Laminate for dimming sheet and method for manufacturing the same

Abstract

To provide a laminate for a dimming sheet and a method for manufacturing the laminate for a dimming sheet, the laminate enabling improvement in the productivity of the dimming sheet.SOLUTION: A laminate 10 for a dimming sheet includes: two transparent electrode films; and a liquid-crystal holding layer sandwiched between the transparent electrode films. The transparent electrode films include transparent electrode layers forming a dimming sheet 20, and the liquid-crystal holding layer includes a dimming layer forming the dimming sheet. The transparent electrode films include a plurality of isolated cut marks 15M detectable by visual inspection, and the plurality of cut marks 15M are arranged so that the outer edge of the dimming sheet 20 is identified on the basis of relative positions between the cut marks 15M.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a laminate for a light controlling sheet and a method for manufacturing a laminate for a light controlling sheet. [Background technology]

[0002] The light-controlling sheet comprises a light-controlling layer between two transparent electrode films. The light-controlling layer comprises an ionizing radiation-curable resin layer that defines a plurality of voids, and a liquid crystal composition that fills the voids. Changing the voltage between the transparent electrode films changes the alignment state of the liquid crystal compound. Changing the alignment state of the liquid crystal compound changes the degree of scattering at the interface between the ionizing radiation-curable resin layer and the liquid crystal composition, thereby changing the transparency of the light-controlling sheet (see, for example, Patent Documents 1 and 2). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2022-148343 [Patent Document 2] Japanese Patent Publication No. 2022-098845 Summary of the Invention [Problem to be solved by the invention]

[0004] The outer edge of the light-controlling sheet has various shapes depending on the specifications of the light-controlling sheet. For example, if the light-controlling sheet allows for divided driving, the outer edge of the light-controlling sheet has a shape that includes a transparent electrode layer arranged in one part of the light-controlling range and a transparent electrode layer arranged in another part of the light-controlling range. If the light-controlling sheet is coated with a sealant around its periphery, the outer edge of the light-controlling sheet has a shape that leaves a space required for the sealant.

[0005] Meanwhile, the manufacturing process of light-controlling sheets includes cutting the light-controlling sheet from a base sheet. The process of cutting the light-controlling sheet involves forming the outer edge of the above-mentioned light-controlling sheet by cutting the base sheet. In this process, the outer edge of the light-controlling sheet has various shapes depending on specifications, etc., so cutting the base sheet also requires setting various cutting positions according to specifications, etc. However, because it is difficult to determine the specifications of the light-controlling sheet from the appearance of the base sheet, the burden required to set the cutting position reduces the production of light-controlling sheets. [Means for solving the problem]

[0006] A laminate for a light-adjusting sheet to solve the above problem is a laminate for a light-adjusting sheet from which a light-adjusting sheet is cut out, and comprises two transparent electrode films and a liquid crystal retention layer sandwiched between the transparent electrode films, wherein the transparent electrode films comprise the transparent electrode layer that constitutes the light-adjusting sheet, and the liquid crystal retention layer comprises the light-adjusting layer that constitutes the light-adjusting sheet, and the transparent electrode films have a plurality of isolated cut marks that can be detected by visual observation, and the multiple cut marks are arranged so that the outer edge of the light-adjusting sheet can be identified based on the relative position of one of the cut marks to the other cut marks.

[0007] A laminate for a light-adjusting sheet to solve the above problem is a laminate for a light-adjusting sheet from which a light-adjusting sheet is cut out, and comprises two transparent electrode films and a liquid crystal retention layer sandwiched between the transparent electrode films, wherein the transparent electrode films comprise the transparent electrode layer that constitutes the light-adjusting sheet, and the liquid crystal retention layer comprises the light-adjusting layer that constitutes the light-adjusting sheet, and the transparent electrode films have isolated cut marks that can be detected by visual observation, and the cut marks are positioned so that the outer edge of the light-adjusting sheet can be identified based on the relative position of the cut marks with respect to the laminate for the light-adjusting sheet.

[0008] A manufacturing method for a laminate for a light-controlling sheet to solve the above problem is a manufacturing method for a laminate for a light-controlling sheet from which a light-controlling sheet is cut out, which includes forming a liquid crystal retention layer sandwiched between two transparent electrode films, wherein the transparent electrode film comprises a transparent electrode layer that constitutes the light-controlling sheet, and the liquid crystal retention layer comprises a light-control layer that constitutes the light-controlling sheet, and further includes forming a plurality of isolated cut marks on the transparent electrode film that are detected by visual observation, so that the outer edge of the light-controlling sheet can be identified based on the relative position of one cut mark to another cut mark.

[0009] A manufacturing method for a laminate for a light-controlling sheet to solve the above problem is a manufacturing method for a laminate for a light-controlling sheet from which a light-controlling sheet is cut out, which includes forming a liquid crystal retention layer sandwiched between two transparent electrode films, wherein the transparent electrode film comprises a transparent electrode layer that constitutes the light-controlling sheet, and the liquid crystal retention layer comprises a light-control layer that constitutes the light-controlling sheet, and further includes forming a plurality of isolated cut marks on the transparent electrode film that are detected by external observation, so that the outer edge of the light-controlling sheet can be identified based on the relative position of the cut mark with respect to the laminate for the light-controlling sheet.

