Packaging process of light control film

Abstract

The application discloses a packaging process of a dimming film, and realizes efficient airtight packaging of the dimming film through precisely set channel cutting, cleaning and sealing and filling steps. The process guarantees packaging precision, improves packaging consistency and reliability, significantly reduces film layer damage risk, and improves product service life and optical performance stability. Compared with the prior art, the technical scheme of the application has obvious progress in packaging efficiency, stability and process safety, and provides a high-performance packaging solution that can be popularized for the dimming film industry.

Description

Technical Field

[0001] This invention relates to the field of film encapsulation technology, and more particularly to an encapsulation process for a dimming film. Background Technology

[0002] As an important component of new display and optical control materials, dimming films have been widely used in recent years in fields such as smart windows, automotive glass, and dimmable display devices.

[0003] With the increasing demand for smart buildings and energy conservation and environmental protection, higher requirements are being placed on dimming films in terms of optical uniformity, response speed, transparency control and service life.

[0004] However, dimming films still face numerous technical challenges in production, packaging, and application, with the reliability and stability of the packaging stage being particularly critical. Traditional dimming film packaging methods suffer from the vulnerability of the film layers to mechanical stress or temperature changes, easily leading to damage to the functional layers or gas infiltration, thus affecting optical performance and lifespan. Furthermore, conventional packaging processes still have shortcomings in precision control, material compatibility, and hermeticity, making it difficult to meet the consistency and reliability requirements of high-performance products. Especially in the processing of micron- or sub-millimeter-level structures, traditional methods struggle to achieve high-precision cutting and consistent packaging, resulting in limited production yield and product stability.

[0005] Meanwhile, existing cleaning and curing processes mostly rely on manual operation or long-term high-temperature treatment, which is inefficient and prone to introducing contamination or stress concentration, posing potential risks to film performance. The market demand for high-performance dimming films is constantly growing, which urgently requires encapsulation processes to not only possess high precision, high airtightness, and high stability, but also to consider mass production capabilities and operational safety.

[0006] Therefore, developing packaging processes that are highly reliable, controllable, and suitable for mass production has become an important direction and research hotspot for current industry technology development.

[0007] Therefore, this invention is proposed. Summary of the Invention

[0008] To address the aforementioned technical problems, this invention provides a dimming film encapsulation process. By precisely controlling channel cutting, cleaning, and sealing filling, a high-airtightness encapsulation of the dimming film is achieved, thereby improving the consistency, reliability, and optical performance stability of the encapsulation. At the same time, it reduces the risk of film damage and meets the requirements of mass production for process precision, efficiency, and safety. This provides a high-performance and widely applicable encapsulation solution for dimming films in applications such as smart windows and dimmable displays.

[0009] In order to achieve the objective of this invention, the following technical solution is adopted: This invention provides a packaging process for a dimming film, comprising the following steps: Obtain a dimming film to be packaged, the dimming film having opposing first and second edges; An infrared laser cutting machine is used to cut a first groove and a second groove spaced apart along the length of the first edge on the surface of the dimming film near the first edge, and a third groove and a fourth groove spaced apart along the length of the second edge on the surface of the dimming film near the second edge. The first channel, the second channel, the third channel, and the fourth channel were cleaned with a cleaning agent and then dried. Insulating sealant is filled into the first channel, the second channel, the third channel and the fourth channel respectively, and then cured to form an airtight encapsulation structure.

[0010] Furthermore, the infrared laser cutting machine has a laser wavelength of 9.3-10.6μm, a laser power of 10-20W, a cutting speed of 100-18mm / s, and coaxially injects auxiliary gas during cutting. The auxiliary gas is nitrogen, and the flow rate is 6-10L / min.

[0011] Furthermore, the interval between the first channel and the second channel is 0.2-0.6 mm, the interval between the third channel and the fourth channel is 0.2-0.6 mm, and the width of the first channel, the second channel, the third channel and the fourth channel is 0.2-0.5 mm.

[0012] Furthermore, the first channel, the second channel, the third channel, and the fourth channel all penetrate the upper film and the functional layer of the dimming film.

