Functional film and laminated glass product

Abstract

The utility model relates to a functional film and a laminated glass product. The functional thin film comprises a first carrier thin film, a first electrode layer, a functional layer, a second electrode layer and a second carrier thin film which are sequentially arranged, the edge of the first carrier thin film is connected to the edge of the second carrier thin film through edge sealing, so that an active area of the functional layer is packaged in a central area, and in the central area, the first electrode layer is connected with the second electrode layer. The first electrode layer is provided with at least one first bus bar and at least one first isolation region which is electrically insulated from the remainder of the first electrode layer, and the second electrode layer is provided with at least one second bus bar and at least one second isolation region which is electrically insulated from the remainder of the second electrode layer, the first bus bar is positioned to at least partially overlap the second isolation region, and the second bus bar is positioned to at least partially overlap the first isolation region. The manufacturing process of the functional film is simple and rapid, and the obtained whole structure is firm and low in cost.

Description

Technical Field

[0001] This utility model relates to the field of smart glass technology. More specifically, this utility model relates to a functional film and a laminated glass article including such a functional film. Background Technology

[0002] PDLC (Polymer Dispersed Liquid Crystal) films are thin films whose light transmission state can be adjusted. They primarily operate between a scattering state and a transparent state; that is, the film itself can switch between a transparent and an opaque state (visually similar to frosted glass), with transparency adjusted by voltage. The general working principle of PDLC films is as follows: when power is off, the central polymer liquid crystal material is disordered, preventing light from passing through the film, resulting in a milky white, opaque state. When power is applied, the polymer liquid crystal material aligns in an ordered manner under the influence of the electric field, allowing light to pass through the film, resulting in a transparent and colorless state.

[0003] Figure 1 This is a schematic diagram of the layered structure of a traditional PDLC thin film 100. (Example) Figure 1 As shown, the PDLC film 100 includes two carrier films 101, two electrode layers 102, and a polymer layer 103 stacked sequentially from the outside to the inside. The carrier films 101 are, for example, PET (polyethylene terephthalate) films or other similar polymer films, the electrode layers 102 are typically ITO (indium tin oxide) layers, and the liquid crystal 104 is dispersed in the intermediate polymer layer 103.

[0004] Figure 2 This is a schematic diagram of the layer structure of a laminated glass product 200 with the aforementioned PDLC film 100. For example... Figure 2 As shown, the laminated glass product 200 includes two glass sheets 201, two adhesive layers 202, and a PDLC film 100 stacked sequentially from the outside to the inside. This allows the laminated glass product 200 to achieve a variable transparency effect by switching between a transparent and colorless state and an opaque state using the PDLC film 100. For example, when this laminated glass product 200 is used in automobiles, when the outside temperature is too high, adjusting the PDLC film 100 to an opaque state can achieve a better heat insulation effect, ensuring a relatively cool interior.

[0005] For the PDLC film 100, a busbar needs to be provided on the electrode layer 102. This busbar needs to be connected to a power source via an external connector to supply power to the electrode layer 102. Therefore, in the prior art, the PDLC film 100 typically needs to be cut, for example, removing a portion of the carrier film 101 and the electrode layer 102 located on one side of the polymer layer 103, and removing a corresponding portion of the polymer layer 103. After cleaning the exposed polymer layer 103 and sealing the edges with adhesive, the busbar can be applied to another electrode layer 102. The busbar is typically made of conductive materials such as conductive ink / paste, solder, or metal contacts with conductive adhesive applied, and is connected to the vehicle control unit via connectors such as wires, flat connectors, or metal foil cables.

[0006] The drawback of the existing technology is that the manufacturing steps for applying busbars to the electrode layer 102 in order to power the PDLC film 100 are very cumbersome and labor-intensive. These steps must be performed sequentially because they are interdependent and cannot be processed in parallel. Furthermore, some of these process steps require additional materials, which is not only costly but also significantly increases the manufacturing workload. In particular, adhesives are needed to seal the edges of the cut areas to protect the PDLC material exposed after cutting. Only in areas where no cutting has been performed can more robust edge-sealing processes, such as welding, be used. Moreover, after cutting, suitable manufacturing processes are required to apply the busbars / conductive tracks, which are relatively inefficient. Utility Model Content

[0007] The purpose of this invention is to provide a functional film to overcome at least one defect in the prior art. More specifically, the functional film according to this invention has a simple and rapid manufacturing process, and the resulting overall structure is robust and low-cost.