[0010] According to each of the above configurations, the outer edge of the light controlling sheet can be identified in the light controlling sheet laminate by detecting the cut mark, which reduces the load required to set the cutting position and increases the productivity of the light controlling sheet.

[0011] The laminate for the light-adjusting sheet is a roll from which a plurality of the light-adjusting sheets are cut out, and the transparent electrode film comprises a transparent substrate that forms the outer surface of the transparent electrode film, and a conductive layer that is supported by the transparent substrate and includes the transparent electrode layer, and the conductive layer may comprise the cut mark and a plurality of the transparent electrode layers that are separated from each other within the outer edge specified by the cut mark.

[0012] According to the above configuration, since the cut marks are provided inside the laminate for the light controlling sheet, chipping or peeling of the cut marks due to physical or chemical contact is suppressed. Furthermore, it is possible to simultaneously perform the process of forming the plurality of transparent electrode layers from the conductive layer and the process of forming the cut marks from the conductive layer.

[0013] In the laminate for the light controlling sheet, the transparent electrode film may have an inner surface that contacts the liquid crystal retention layer, and the cut mark may be printed on the outer surface of the transparent electrode film. With this configuration, the cut mark can be easily detected.

[0014] In the laminate for the light controlling sheet, the transparent electrode film may include a transparent substrate that forms an outer surface of the transparent electrode film, and a conductive layer that is supported by the transparent substrate and includes the transparent electrode layer, and the cut mark may include a hole that penetrates the transparent substrate. This configuration improves the robustness of the cut mark.

[0015] In the laminate for the light controlling sheet, the transparent electrode film may have an inner surface that contacts the liquid crystal retention layer, and the cut mark may have a recess that is disposed on the outer surface of the transparent electrode film. With this configuration, the robustness of the cut mark is improved while protecting the liquid crystal retention layer. [Effects of the Invention]

[0016] According to the laminate for a light controlling sheet and the method for manufacturing the laminate for a light controlling sheet of the present disclosure, the productivity of the light controlling sheet can be improved. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 1 is a diagram showing the configuration of a laminate for a light controlling sheet. [Figure 2] FIG. 2 is a cross-sectional view taken along line 2-2 in FIG. 1, and shows the cross-sectional structure of the laminate for the light controlling sheet. [Figure 3] FIG. 3 is a cross-sectional view taken along line 3-3 in FIG. 1, showing a partially enlarged cross-sectional structure of the laminate for the light controlling sheet. [Figure 4] FIG. 4 is a structural diagram of a laminate for a light controlling sheet according to a modified example. [Figure 5] FIG. 5 is a structural diagram of a laminate for a light controlling sheet according to a modified example. [Figure 6] FIG. 6 is a structural diagram of a laminate for a light controlling sheet according to a modified example. DETAILED DESCRIPTION OF THE INVENTION

[0018] As shown in FIG. 1, as an example of the light controlling sheet laminate 10, a roll 10R on which a base sheet 20H for cutting out the light controlling sheet 20 is wound will be described. The light controlling sheet 20 is formed by a roll-to-roll method using the roll 10R. Furthermore, as an example of the light controlling sheet 20, the light controlling sheet laminate 10 will be described using a rectangular light controlling sheet 20 that allows for segmented driving. Segmented driving separately controls light from a light controlling portion 20S, which is one portion of the light controlling sheet 20, and a light controlling portion 20S, which is another portion of the light controlling sheet 20. Each light controlling portion 20S is separated by a dividing line L1 in the light controlling sheet laminate 10.

[0019] [Light Control Sheet 20] The light controlling sheet 20 may be used in a partition device that divides a space. The light controlling sheet 20 itself may be a partition member that divides a space, or a light controlling adhesive body in which a light controlling sheet is mounted on a transparent member may be a partition member that divides a space. The partition member may be window glass or a partition. The window glass may be mounted on a moving body such as a vehicle or an airplane, or may be installed in a building such as an office building or a public facility. The partition may be placed in the interior space of a vehicle or in an indoor space.

[0020] The light controlling sheet 20 may be used as a screen for displaying images. The light controlling sheet 20 itself may be the screen, or a light controlling adhesive in which the light controlling sheet 20 is mounted on a transparent member may be the screen. The screen may be a front screen that uses reflected light for the image, or a rear screen that uses transmitted light for the image. The light controlling adhesive may have one light controlling sheet 20 mounted on one transparent member, or may have multiple light controlling sheets 20 mounted on one transparent member. The light controlling adhesive may have the light controlling sheet 20 sandwiched between two transparent substrates. The light controlling sheet 20 is flexible. The light controlling adhesive may be flexible or not. The light controlling adhesive may have a flat or curved shape.

[0021] The driving type of the light controlling sheet 20 may be a reverse type. A reverse type light controlling sheet 20 changes from transparent to opaque in response to the input of a voltage signal. A reverse type light controlling sheet 20 remains opaque while a voltage signal is being input. A reverse type light controlling sheet 20 returns from opaque to transparent in response to the cessation of the input of the voltage signal.