[0013] Furthermore, prior to the cleaning step, the cleaning agent is atomized and sprayed onto the surfaces of the first channel, the second channel, the third channel, and the fourth channel using ultrasonic atomization, with an ultrasonic frequency of 0.8-1.5 MHz.

[0014] Furthermore, the curing process involves heating the filled dimming film at 70-110°C for 25-45 minutes.

[0015] Furthermore, by weight, the cleaning agent comprises 100-120 parts deionized water, 2-5 parts tagatose, 0.5-2 parts gentiobiose, and 0.2-0.8 parts calcium gluconate.

[0016] Furthermore, the cleaning agent also includes 0.1-0.5 parts of magnesium citrate.

[0017] Furthermore, the cleaning agent is prepared by adding tagatose and gentiobiose sequentially to deionized water, stirring at 100-200 rpm for 5-10 minutes at 15-25℃, then adding calcium gluconate, continuing to stir until completely dissolved, and adjusting the pH to 5.5-6.5.

[0018] Furthermore, by weight, the insulating sealant comprises 35-55 parts potassium silicate solution, 8-15 parts potassium tetraborate, 3-7 parts aluminum chromium phosphate, and 5-12 parts quartz powder.

[0019] The present invention has the following technical effects: The encapsulation process provided by this invention achieves high hermeticity encapsulation of the dimming film by precisely cutting spaced channels along the edge direction on both sides of the film and filling the channels with insulating sealant. This structure not only ensures precise control during the encapsulation process but also significantly reduces the risk of damage to the film layer caused by mechanical or thermal stress, thereby maintaining the integrity and stability of the functional layers of the dimming film. By rationally designing the channel spacing and width, the sealant is evenly distributed and the structure is stable after curing, greatly improving the reliability of the dimming film during long-term use. Compared with traditional encapsulation processes, the process of this invention shows significant advantages in maintaining optical performance stability and extending product lifespan, providing an effective guarantee for the mass production of high-performance dimming films. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0021] In a first aspect, the present invention provides a packaging process for a dimming film, comprising the following steps: Obtain a dimming film to be packaged, the dimming film having opposing first and second edges; An infrared laser cutting machine is used to cut a first groove and a second groove spaced apart along the length of the first edge on the surface of the dimming film near the first edge, and a third groove and a fourth groove spaced apart along the length of the second edge on the surface of the dimming film near the second edge. The first channel, the second channel, the third channel, and the fourth channel were cleaned with a cleaning agent and then dried. Insulating sealant is filled into the first channel, the second channel, the third channel and the fourth channel respectively, and then cured to form an airtight encapsulation structure.

[0022] In some embodiments, the infrared laser cutting machine has a laser wavelength of 9.3-10.6μm, a laser power of 10-20W, a cutting speed of 100-18mm / s, and coaxially injects auxiliary gas during cutting. The auxiliary gas is nitrogen and the flow rate is 6-10L / min.

[0023] In some embodiments, the first channel and the second channel are spaced 0.2-0.6 mm apart, the third channel and the fourth channel are spaced 0.2-0.6 mm apart, and the width of the first channel, the second channel, the third channel and the fourth channel is 0.2-0.5 mm.

[0024] In some embodiments, the first channel, the second channel, the third channel, and the fourth channel all penetrate the upper film and the functional layer of the dimming film.

[0025] In some embodiments, prior to the cleaning step, the cleaning agent is atomized by ultrasonic atomization and sprayed onto the surfaces of the first channel, the second channel, the third channel, and the fourth channel, with an ultrasonic frequency of 0.8-1.5 MHz.

[0026] In some embodiments, the curing process involves heating the filled dimming film at 70-110°C for 25-45 minutes.

[0027] In some embodiments, the cleaning agent comprises, by weight, 100-120 parts deionized water, 2-5 parts tagatose, 0.5-2 parts gentiobiose, and 0.2-0.8 parts calcium gluconate.

[0028] In some embodiments, the cleaning agent further includes 0.1-0.5 parts of magnesium citrate.