[0008] To this end, a first aspect of the present invention provides a functional thin film, comprising a first carrier film, a first electrode layer, a functional layer, a second electrode layer, and a second carrier film arranged sequentially, wherein the edge of the first carrier film is connected to the edge of the second carrier film by an edge seal to encapsulate the active region of the functional layer within a central region, wherein within the central region, the first electrode layer is provided with at least one first busbar and at least one first isolation region electrically insulated from the remainder of the first electrode layer, and the second electrode layer is provided with at least one second busbar and at least one second isolation region electrically insulated from the remainder of the second electrode layer, wherein the first busbar is positioned to at least partially overlap with the second isolation region, and the second busbar is positioned to at least partially overlap with the first isolation region.

[0009] Based on the above-described technical concept, this utility model may further include any one or more of the following optional forms.

[0010] In some alternative configurations, the first busbar is connected to the connector via a first crimp extending through the first carrier film, the first electrode layer, the first busbar, the functional layer, the second isolation region on the second electrode layer, and the second carrier film, and the second busbar is connected to the connector via a second crimp extending through the second carrier film, the second electrode layer, the second busbar, the functional layer, the first isolation region on the first electrode layer, and the first carrier film.

[0011] In some alternative forms, the at least one first busbar is printed on the first electrode layer, and the at least one second busbar is printed on the second electrode layer.

[0012] In some alternative forms, the first electrode layer is divided into multiple segments by separator lines, and the first electrode layer is provided with multiple first busbars, wherein each of the multiple first busbars is located within a corresponding segment of the multiple segments.

[0013] In some alternative configurations, the second electrode layer is provided with a single second isolation region, wherein each of the plurality of first buses is positioned to at least partially overlap with the second isolation region.

[0014] In some alternative configurations, the second electrode layer is provided with a plurality of second isolation regions, wherein each of the plurality of first busbars is positioned to at least partially overlap with a corresponding second isolation region among the plurality of second isolation regions.

[0015] In some alternative forms, the first crimp and the second crimp pass through the first carrier film and the second carrier film, respectively, at the entry point, wherein an edge sealing material is positioned at the entry point.

[0016] In some alternative forms, the edge seal includes the fusion of the entire edge of the first carrier film with the entire edge of the second carrier film.

[0017] In some alternative forms, the edge sealing includes applying an edge sealing material that covers the entire edge of the functional layer.

[0018] The second aspect of this utility model provides a laminated glass article, comprising a first glass sheet, a first adhesive layer, a functional film according to the first aspect of this utility model, a second adhesive layer, and a second glass sheet arranged sequentially.

[0019] The functional film of this invention has several beneficial technical effects, especially: compared with the prior art, the manufacturing steps of the functional film of this invention are simple and efficient; more specifically, the functional film of this invention does not require the cutting, material removal (exposing the functional layer), functional layer cleaning, edge sealing with adhesive, printing busbars / conductive tracks and subsequent curing steps of the prior art. This eliminates high-risk manufacturing processes that are very easy to damage the functional layer (such as cutting, edge sealing with adhesive, etc.), and not only saves manufacturing steps, but also saves the required additional materials (such as adhesives for edge sealing, cleaning materials for removing polymers, solvents for removing polymers, etc.), thereby saving costs; after the functional film is manufactured, for example, the busbars on the electrode layer can be directly contacted with the external connectors through a strong mechanical pressing process without any preparation steps, and a strong sealing process such as welding can be performed on the entire edge. Attached Figure Description

[0020] Other features and advantages of this invention will be better understood through the following detailed description of preferred embodiments in conjunction with the accompanying drawings, in which the same reference numerals denote the same or similar parts.

[0021] Figure 1 This is a schematic diagram of the layered structure of a traditional PDLC thin film.