[0022] The driving type of the light controlling sheet 20 may be a normal type. The normal type light controlling sheet 20 changes from opaque to transparent in response to the input of a voltage signal. The normal type light controlling sheet 20 remains transparent while the voltage signal is being input. The normal type light controlling sheet 20 returns from transparent to opaque in response to the cessation of the input of the voltage signal.

[0023] The light controlling sheet 20 achieves its opacity by scattering transmitted light through the light controlling sheet 20. An opaque light controlling sheet 20 has a lower parallel light transmittance than a transparent light controlling sheet 20. An opaque light controlling sheet 20 has a higher haze than a transparent light controlling sheet 20. The color of the opaque light controlling sheet 20 may be either achromatic or chromatic. The color of the transparent light controlling sheet 20 may be either achromatic or chromatic.

[0024] [Light-modulating sheet laminate 10] The roll 10R, which is the laminate 10 for the light controlling sheet, has a strip-shaped base sheet 20H wound around a core material. The base sheet 20H has a cutout target 30 corresponding to the light controlling sheet 20. The light controlling sheet 20 is formed by cutting out the cutout target 30 from the base sheet 20H. The outer edge 20E of the light controlling sheet 20 comprises the cut surface of the base sheet 20H. The base sheet 20H may be cut using a laser processing device or a plotting cutter.

[0025] The base sheet 20H has multiple cutout targets 30 attached along the extension direction X of the base sheet 20H. The base sheet 20H has the cutout targets 30 repeatedly arranged at equal intervals along the extension direction X of the base sheet 20H. The cutout targets 30 have a rectangular shape composed of a side extending in the extension direction X and a side extending in the width direction Y. The cutout targets 30 are the outer edges 20E of the light controlling sheet 20.

[0026] The roll body 10R has four division lines L1 in one cut-out target 30. The division lines L1 extend along the extension direction X of the base sheet 20H. The division lines L1 are repeated in the width direction Y of the base sheet 20H. The outer edge 20E of the light controlling sheet 20 surrounds the four division lines L1 aligned in the width direction Y. One cut-out target 30 is divided into multiple light controlling portions 20S by the division lines L1. The light controlling portions 20S are aligned in the width direction Y.

[0027] The roll 10R has a plurality of isolated cut marks 15M. The roll 10R has four cut marks 15M for each cut-out target 30. The four cut marks 15M are arranged around each cut-out target 30. The cut-out target 30 is electrically insulated from conductive elements such as the transparent electrode layer and wiring of the light controlling sheet 20 formed from that cut-out target 30. The four cut marks 15M for each cut-out target 30 are electrically insulated from the conductive elements of the light controlling sheet 20 formed from that cut-out target 30.

[0028] A cutting device such as a laser processing device or a plotting cutter that cuts out the cutting target 30 from the light-controlling sheet laminate 10 may be equipped with an appearance observation device that observes the appearance of the light-controlling sheet laminate 10. The appearance observation device captures images of the light-controlling sheet laminate 10 and processes the images of the captured images. The appearance observation device pre-stores the outer shape and dimensions of the cut mark 15M. Based on the image processing of the captured images, the appearance observation device detects the relative position of the cut mark 15M to other cut marks 15M, or the relative position of the edge of the light-controlling sheet laminate 10 to the cut mark 15M. The appearance observation of the light-controlling sheet laminate 10 may be observation of reflected light from the light-controlling sheet laminate 10 or observation of transmitted light from the light-controlling sheet laminate 10. The reflected light or transmitted light from the light-controlling sheet laminate 10 may be of visible wavelength or infrared wavelength. When the reflected light or transmitted light has a wavelength other than that of the visible light, the appearance of the laminate 10 for the light controlling sheet is observed by separately irradiating the laminate 10 for the light controlling sheet with observation light of a wavelength other than that of the visible light.

[0029] The cut mark 15M has a size that can be detected by visual observation of the laminate 10 for light controlling sheet. The cut mark 15M may be an isolated figure or line segment within the laminate 10 for light controlling sheet, or a collection of two or more isolated figures or line segments. The process of cutting out the cutout target 30 from the laminate 10 for light controlling sheet may be performed manually by an operator. In this case, the outer shape and dimensions of the cut mark 15M are known to the operator in advance. The visual observation of the laminate 10 for light controlling sheet, including detection of the cut mark 15M, may be performed visually by an operator.

[0030] The four cut marks 15M for each cut-out target 30 are arranged so that the outer edge of the cut-out target 30, i.e., the outer edge 20E of the light-controlling sheet 20, can be identified based on the relative positions of the four cut marks 15M. For example, two cut marks 15M aligned in the extension direction X are arranged at a distance approximately equal to the length of the side so that the imaginary line connecting the cut marks 15M runs along the side of the outer edge 20E of the light-controlling sheet 20 extending in the extension direction X. Two cut marks 15M aligned in the width direction Y are arranged at a distance approximately equal to the length of the side so that the imaginary line connecting the cut marks 15M runs along the side of the outer edge 20E of the light-controlling sheet 20 extending in the width direction Y. The distance between adjacent cut marks 15M is determined in advance based on the design of the outer edge 20E of the light-controlling sheet 20.

