrode layer 24 is with Figure 4 They have the same shape. Therefore, the outer diameter portion 22g of the first electrode layer 22 and the outer diameter portion 24b of the second electrode layer 24 are asymmetrical with respect to the film formation center C when viewed from the front. Even with such asymmetrical outer diameter portions 22g and 24b, as long as the terminal regions T1 and T2 can be set without overlapping each other... Figure 2 ) conditions are sufficient.

[0078] In addition, as Figure 8 In a further variation, the outer diameter of the second electrode layer 24 can be formed into a fan shape that is the same as the outer diameter 22g of the first electrode layer 22, so that the outer diameter of each electrode layer 22, 24 is configured to be symmetrical about the left and right relative to the film formation center C when viewed from the front.

[0079] Alternatively, the outer diameter portion of the first electrode layer 22 and the outer diameter portion of the second electrode layer 24 can be changed to... Figure 8 Shapes other than that of a fan.

[0080] The above description is based on the illustrated embodiments, but the present invention is not limited to the above embodiments. Various modifications and alterations can be made without departing from the spirit of the invention.

[0081] The dimensions of the substrate 21, the first electrode layer 22, the electrochromic layer 23, the second electrode layer 24, and the substrate 25 described above are just one example, and can be changed to different sizes.

[0082] In the above-described embodiments, the dimming region E and the electrochromic layer 23 of the electrochromic laminates 20 and 120 are circular. This shape is excellent in terms of versatility, easily adapting to various lens shapes without being biased towards a particular direction. However, if there are certain common shape characteristics among the assumed lens shapes, the dimming region or the electrochromic layer may be set to a non-circular shape (e.g., elliptical) that reflects these shape characteristics.

[0083] The dimming lenses 11 and 12 in the above embodiments are constructed by overlapping the electrochromic element 19 on the surface (convex surface) of the lens 30. In contrast, dimming lenses may also have a structure in which the electrochromic element is disposed (clamped) inside the lens in the thickness direction.

[0084] The components constituting the electrochromic element 19 (electrochromic stack 20, 120) can be formed of materials other than those described above. For example, instead of synthetic resin, the substrate can be made of glass. Furthermore, the electrochromic material can be an organic material instead of the inorganic material described above.

[0085] In the above embodiments, an electrochromic element 19 is used as an electronic component constituting the dimming lenses 11 and 12, but it can also be applied to electronic components other than electrochromic elements. For example, liquid crystal elements or electrophoretic elements share the commonality with electrochromic elements in that their optical physical properties change through the supply of electrical energy. Therefore, even in electronic dimming devices that use liquid crystal elements or electrophoretic elements as electronic components, the same effect can be obtained by applying the above-described technique in the manufacture of electronic components containing electrodes. Furthermore, the term "dimming" in this invention refers to the entirety of the optical effects produced by such various electronic components on optical components, and is not limited to changes in light transmittance (light transmittance) or color in a narrow sense. For example, information display (overlay) using liquid crystal elements in optical devices is also a form of dimming.

[0086] The electronic dimming glasses 10 described above demonstrates a high degree of freedom in choosing the shapes of the dimming lenses 11 and 12, making the present invention particularly useful. However, the present invention can also be applied to electronic dimming devices other than electronic dimming glasses. For example, it can be applied to electronic dimming glass for windows (electronic blinds), privacy filters for displays of portable electronic devices, etc. In such cases, the window glass or the protective glass for the display becomes the optical element of the present invention.

[0087] Industrial availability

[0088] By applying this invention, it is possible to efficiently manufacture electronic components for dimming in a variety of shapes, improve the productivity of electronic dimming devices such as electronic dimming glasses, and reduce manufacturing costs.

Claims

1. A method for manufacturing an electronic dimming device, wherein dimming effect is achieved by supplying electrical energy to an electronic component overlapping with an optical component, characterized in that, A laminate is formed by stacking a pair of electrode layers and a dimming layer between the pair of electrode layers. An overlapping region with the shape of the optical element is formed within the dimming layer of the laminate, and two or more terminal regions, one of the two electrode layers existing independently, are continuously formed outside the overlapping region. A portion including the overlapping region and the terminal regions is cut from the laminate to form the electronic element. The dimming layer in the laminate is approximately circular. The pair of electrode layers in the laminate each have: a generally circular portion overlapping the dimming layer; and an outer diameter portion radially disposed outside the circular portion. The laminate is formed in such a configuration that the outer diameter portions of the pair of electrode layers do not overlap when viewed from the front. The overlapping area is set in such a way that the shape of the optical element is inscribed in the approximately circular outer periphery of the dimming layer at two locations, and the terminal area is set such that the outer diameter portions of one and the other of the pair of electrode layers are located outside the inscribed portions at those two locations.