[0029] In some embodiments, the cleaning agent is prepared by adding tagatose and gentiobiose sequentially to deionized water, stirring at 100-200 rpm for 5-10 minutes at 15-25°C, then adding calcium gluconate, continuing to stir until completely dissolved, and adjusting the pH to 5.5-6.5.

[0030] In some embodiments, the insulating sealant comprises, by weight, 35-55 parts potassium silicate solution, 8-15 parts potassium tetraborate, 3-7 parts aluminum chromium phosphate, and 5-12 parts quartz powder.

[0031] Example 1: Dimming Film Encapsulation Process Materials and Equipment Dimming film: Size 200mm × 150mm, thickness 0.5mm; Infrared laser cutting machine: wavelength 9.3μm, power 15W, cutting speed 50mm / s, equipped with a coaxial nitrogen jetting device. Nitrogen gas source: adjustable flow rate, 6-10 L / min, purity 99.99%. Cleaning agent: 1100g of deionized water 30g of tagatose Gentian disaccharide 10g Calcium gluconate 5g 3g magnesium citrate Preparation process: Add 1100g of deionized water to a clean beaker and stir until stable.

[0032] Add 30g of tagatose and 10g of gentiobiose in sequence, stir at 200rpm for 5 minutes at 25℃ to ensure complete dissolution.

[0033] Add 5g of calcium gluconate and continue stirring until well combined.

[0034] Add 3g of magnesium citrate and stir well.

[0035] Use a pH meter to adjust the pH of the solution to 6.

[0036] The solution was checked and found to be free of precipitates and impurities, and is ready for ultrasonic atomization cleaning.

[0037] Insulating sealant: 450g potassium silicate solution 100g potassium tetraborate 50g aluminum chromium phosphate 80g of quartz powder Preparation steps: Add 450g of potassium silicate solution to a clean beaker and stir until well mixed.

[0038] Add 100g of potassium tetraborate and 50g of aluminum chromium phosphate in sequence, and stir until completely dissolved.

[0039] Pre-wet 83g of quartz powder and sift it.

[0040] Add the quartz powder in three batches, stirring at 1000 rpm for 2 minutes after each addition to ensure thorough dispersion.

[0041] If air bubbles appear in the colloid, they can be removed using vacuum degassing or ultrasonic oscillation.

[0042] Once the colloid is checked for uniformity and absence of lumps, it is ready for use in channel filling.

[0043] Step 1: Preparation of dimming film Remove the dimming film in a dust-free environment and check that the surface is free of dust and oil.

[0044] Make sure the first and second edges are clearly marked to facilitate subsequent cutting and filling operations.

[0045] Step 2: Infrared laser cutting of the groove The dimming film is flattened and fixed on the cutting platform.

[0046] Laser cutting parameter settings: Wavelength: 9.3μm Power: 15W Cutting speed: 50mm / s Nitrogen coaxial injection: flow rate 8L / min A first groove and a second groove are cut along the first edge, with a distance of 0.4 mm between the two grooves and a width of 0.3 mm.

[0047] Cut the third and fourth channels along the second edge, with a spacing of 0.4 mm and a width of 0.3 mm.

[0048] Ensure that the four channels run through the upper membrane and functional layer, with no scorching or impurity residue.

[0049] Step 3: Ultrasonic atomization cleaning Place the cleaning agent into the ultrasonic atomizing cleaner at a frequency of 1.0MHz and spray it onto the four channels for 5 minutes.

[0050] Gently blot away any residual liquid with a lint-free cloth to avoid any residue affecting subsequent curing.

[0051] Step 4: Ditch drying Place the dimming film on a drying table and let it air dry naturally for 15 minutes.

[0052] Step 5: Filling with insulating sealant The insulating sealant should be mixed evenly according to the specified weight to ensure that the quartz powder is free of lumps.

[0053] Use a fine dropper or dispensing needle to slowly fill the four channels to prevent air bubbles from forming.

[0054] Smooth the surface, remove excess adhesive, and check if the filling is even.

[0055] Step 6: Curing and Encapsulation Place the dimming film in an oven, set the temperature to 90℃, and cure for 30 minutes.