[0031] The imaginary line connecting adjacent cut marks 15M may coincide with the outer edge 20E of the light-controlling sheet 20, or may be a predetermined distance away from the outer edge 20E of the light-controlling sheet 20. The predetermined distance is determined in advance in the cutting process of the light-controlling sheet 20. The predetermined distance may be stored in a laser processing device for cutting the laminate 10 for the light-controlling sheet, or may be stored in a plotting cutter. In the cutting process of the light-controlling sheet 20, an imaginary line is set to connect the cut marks 15M obtained based on an observation of the appearance of the laminate 10 for the light-controlling sheet, and cutting is performed on a line a predetermined distance away from the imaginary line. In this way, the cutting process of the light-controlling sheet 20 forms the outer edge 20E of the light-controlling sheet 20 based on the design.

[0032] [Cross-sectional structure of the laminate 10 for light controlling sheet] 2, the laminate 10 for the light control sheet includes a first transparent electrode film 21, a second transparent electrode film 22, and a liquid crystal retention layer 31 sandwiched between the first transparent electrode film 21 and the second transparent electrode film 22. The first transparent electrode film 21 and the second transparent electrode film 22 are in contact with the liquid crystal retention layer 31.

[0033] The first transparent electrode film 21 includes a first transparent substrate 21A and a first conductive layer 21B. The first transparent substrate 21A supports the first conductive layer 21B and forms the outer surface of the first transparent electrode film 21. The first conductive layer 21B forms the inner surface of the first transparent electrode film 21 and is in contact with the liquid crystal retention layer 31. The first transparent electrode film 21 may include an alignment layer between the first conductive layer 21B and the liquid crystal retention layer 31.

[0034] The second transparent electrode film 22 includes a second transparent substrate 22A and a second conductive layer 22B. The second transparent substrate 22A supports the second conductive layer 22B and forms the outer surface of the second transparent electrode film 22. The second conductive layer 22B forms the inner surface of the second transparent electrode film 22 and is in contact with the liquid crystal retention layer 31. The second transparent electrode film 22 may include an alignment layer between the second conductive layer 22B and the liquid crystal retention layer 31.

[0035] The first transparent electrode film 21 may include another functional layer between the first transparent substrate 21A and the first conductive layer 21B. The second transparent electrode film 22 may include another functional layer between the second transparent substrate 22A and the second conductive layer 22B. The other functional layers between the first transparent electrode film 21 and the second transparent electrode film 22 may have the same configuration as each other, or may have different configurations. The other functional layer may be a gas barrier layer that suppresses the transmission of oxygen and moisture toward the liquid crystal retention layer 31, or may be an ultraviolet barrier layer that suppresses the transmission of ultraviolet light other than a specific wavelength toward the liquid crystal retention layer 31. The other functional layer may be a hard coat layer that mechanically protects the first transparent electrode film 21, or an adhesive layer that improves adhesion between layers.

[0036] The light-controlling sheet 20 includes a first transparent electrode layer cut out from the first conductive layer 21B, a second transparent electrode layer cut out from the second conductive layer 22B, and a light-controlling layer cut out from the liquid crystal retention layer 31. The first transparent electrode layer, the second transparent electrode layer, and the light-controlling layer are cut out as a single unit from the laminate 10 for the light-controlling sheet as surrounded by the two-dot chain line. The light-controlling layer is sandwiched between the first transparent electrode layer and the second transparent electrode layer. The transparency of the light-controlling layer changes depending on the voltage applied between the first transparent electrode layer and the second transparent electrode layer.

[0037] The parting lines L1 are formed by insulating a portion of the first conductive layer 21B. The insulating of the first conductive layer 21B may be achieved by removing a portion of the first conductive layer 21B by etching, or by irradiating a portion of the first conductive layer 21B with a laser to alter the layer's properties. The alteration caused by the laser irradiation may include discoloration caused by the laser irradiation. Insulating the first conductive layer 21B makes the parting lines L1 visible. To reduce the visibility of the parting lines L1, the width of the parting lines L1 is preferably 50 μm or less, and more preferably 5 μm to 30 μm.

[0038] The cut marks 15M are formed by insulating a portion of the first conductive layer 21B. The first conductive layer 21B may be insulated over the entire cut mark 15M or may be insulated so as to border the cut mark 15M. When simplification of the manufacturing process of the light controlling sheet 20 is required, the cut marks 15M may be formed together with the formation of the division lines L1. The cut marks 15M may be formed simultaneously with the division lines L1 or separately from the division lines L1. When the cut marks 15M are formed prior to the formation of the division lines L1, the cut marks 15M may be used to set the planned positions of the division lines L1 so that the planned positions of the division lines L1 are identified based on the positions of the cut marks 15M.

[0039] If improved detection accuracy of the cut mark 15M is required, the length of the cut mark 15M in the extension direction X and the length of the cut mark 15M in the width direction Y may each be greater than the line width of the division line L1. If improved detection accuracy of the cut mark 15M is required, the contrast of the observation light between the cut mark 15M and the surrounding area of ​​the cut mark 15M may be higher than that between the division line L1 and the surrounding area of ​​the division line L1.