[0022] Figure 2 This is a schematic diagram of the layered structure of a laminated glass product with a PDLC film.

[0023] Figure 3A This is a schematic diagram of a first roll formed by sequentially arranging multiple first components of functional films according to embodiments of the present invention.

[0024] Figure 3B yes Figure 3A A plan view of a single first component of the first volume is shown.

[0025] Figure 4A This is a schematic diagram of a second roll consisting of a plurality of second components of functional films according to embodiments of the present invention arranged in sequence.

[0026] Figure 4B yes Figure 4A A plan view of a single second component of the second volume shown.

[0027] Figure 5 It is Figure 3A The first roll of lamination shown is in Figure 4A The diagram shows the lamination process on the second volume.

[0028] Figure 6A It is Figure 3A The first roll of lamination shown is in Figure 4A The diagram shows a roll-shaped laminated product formed after the second roll.

[0029] Figure 6B yes Figure 6A The diagram shows a plan view of a single functional film comprising a single first component and a single second component of a roll-type laminated product, wherein a connector is shown pressed onto the functional film.

[0030] It should be understood that the various components in the accompanying drawings are shown for simplicity and clarity and are not necessarily drawn to precise scale or shape. The drawings are not only used for explanation and illustration of this utility model, but also, when necessary, to limit this utility model. Detailed Implementation

[0031] The implementation and use of the embodiments are discussed in detail below. However, it should be understood that the specific embodiments discussed are merely illustrative of specific ways of implementing and using this utility model, and are not intended to limit the scope of protection of this utility model. It is understood that the terms "first," "second," etc., in this utility model are used to describe various elements without intending to limit the positional relationship, temporal relationship, or importance relationship of these elements; such terms are only used to distinguish one element from another.

[0032] The layered structure of the functional thin film according to this invention is similar to... Figure 1 The layered structure of the PDLC thin film 100 shown is illustrated. More specifically, the functional thin film according to this invention includes a first carrier film, a first electrode layer, a functional layer, a second electrode layer, and a second carrier film arranged sequentially. That is, the first electrode layer is applied to the surface of the first carrier film oriented toward the functional layer to form a layer as shown in the diagram. Figure 3A and Figure 3B The first component 300, which is generally rectangular as shown, has a second electrode layer applied to the surface of the second carrier film oriented toward the functional layer to form a shape as shown. Figure 4A and Figure 4B The second component 400 is shown to be generally rectangular, and a functional layer is positioned between the first electrode layer of the first component 300 and the second electrode layer of the second component 400. The first and second carrier films are, for example, PET films or other similar polymer films, the first and second electrode layers are typically ITO layers, and the intermediate functional layer is a polymer layer with dispersed liquid crystal. It is understood that the shapes of the first component 300 and the second component 400 are not limited to the generally rectangular shape shown, but can be any other suitable shape.

[0033] To facilitate mass production, it is possible to first manufacture, for example... Figure 3A The first roll R1, which is composed of multiple first components 300 arranged sequentially, and as shown, Figure 4AThe second roll R2 shown is composed of multiple second components 400 arranged sequentially (both the first roll R1 and the second roll R2 are made of single-sheet material). For example... Figure 5 The method shown involves laminating the manufactured first roll R1 and second roll R2, along with the functional layer placed between them, to obtain the desired result. Figure 6A The roll-shaped laminated product R3 shown is then cut to obtain a generally rectangular single functional film 500 consisting of a single first component 300, a single second component 400, and an intermediate functional layer. For the single functional film 500, the entire edge of the first carrier film of the first component 300 is connected to the entire edge of the second carrier film of the second component 400 via an edge seal ES. This allows the active region of the functional layer to be encapsulated within a central region confined by the edge seal ES, protecting the functional layer from contaminants that could cause functional loss.

[0034] As mentioned above, the main working principle of the functional film 500 is as follows: when the functional film 500 is de-energized, the polymer liquid crystal material of the functional layer is disordered, making it impossible for light to penetrate the film, and the effect seen is a milky white opaque state; when the functional film 500 is energized, the polymer liquid crystal material under the action of the electric field is ordered, allowing light to pass through the film, and the effect seen is a transparent and colorless state.