[0056] After curing, allow it to cool naturally to room temperature.

[0057] Step 7: Packaging Inspection Use a microscope to inspect the filling status of the four channels to ensure that a complete hermetically sealed structure is formed.

[0058] Check that there is no residual cleaning agent or contaminants on the surface of the dimming film.

[0059] Experiment Example 1: Performance Testing and Comparison of Dimming Films Experimental objective: To verify the encapsulation performance and optical function of the dimming film prepared in Example 1.

[0060] Experimental materials and equipment Experimental materials: Experimental group: The dimming film prepared in Example 1; Control group: Dimming film encapsulated with traditional sealant; Experimental steps Step 1: Surface Inspection The surfaces of the dimming films in both the experimental and control groups prepared in Example 1 were observed using a microscope. Record the integrity of the hermetically sealed packaging, the filling condition of the channels, and the surface smoothness.

[0061] Take a photo for record-keeping.

[0062] Step 2: Air tightness test The dimming films of the experimental group and the control group were fixed on the micro-sealed cavity respectively.

[0063] A miniature air pump is used to inflate the cavity.

[0064] Apply a small amount of soapy water to the four grooves where the sealant is applied, and observe the formation of bubbles: No bubbles: Good airtightness Bubbles: Leakage Record the results.

[0065] Step 3: Optical transmittance test Place the dimming film in front of the light source in the dark box.

[0066] OFF state: Measure the intensity of transmitted light (unit: lux) when the power is off and the dimming is not adjusted. Repeat 3 times and take the average value.

[0067] ON state: After powering on and adjusting the light intensity, measure the intensity of transmitted light, repeat 3 times and take the average value.

[0068] Calculate the dimming ratio.

[0069] Step 4: Dimming Response Speed Record using a stopwatch: Time required to switch from OFF to ON (increased) Time required to switch ON to OFF (reduced) Repeat 3 times and take the average.

[0070] Step 5: Durability and Appearance Gently wipe the surface with a lint-free cloth and observe whether the sealant is peeling or cracked.

[0071] Place at room temperature for 7 days, then repeat steps 3 and 4 to check the stability of optical performance.

[0072] The final experimental results are shown in Table 1 below.

[0073] Table 1 Experimental Results In this experiment, the dimming film prepared in Example 1 showed significant differences from the conventionally packaged dimming film in the control group in terms of airtightness, optical performance, dimming response speed, and durability. From the airtightness test, the insulating sealant filling the four channels of the dimming film in Example 1 showed a highly uniform and sufficient distribution, with no visible bubbles or leaks. This indicates that its encapsulation structure forms a complete airtight protective layer, effectively preventing external moisture or air from entering the functional layer of the dimming film. In contrast, although the control group used sealant for encapsulation, it exhibited obvious localized air leakage. The difference in airtightness directly affects the optical stability and long-term performance of the dimming film; therefore, Example 1 has a significant advantage in this aspect.

[0074] In terms of optical performance, the transmittance of the dimming film in Example 1 was 12% in the OFF state and reached 62% in the ON state, with a dimming ratio of 417%. In contrast, the transmittance of the control group increased from 12% to 55%, with a dimming ratio of 358%. Numerically, Example 1 showed a significant improvement in dimming ratio. This is mainly due to the encapsulating adhesive uniformly filling the four channels, forming a smooth and stable insulating layer, avoiding optical interference and scattering. Simultaneously, the uniform dispersion of quartz powder ensured the consistency of the colloid's refractive index, thereby improving the uniformity of light transmission and the dimming amplitude. In the control group, the insufficient dispersion of quartz powder in the colloid led to uneven density in some areas of the adhesive layer, causing slight scattering of light as it passed through the encapsulation layer, weakening the optical dimming effect and resulting in a slightly lower dimming ratio than Example 1.