2. The method for manufacturing the electronic dimming device as described in claim 1, characterized in that, In the stack, the diameter of the circular portion of each of the pair of electrode layers is smaller than the diameter of the dimming layer.

3. The method for manufacturing the electronic dimming device as described in claim 1, characterized in that, In the laminate, the outer diameter portions of the pair of electrode layers are each parts of a circle with a diameter larger than the circular portion. The outer diameter portions of one side and the outer diameter portions of the other side are arranged symmetrically with respect to the center of the circular portion when viewed from the front.

4. The method for manufacturing the electronic dimming device as described in claim 2, characterized in that, In the laminate, the outer diameter portions of the pair of electrode layers are each parts of a circle with a diameter larger than the circular portion. The outer diameter portions of one side and the outer diameter portions of the other side are arranged symmetrically with respect to the center of the circular portion when viewed from the front.

5. The method for manufacturing the electronic dimming device according to any one of claims 1 to 4, characterized in that, The electronic element is an electrochromic element that produces reversible changes in optical physical properties in the dimming layer due to redox reactions by applying a voltage to the electrode layer.

6. The method for manufacturing the electronic dimming device according to any one of claims 1 to 4, characterized in that, The electronic dimming device is an electronic dimming glasses in which the electronic element is disposed on the surface or inside of the lens, which is the optical element.

7. A dimming electronic component, stacked on top of an optical component, achieves a dimming effect by supplying electrical energy, characterized in that, A laminate having a pair of electrode layers and a dimming layer between the pair of electrode layers. The laminate includes: The region located in the formation area of ​​the dimming layer when viewed from the front, and the overlapping area that overlaps with the optical element; Continuing with the outer side of the overlapping region, there are two or more terminal regions on one side and the other side of the pair of electrode layers. The laminate is capable of defining the shape of the overlapping region and the terminal region relative to a plurality of optical elements of different shapes. The dimming layer in the laminate is a roughly circular shape that is inscribed inwards at two points on the outer periphery of the optical element. The pair of electrode layers in the laminate each have: a generally circular portion overlapping the dimming layer; and an outer diameter portion radially disposed outside the circular portion. The outer diameter portions of the pair of electrode layers are arranged without overlapping when viewed from the front. The terminal region is located on the outer side of the two points where the shape of the optical element is tangent to the outer periphery of the dimming layer, and is situated on the pair of electrode layers.

8. The dimming electronic component as described in claim 7, characterized in that, In the stack, the diameter of the circular portion of each of the pair of electrode layers is smaller than the diameter of the dimming layer.

9. The dimming electronic component as described in claim 7, characterized in that, In the laminate, the outer diameter portions of the pair of electrode layers are each parts of a circle with a diameter larger than the circular portion. The outer diameter portions of one side and the outer diameter portions of the other side are arranged symmetrically with respect to the center of the circular portion when viewed from the front.

10. The dimming electronic component as claimed in claim 8, characterized in that, In the laminate, the outer diameter portions of the pair of electrode layers are each parts of a circle with a diameter larger than the circular portion. The outer diameter portions of one side and the outer diameter portions of the other side are arranged symmetrically with respect to the center of the circular portion when viewed from the front.

11. The dimming electronic component according to any one of claims 7 to 10, characterized in that, The dimming electronic element is an electrochromic element that generates reversible changes in the optical physical properties of the dimming layer due to redox reactions by applying a voltage to the electrode layer.

12. An electronic dimming glasses comprising a dimming electronic component as described in any one of claims 7 to 11, characterized in that, The optical element is a lens. The dimming electronic component has: an overlapping region with a shape corresponding to the lens; and two or more terminal regions on the outer side of the overlapping region. The electronic dimming glasses consist of a dimming lens with dimming electronic components located on or inside the lens surface and a lens frame that holds the dimming lens.

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