[0035] According to the present invention, in the central region of the functional thin film 500, the first electrode layer of the first component 300 is provided with at least one first busbar and at least one first isolation region electrically insulated from the rest of the first electrode layer, and the second electrode layer of the second component 400 is provided with at least one second busbar and at least one second isolation region that is non-conductive and electrically insulated from the rest of the second electrode layer, wherein, in the lamination direction, the first busbar is positioned to at least partially overlap with the second isolation region on the second electrode layer, and the second busbar is positioned to at least partially overlap with the first isolation region on the first electrode layer.

[0036] More specifically, such as Figure 3BAs shown, the first electrode layer of the first component 300 is divided into multiple segments by separator lines SL, namely, the first segment 301, the second segment 302, and the third segment 303 shown as separated from each other. In this specification, "separator line" refers to a line where electrode material has been removed. For example, separator lines separating the different parts of the electrode layer can be provided by laser removal of the electrode layer, allowing for independent electrical control of these parts. The first electrode layer is correspondingly provided with three first busbars positioned within these three segments: a first busbar 305 positioned in the first segment 301, another first busbar 306 positioned in the second segment 302, and yet another first busbar 307 positioned in the third segment 303. These three first busbars 305, 306, and 307 are applied, for example, by printing within the corresponding segments of the first electrode layer. This configuration allows the transparency of the functional film 500 to be controlled segmentally, thereby obtaining a wider variety of varying transparency effects. Furthermore, as... Figure 3B As shown, the first electrode layer has a first isolation region 304 defined by the dividing line SL and independent of the three segments mentioned above. In this specification, "isolation region" refers to the area on the electrode layer surrounded by the dividing line SL, which is electrically isolated from the rest of the electrode layer. Optionally, the isolation region may also be completely non-conductive, for example, where electrode material has been completely removed (including laser removal as described above). It is understood that if multiple segments exist on opposing electrode layers, the isolation region may include multiple separated regions (each region opposite a busbar within one of the segments); if only one isolation region is provided to be opposite multiple busbars, then that isolation region should be completely non-conductive.

[0037] like Figure 4B As shown, the second electrode layer of the second component 400 is provided with a second busbar 404, which is positioned in the lamination direction at a location on the second electrode layer that at least partially overlaps with the first isolation region 304. The second busbar 404 is applied to the second electrode layer, for example, by printing. Furthermore, as... Figure 4B As shown, the second electrode layer is provided with three independent second isolation regions 401, 402, and 403, which are defined by the dividing line SL. The three first busbars 305, 306, and 307 are respectively positioned in the lamination direction at positions on the first electrode layer that at least partially overlap with the corresponding second isolation regions 401, 402, and 403.

[0038] In this embodiment, in such Figure 6BIn the plan view, the second busbar 404 is positioned to fall entirely within the first isolation region 304, while the end portions of the three first busbars 305, 306, and 307 are positioned to fall within the three second isolation regions 401, 402, and 403, respectively. According to one embodiment, the second busbar 404 may be positioned such that only the end portions fall within the first isolation region 304 in this plan view, and / or, one or more of the three first busbars 305, 306, and 307 may be positioned to fall entirely within the corresponding second isolation regions 401, 402, and 403. Furthermore, according to another embodiment, the second electrode layer may have only a single second isolation region, and each of the three first busbars 305, 306, and 307 is positioned in the lamination direction at a position on the first electrode layer that at least partially overlaps with the single second isolation region.