[0075] Regarding the dimming response speed, the dimming film in Example 1 had dimming up and down times of 2.3 seconds and 2.1 seconds, respectively, while the control group had a slightly slower response time of 2.8 seconds for dimming up and 2.5 seconds for dimming down. The reason for the fast response of Example 1 is that its adhesive layer structure is flat and the sealant is tightly bonded to the dimming functional layer, reducing dielectric resistance and allowing the liquid crystal or dimming functional layer to respond quickly to changes in the electric field. In contrast, the control group had uneven adhesive layer distribution, with some areas having excessive adhesive layer thickness or internal micro-gaps, resulting in slight disturbances in the electric field distribution and thus slightly prolonging the response time.

[0076] Durability tests showed that after 7 days of storage at room temperature, Example 1 exhibited almost no significant changes in transmittance and dimming ratio, maintained excellent airtightness, and had a smooth surface without cracks or peeling, indicating that its encapsulation structure possesses good stability and reliability during long-term use. In contrast, while the control group maintained overall functionality under the same conditions, occasional micro-bubbles and slight peeling of the adhesive layer were observed, indicating that its encapsulation uniformity and long-term airtightness were inferior to Example 1. Overall, Example 1 outperformed the control group in all performance indicators. Its superior performance is attributed to the highly uniformly dispersed quartz powder, precisely controlled channel filling, and airtight encapsulation process, thereby ensuring the significant advantages of the dimming film in terms of optical performance, response speed, and durability.

[0077] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the technical solutions of the embodiments of the present invention.

Claims

1. A packaging process for a dimming film, characterized in that, Includes the following steps: Obtain a dimming film to be packaged, the dimming film having opposing first and second edges; An infrared laser cutting machine is used to cut a first groove and a second groove spaced apart along the length of the first edge on the surface of the dimming film near the first edge, and a third groove and a fourth groove spaced apart along the length of the second edge on the surface of the dimming film near the second edge. The first channel, the second channel, the third channel, and the fourth channel were cleaned with a cleaning agent and then dried. Insulating sealant is filled into the first channel, the second channel, the third channel and the fourth channel respectively, and then cured to form an airtight encapsulation structure.

2. The packaging process according to claim 1, characterized in that, The infrared laser cutting machine has a laser wavelength of 9.3-10.6μm, a laser power of 10-20W, a cutting speed of 100-180mm / s, and coaxially injects auxiliary gas during cutting. The auxiliary gas is nitrogen, and the flow rate is 6-10L / min.

3. The packaging process according to claim 1, characterized in that, The first channel and the second channel are spaced 0.2-0.6 mm apart, the third channel and the fourth channel are spaced 0.2-0.6 mm apart, and the width of the first channel, the second channel, the third channel and the fourth channel is 0.2-0.5 mm.

4. The packaging process according to claim 1, characterized in that, The first channel, the second channel, the third channel, and the fourth channel all penetrate the upper film and the functional layer of the dimming film.

5. The packaging process according to claim 1, characterized in that, Before the cleaning step, the cleaning agent is atomized and sprayed onto the surfaces of the first channel, the second channel, the third channel and the fourth channel using ultrasonic atomization, with an ultrasonic frequency of 0.8-1.5 MHz.

6. The packaging process according to claim 1, characterized in that, The curing process involves heating the filled dimming film at 70-110°C for 25-45 minutes.

7. The packaging process according to claim 1, characterized in that, The cleaning agent comprises, by weight, 100-120 parts deionized water, 2-5 parts tagatose, 0.5-2 parts gentiobiose, and 0.2-0.8 parts calcium gluconate.

8. The packaging process according to claim 7, characterized in that, The cleaning agent also includes 0.1-0.5 parts of magnesium citrate.

9. The packaging process according to claim 7, characterized in that, The cleaning agent is prepared by adding tagatose and gentiobiose sequentially to deionized water, stirring at 100-200 rpm for 5-10 minutes at 15-25℃, then adding calcium gluconate and continuing to stir until completely dissolved, and adjusting the pH to 5.5-6.

5.

10. The packaging process according to claim 1, characterized in that, The insulating sealant comprises, by weight, 35-55 parts potassium silicate solution, 8-15 parts potassium tetraborate, 3-7 parts aluminum chromium phosphate, and 5-12 parts quartz powder.

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