[0040] [Liquid crystal holding layer 31] 3, the liquid crystal holding layer 31 is located between the first conductive layer 21B and the second conductive layer 22B. The liquid crystal holding layer 31 contacts the first conductive layer 21B. If the cut mark 15M is formed by removing the first conductive layer 21B, the liquid crystal holding layer 31 may fill the cut mark 15M. The liquid crystal holding layer 31 contacts the second conductive layer 22B.

[0041] The first conductive layer 21B and the second conductive layer 22B are visually recognized as colorless and transparent or colored and transparent, respectively. The materials constituting the first conductive layer 21B and the second conductive layer 22B are each a conductive inorganic oxide, a metal, or a conductive organic polymer compound. An example of the conductive inorganic oxide is any one selected from the group consisting of indium tin oxide, fluorine-doped tin oxide, tin oxide, and zinc oxide. The metal is gold or silver nanowires. An example of the conductive organic polymer compound is any one selected from the group consisting of carbon nanotubes and poly(3,4-ethylenedioxythiophene). An example of the thickness of the first conductive layer 21B and the second conductive layer 22B is 5 nm or more and 200 nm or less.

[0042] The driving unit of the light control sheet 20 changes the voltage between the first transparent electrode layer cut out from the first conductive layer 21B and the second transparent electrode layer cut out from the second conductive layer 22B. Changing the voltage between the first conductive layer 21B and the second conductive layer 22B changes the alignment state of the liquid crystal compound LCM. The driving unit of the light control sheet 20 reversibly switches the light control sheet 20 from transparent to opaque by changing the alignment state of the liquid crystal compound LCM.

[0043] The liquid crystal holding layer 31 includes a liquid crystal composition 31LC, spacers SP, and an ionizing radiation curable resin layer 31P. The liquid crystal composition 31LC includes a liquid crystal compound LCM. The liquid crystal composition 31LC may contain additives such as a dichroic dye DP, an antifoaming agent, an antioxidant, a weathering agent, and a solvent. The liquid crystal composition 31LC may also contain a viscosity reducing agent. The liquid crystal compound LCM may have a positive dielectric anisotropy, i.e., a dielectric constant in the long axis direction of the liquid crystal compound LCM is greater than a dielectric constant in the short axis direction of the liquid crystal compound LCM. The liquid crystal compound LCM may have a negative dielectric anisotropy, i.e., a dielectric constant in the long axis direction of the liquid crystal compound LCM is lower than a dielectric constant in the short axis direction of the liquid crystal compound LCM. The dielectric anisotropy of the liquid crystal compound LCM is appropriately selected based on the driving type of the light control sheet 20.

[0044] The spacers SP are dispersed throughout the ionizing radiation cured resin layer 31P. The particle size of the spacers SP determines the thickness of the liquid crystal retention layer 31. An example of the thickness of the liquid crystal retention layer 31 is 5 μm or more and 100 μm or less. The spacers SP make the thickness of the liquid crystal retention layer 31 uniform. The spacers SP may be bead spacers or photospacers formed by exposing and developing a photoresist. The spacers SP may be colorless and transparent, or colored and transparent. When the liquid crystal composition 31LC contains a dichroic dye DP, the color of the spacers SP is preferably the same color as the color exhibited by the dichroic dye DP.

[0045] The ionizing radiation cured resin layer 31P is a cured product of an ionizing radiation curable composition. The ionizing radiation may be ultraviolet light or electron beams. The ionizing radiation curable composition may be an ultraviolet-curable composition or an electron beam curable composition. The lower limit of the content of the ionizing radiation curable resin layer 31P relative to the total amount of the ionizing radiation curable resin layer 31P and the liquid crystal composition 31LC is 20% by mass, and more preferably 30% by mass. If the content of the ionizing radiation curable resin layer 31P is 20% by mass or more, high transmittance is likely to be obtained when transparent. The upper limit of the content of the ionizing radiation curable resin layer 31P relative to the total amount of the ionizing radiation curable resin layer 31P and the liquid crystal composition 31LC is 70% by mass, and more preferably 60% by mass. If the content of the ionizing radiation curable resin layer 31P is 70% by mass or less, high haze is likely to be obtained when opaque.

[0046] The ionizing radiation curable resin layer 31P defines voids 31D in the liquid crystal retention layer 31. The liquid crystal composition 31LC is filled in the voids 31D. The voids 31D may be isolated from other voids 31D adjacent to the void 31D, or may be connected to other adjacent voids 31D. The voids 31D may have two or more sizes. The shape of the voids 31D is spherical, ellipsoidal, or irregular. The diameter of the sphere circumscribing the void 31D may be 0.4 μm or more, or 1 μm or more. The diameter of the sphere circumscribing the void 31D may be 20 μm or less, or 10 μm or less. The diameter of the sphere circumscribing the void 31D is, for example, 1 μm or more and 10 μm or less.