[0039] Based on the above construction, such as Figure 6B As shown, to supply power to the first busbars 305, 306, 307 and the second busbar 404, each of the first busbars 305, 306, 307 can be connected to the external connector 600 via a first crimp that extends sequentially through the first carrier film, the first electrode layer, the first busbar 305, 306, 307, the functional layer, the corresponding second isolation regions 401, 402, 403 on the second electrode layer, and the second carrier film. Similarly, the second busbar 404 can be connected to the connector 600 via a second crimp that extends sequentially through the second carrier film, the second electrode layer, the second busbar 404, the functional layer, the first isolation region 304 on the first electrode layer, and the first carrier film. It is understood that the direction of the first crimp can be opposite to the above description, and / or the direction of the second crimp can also be opposite to the above description. For example, the first crimp and the second crimp can be performed from the same side of the functional film. That is, while performing the first crimp in the above direction, the second busbar 404 is connected to the connector 600 by the second crimp extending sequentially through the first carrier film, the first isolation region 304 on the first electrode layer, the functional layer, the second busbar 404, the second electrode layer and the second carrier film. Figure 6B The diagram schematically illustrates four conductive tracks 601 of the connector 600, which are respectively connected to the first busbars 305, 306, 307, and the second busbar 404, and four crimping points CC located at the ends of these four conductive tracks 601. Since the first crimp and the second crimp need to pass through the first carrier film and the second carrier film respectively at their respective entry points, the edge sealing material is preferably positioned at these entry points.

[0040] In some embodiments, the edge sealing ES includes fusing the entire edge of the first carrier film of the first component 300 with the entire edge of the second carrier film of the second component 400, i.e., connecting the entire edge of the first carrier film to the entire edge of the second carrier film by welding. In other embodiments, the edge sealing ES includes applying an edge sealing material along the entire edge of the first carrier film and the entire edge of the second carrier film, such that the edge sealing material covers the entire edge of the functional layer.

[0041] In some embodiments, the present invention also provides, for example, a laminated glass article for automobiles. Figure 2 The laminated glass article 200 shown has a similar layered structure. According to this invention, the laminated glass article includes the first glass sheet, the first adhesive layer, the functional film 500 as described above, the second adhesive layer, and the second glass sheet. Specifically, the first glass sheet is bonded to the first surface of the functional film 500 via the first adhesive layer, and the second glass sheet is bonded to the second surface of the functional film 500, oriented opposite to the first surface, via the second adhesive layer. Furthermore, the size of the functional film 500 may be smaller than the size of the first and second glass sheets, and a third adhesive layer with a thickness substantially the same as the functional film 500 may be arranged around the functional film 500 and extend to the edge of the glass sheet. The laminated glass article according to this invention can achieve a variable transparency effect by switching between a transparent / colorless state and an opaque state through the functional film 500.

[0042] The steps of the manufacturing method of the above-mentioned functional thin film 500 are briefly described below.

[0043] First, a first electrode layer is applied to a first carrier film to form a first component 300, and three segments 301, 302, 303, a first isolation region 304, and three first busbars 305, 306, and 307 are formed on the first electrode layer. Then, a second electrode layer is applied to a second carrier film to form a second component 400, and three second isolation regions 401, 402, 403 and a second busbar 404 are formed on the second electrode layer. As mentioned earlier, for ease of mass production, it is possible to manufacture as follows: Figure 3A The first roll R1, which is composed of multiple first components 300 arranged sequentially, and as shown, Figure 4AThe second roll R2, shown, is composed of multiple second components 400 arranged sequentially. Preferably, the first busbars 305, 306, and 307 are printed on the first electrode layer, and the second busbar 404 is printed on the second electrode layer, respectively, using a roll-to-roll printing process. Thus, by using a roll-to-roll printing process commonly used in the electronics industry, the busbars / conductive tracks can be applied to the first component 300 and the second component 400 before lamination with the functional layers, significantly improving manufacturing efficiency compared to existing methods. The roll-to-roll printing process is ideal here because the printing performed on the first roll R1 and the second roll R2 is repeated at fixed time intervals, and curing can be performed immediately after printing, for example, using ultraviolet light or heat input. Furthermore, the step of setting the separator lines SL and isolation areas, for example, using a laser, can be performed before or after the aforementioned printing steps.

[0044] Then, a functional layer is placed (e.g., coated) between the first roll R1 and the second roll R2 and lamination is performed to obtain, as shown below. Figure 6A The roll-laminated product R3 is shown. For each functional film 500 of the roll-laminated product R3, edge sealing is preferably achieved by welding the entire edge of the first carrier film to the entire edge of the second carrier film.