[0047] The voids 31D may be unevenly distributed in the ionizing radiation cured resin layer 31P, or may be uniformly dispersed in the ionizing radiation cured resin layer 31P. The voids 31D may be unevenly distributed in a range 31H1 closer to the first conductive layer 21B than the center in the thickness direction of the ionizing radiation cured resin layer 31P, so that the number of voids 31D increases toward the first conductive layer 21B. The voids 31D may be unevenly distributed in a range 31H2 closer to the second conductive layer 22B than the center in the thickness direction of the ionizing radiation cured resin layer 31P, so that the number of voids 31D increases toward the second conductive layer 22B. The ionizing radiation cured resin layer 31P may have a portion in the thickness direction center of the ionizing radiation cured resin layer 31P where no voids 31D exist, and may have voids 31D between that portion and the first conductive layer 21B. The ionizing radiation cured resin layer 31P may have a portion where no void 31D exists in the center in the thickness direction of the ionizing radiation cured resin layer 31P, and may have a void 31D between this portion and the second conductive layer 22B.

[0048] The type of retention of the liquid crystal composition 31LC by the ionizing radiation curable resin layer 31P is any one selected from the group consisting of a polymer dispersion type, a polymer network type, and a capsule type. The polymer dispersion type liquid crystal retention layer 31 includes an ionizing radiation curable resin layer 31P that defines a large number of isolated voids 31D. The polymer dispersion type liquid crystal retention layer 31 retains the liquid crystal composition 31LC in the voids 31D dispersed in the ionizing radiation curable resin layer 31P. The polymer network type liquid crystal retention layer 31 includes three-dimensional network-like voids 31D in the ionizing radiation curable resin layer 31P. The polymer network type liquid crystal retention layer 31 retains the liquid crystal composition 31LC in the interconnected network-like voids 31D. The capsule type liquid crystal retention layer 31 retains the liquid crystal composition 31LC in capsule-like voids 31D dispersed in the ionizing radiation curable resin layer 31P.

[0049] [Method of manufacturing the laminate 10 for light controlling sheet] The manufacturing method of the laminate 10 for the light controlling sheet includes a step of forming the cut marks 15M and a step of forming the liquid crystal retaining layer 31. When the cut marks 15M are formed by etching, the step of forming the cut marks 15M is carried out prior to the step of forming the liquid crystal retaining layer 31. When the cut marks 15M are formed by laser irradiation, the step of forming the cut marks 15M may be carried out prior to the step of forming the liquid crystal retaining layer 31, or may be carried out after the step of forming the liquid crystal retaining layer 31. The step of forming the cut marks 15M may be carried out simultaneously with the formation of the parting lines L1, or may be carried out separately from the formation of the parting lines L1.

[0050] The process of forming the cut marks 15M begins by setting the planned positions of the cut marks 15M in the first conductive layer 21B. The planned positions of the cut marks 15M are set so as to identify the outer edge 20E of the light controlling sheet 20 based on the relative position of the cut marks 15M with respect to each other. For example, each planned position may be set based on the design shape and design dimensions of the outer edge 20E so that an imaginary line connecting adjacent planned positions coincides with the outer edge 20E of the light controlling sheet 20. Alternatively, each planned position may be set based on the design shape and design dimensions of the outer edge 20E so that an imaginary line connecting adjacent planned positions is a predetermined distance away from the outer edge 20E of the light controlling sheet 20.

[0051] If components of the light controlling sheet 20, such as the dividing line L1 or the first transparent electrode layer, are formed in advance, the planned positions of the cut marks 15M may be corrected using the measured positions of those components. For example, the planned positions of the cut marks 15M are set based on the designed shape and dimensions of the outer edge 20E so that an imaginary line connecting adjacent planned positions coincides with the outer edge 20E of the light controlling sheet 20. Next, the planned positions of the cut marks 15M may be corrected based on the measured positions of the components formed in advance so that the measured positions of the components are the designed positions relative to the imaginary line.

[0052] In the step of forming the cut marks 15M, when the cut marks 15M are formed by etching, openings are formed in the resist mask layer so that the openings overlap predetermined positions of the first conductive layer 21B. Then, the first conductive layer 21B is etched through the openings to form the cut marks 15M at the predetermined positions of the first conductive layer 21B.

[0053] When the cut marks 15M are formed by laser irradiation in the process of forming the cut marks 15M, a laser for insulating the first conductive layer 21B is irradiated onto the predetermined positions of the cut marks 15M. The laser irradiated onto the first conductive layer 21B has low transmittance to the first conductive layer 21B, such as in the infrared wavelength range, and high transmittance to the first transparent substrate 21A and the liquid crystal retention layer 31. Then, by irradiating the laser onto the predetermined positions of the cut marks 15M, the cut marks 15M are formed at the predetermined positions of the first conductive layer 21B.

[0054] The process of forming the liquid crystal retention layer 31 includes forming a coating layer containing an ionizing radiation curable composition and a liquid crystal composition 31LC between the first conductive layer 21B and the second conductive layer 22B. The process of forming the liquid crystal retention layer 31 involves irradiating the coating layer with ionizing radiation to form the liquid crystal retention layer 31 between the first conductive layer 21B and the second conductive layer 22B. The process of forming the liquid crystal retention layer 31 may involve irradiating the ionizing radiation from the first conductive layer 21B toward the second conductive layer 22B, or from the second conductive layer 22B toward the first conductive layer 21B, or a combination of these. The ionizing radiation curable composition irradiated with ionizing radiation initiates polymerization and phase-separates liquid crystal particles made of the liquid crystal composition 31LC from the polymer. Phase separation of the liquid crystal particles made of the liquid crystal composition 31LC proceeds through polymerization of the ionizing radiation curable composition and diffusion of the liquid crystal composition 31LC. As a result, a laminate 10 for a light controlling sheet having cut marks 15M is formed.

[0055] According to the above embodiment, the following effects can be obtained. (1) By detecting the cut mark 15M, the outer edge 20E of the light controlling sheet 20 is identified within the light controlling sheet laminate 10. This reduces the load required to set the cutting position, thereby increasing the productivity of the light controlling sheet 20.

[0056] (2) Since the cut marks 15M are formed by patterning the first conductive layer 21B, the division lines L1 and the cut marks 15M can be processed simultaneously. This prevents an increase in the number of steps in manufacturing the light controlling sheet laminate 10.

[0057] (3) Because the cut mark 15M is sandwiched between the first transparent base material 21A and the second transparent base material 22A, chipping or peeling of the cut mark 15M due to physical or chemical contact is suppressed, thereby improving the robustness of the cut mark 15M.

[0058] The above embodiment can be modified as follows. [Cut mark 15M] As shown in FIG. 4, the cut marks 15M may comprise printed matter formed on the outer surface of the first transparent electrode film 21. The cut marks 15M may be achromatic printed matter or colored printed matter. The cut marks 15M may be printed by inkjet printing or screen printing. According to this modification, the detection accuracy of the cut marks 15M is improved by the amount that the cut marks 15M are arranged on the outer surface of the laminate 10 for the light controlling sheet.

[0059] The cut marks 15M may be printed prior to the formation of the parting lines L1, or may be printed after the parting lines L1 are formed. If the cut marks 15M are printed prior to the formation of the parting lines L1, the etching process or laser processing required to form the parting lines L1 may cause the cut marks 15M to peel off from the outer surface of the first transparent electrode film 21. In this case, the ink properties for forming the cut marks 15M may be selected to improve adhesion between the outer surface of the first transparent electrode film 21 and the cut marks 15M, or the outer surface of the first transparent electrode film 21 may be subjected to a surface treatment in advance. Furthermore, the first transparent electrode film 21 may further include a protective layer that covers the cut marks 15M to prevent physical contact with the cut marks 15M.

[0060] As shown in FIG. 5, the cut mark 15M may have a hole penetrating the first transparent base material 21A. The cut mark 15M may have one hole or a group of two or more holes. The hole that makes up the cut mark 15M may be hollow or solid and filled with resin. The hole that makes up the cut mark 15M may be a circular hole, an elliptical hole, or an elongated hole extending in the extension direction X or the width direction Y. This modification improves the detection accuracy of the cut mark 15M and prevents peeling or deformation of the cut mark 15M.

[0061] The holes that make up the cut marks 15M may or may not penetrate the first conductive layer 21B. The holes that make up the cut marks 15M are formed by punching the first transparent electrode film 21 using, for example, a punching device. When the cut marks 15M overlap the liquid crystal retention layer 31, it is preferable that the holes that make up the cut marks 15M do not penetrate the first conductive layer 21B, from the viewpoint of protecting the liquid crystal retention layer 31 from the outside.

[0062] As shown in FIG. 6, the cut mark 15M may have a recess recessed into the outer surface of the first transparent base material 21A. The cut mark 15M may have one recess or a group of two or more recesses. The recess forming the cut mark 15M may be hollow or solid and filled with resin. The recess forming the cut mark 15M may be a circular hole, an elliptical hole, or an elongated hole extending in the extension direction X or the width direction Y. The hole forming the cut mark 15M is formed by etching the first transparent electrode film 21 using, for example, a laser processing device. This modification improves the detection accuracy of the cut mark 15M and prevents peeling or deformation of the cut mark 15M. Furthermore, the durability of the liquid crystal retention layer 31 is maintained.

[0063] The cut marks 15M may be arranged so as to overlap the outer edge of the cut-out target 30, or may be arranged outside the outer edge of the cut-out target 30, or may be arranged inside the cut-out target 30. If it is not necessary to leave the cut marks 15M on the light controlling sheet 20, the cut marks 15M are preferably arranged outside the cut-out target 30. If the cut marks 15M are left on the light controlling sheet 20 to inspect the cutting accuracy, the cut marks 15M are preferably arranged so as to overlap the outer edge of the cut-out target 30 or inside the cut-out target 30. Note that if the cut marks 15M are arranged on the light controlling sheet 20, it is preferable that the cut marks 15M be covered with a sealant to make them invisible when the light controlling sheet 20 is mounted.

[0064] The cut marks 15M may be placed at all corners of the outer edge of the cut-out object 30, or may be placed at some corners of the outer edge of the cut-out object 30. The cut marks 15M may be placed in any manner that allows the outer edge of the cut-out object 30 to be identified based on the relative position of the cut marks 15M with respect to other cut marks 15M.