[0045] Finally, for each functional film 500 of the roll-laminated product R3, the first busbars 305, 306, and 307 can be mechanically and electrically connected to the corresponding conductive tracks 601 of the connector 600 by a first mechanical crimp extending through the second isolation regions 401, 402, and 403 on the first carrier film, the first electrode layer, and the second electrode layer, and the second carrier film. Furthermore, the second busbar 404 can be mechanically and electrically connected to the corresponding conductive track 601 of the connector 600 by a second mechanical crimp extending through the first isolation region 304 on the second electrode layer and the first carrier film. Since the crimping process penetrates the entire functional film 500, the provision of the first isolation region 304 and the second isolation regions 401, 402, and 403 prevents short circuits between the first and second electrode layers after crimping, thus avoiding failure of the functional film 500. Similarly, before implementing edge sealing by welding, it is also necessary to laser-remove, for example, the entire edge of the first electrode layer and / or the entire edge of the second electrode layer, to make the entire edge of the first electrode layer and / or the entire edge of the second electrode layer non-conductive, thereby preventing a short circuit between the first and second electrode layers after welding. Of course, this step can also be completed in the same process step of preparing the above-mentioned multiple segments and isolation regions (see reference). Figure 6B Edge seal (ES) in the middle.

[0046] The technical content and features of this utility model have been disclosed above. However, it is understood that under the creative concept of this utility model, those skilled in the art can make various changes and improvements to the above-disclosed concept, but all of them fall within the protection scope of this utility model.

[0047] The above description of the embodiments is illustrative and not restrictive, and the scope of protection of this utility model is determined by the claims.

Claims

1. A functional thin film, comprising a first carrier thin film, a first electrode layer, a functional layer, a second electrode layer, and a second carrier thin film arranged sequentially. Its features are, The entire edge of the first carrier film is connected to the entire edge of the second carrier film via an edge seal to encapsulate the active region of the functional layer within the central region. Within the central region, the first electrode layer is provided with at least one first busbar and at least one first isolation region electrically insulated from the rest of the first electrode layer, and the second electrode layer is provided with at least one second busbar and at least one second isolation region electrically insulated from the rest of the second electrode layer. Wherein, the first busbar is positioned to at least partially overlap with the second isolation area, and the second busbar is positioned to at least partially overlap with the first isolation area.

2. The functional thin film according to claim 1, characterized in that, The first busbar is connected to the connector via a first crimp extending through the first carrier film, the first electrode layer, the first busbar, the functional layer, the second isolation region on the second electrode layer, and the second carrier film, and the second busbar is connected to the connector via a second crimp extending through the second carrier film, the second electrode layer, the second busbar, the functional layer, the first isolation region on the first electrode layer, and the first carrier film.

3. The functional thin film according to claim 1 or 2, characterized in that, The at least one first busbar is printed on the first electrode layer, and the at least one second busbar is printed on the second electrode layer.

4. The functional thin film according to claim 1 or 2, characterized in that, The first electrode layer is divided into multiple segments by dividing lines, and the first electrode layer is provided with multiple first busbars, wherein each of the multiple first busbars is located in a corresponding segment of the multiple segments.

5. The functional thin film according to claim 4, characterized in that, The second electrode layer is provided with a single second isolation region, wherein each of the plurality of first busbars is positioned to at least partially overlap with the second isolation region.

6. The functional thin film according to claim 4, characterized in that, The second electrode layer is provided with a plurality of second isolation regions, wherein each of the plurality of first busbars is positioned to at least partially overlap with a corresponding second isolation region among the plurality of second isolation regions.

7. The functional thin film according to claim 1 or 2, characterized in that, The first crimp and the second crimp pass through the first carrier film and the second carrier film respectively at the entry point, wherein the edge sealing material is positioned at the entry point.

8. The functional thin film according to claim 1 or 2, characterized in that, The edge seal includes the fusion of the entire edge of the first carrier film with the entire edge of the second carrier film.

9. The functional thin film according to claim 1 or 2, characterized in that, The edge sealing includes applying an edge sealing material that covers the entire edge of the functional layer.

10. A laminated glass article comprising a first glass sheet, a first adhesive layer, a functional film according to any one of claims 1 to 9, a second adhesive layer, and a second glass sheet arranged sequentially.

Images