[0065] For example, if the outer edge 20E of the light controlling sheet 20 is designed as a set of straight lines, a laser processing device or a plotting cutter memorizes the shape and dimensions of the set of straight lines. Then, the planned positions of the cut marks 15M are set at the intersections of the set of straight lines. From the detected positions of each cut mark 15M, the laser processing device or the plotting cutter identifies the straight lines that intersect with the cut marks 15M, and cuts the light controlling sheet laminate 10 along the straight lines.

[0066] For example, if the outer edge 20E of the light controlling sheet 20 is designed to include a curve, a laser processing device or a plotting cutter stores the curvature of the curve and the endpoints of the curve. Then, the planned positions of the cut marks 15M are set at the endpoints of the curve. From the detected positions of each cut mark 15M, the laser processing device or the plotting cutter identifies the curve whose endpoint is the cut mark 15M, and cuts the light controlling sheet laminate 10 along the curve.

[0067] The light-controlling sheet laminate 10 may be positioned so that the outer edge of the cutting target 30, i.e., the outer edge 20E of the light-controlling sheet 20, can be identified based on the relative position of the cut mark 15M with respect to a characteristic position such as the outer edge of the light-controlling sheet laminate 10. For example, a laser processing device or a plotting cutter stores the dimensions and outer shape of the cutting target 30 relative to the long side extending in the extension direction X of the light-controlling sheet laminate 10. An appearance observation device detects the outer edge extending in the extension direction X of the light-controlling sheet laminate 10. The appearance observation device also detects the relative position of the cut mark 15M with respect to the outer edge of the light-controlling sheet laminate 10. The laser processing device or the plotting cutter then identifies the outer edge of the cutting target 30 with respect to the outer edge of the light-controlling sheet laminate 10 so that it passes through the detected position of the cut mark 15M, and cuts the light-controlling sheet laminate 10 along the identified outer edge.

[0068] [Light Control Sheet 20] The light controlling sheet 20 may have a division line L1 that intersects with the extending direction X, may have a curved division line L1, or may not have a division line L1.

[0069] The cutout target 30 is not limited to a rectangular shape that conforms to a window frame or the like, but may be a geometric shape other than a rectangle, or a free-form shape other than a geometric shape. For example, the cutout target 30 may have a trapezoidal shape that conforms to the outline of a side window, or a free-form shape that conforms to the curved glass of a showcase. [Explanation of symbols]

[0070] LCM…liquid crystal compound 10...Laminate for light-controlling sheet 10R...Roll body 15M...Cut mark 20...Light-adjusting sheet 21...First transparent electrode film 21A...First transparent base material 21B...first conductive layer 22...Second transparent electrode film 22A…Second transparent base material 22B…Second conductive layer 30...Cut-out target 31...Liquid crystal holding layer 31P…Ionizing radiation curing resin layer 31LC…Liquid crystal composition 31D…Void

Claims

1. A laminate for a light controlling sheet from which a light controlling sheet is cut out, Two transparent electrode films, a liquid crystal retention layer sandwiched between the transparent electrode films, the transparent electrode film includes a transparent electrode layer that constitutes the light-control sheet, the liquid crystal retention layer includes a light control layer that constitutes the light control sheet, the transparent electrode film has a plurality of isolated cut marks that can be detected by visual observation; The plurality of cut marks are arranged so that the outer edge of the light controlling sheet is identified based on the relative position of one cut mark with respect to another cut mark. A laminate for a light-controlling sheet, characterized in that:

2. A laminate for a light controlling sheet from which a light controlling sheet is cut out, Two transparent electrode films, a liquid crystal retention layer sandwiched between the transparent electrode films, the transparent electrode film includes a transparent electrode layer that constitutes the light-control sheet, the liquid crystal retention layer includes a light control layer that constitutes the light control sheet, the transparent electrode film has an isolated cut mark that can be detected by visual observation; The cut marks are arranged so that the outer edge of the light controlling sheet can be identified based on the relative position of the cut marks with respect to the laminate for the light controlling sheet. A laminate for a light-controlling sheet, characterized in that:

3. The laminate for the light controlling sheet is a roll from which a plurality of the light controlling sheets are cut out, The transparent electrode film is a transparent substrate that constitutes the outer surface of the transparent electrode film; a conductive layer supported by the transparent substrate and including the transparent electrode layer; The conductive layer is The cut mark; a plurality of the transparent electrode layers separated from each other within the outer edge defined by the cut marks; The laminate for a light-controlling sheet according to claim 1 or 2.

4. the transparent electrode film has an inner surface in contact with the liquid crystal retention layer, The cut mark is a printed matter arranged on the outer surface of the transparent electrode film. The laminate for a light-controlling sheet according to claim 1 or 2.

5. The transparent electrode film is a transparent substrate that constitutes the outer surface of the transparent electrode film; a conductive layer supported by the transparent substrate and including the transparent electrode layer; The cut mark comprises a hole penetrating the transparent substrate. The laminate for a light-controlling sheet according to claim 1 or 2.

6. the transparent electrode film has an inner surface in contact with the liquid crystal retention layer, The cut mark comprises a recess disposed on the outer surface of the transparent electrode film. The laminate for a light-controlling sheet according to claim 1 or 2.

7. A method for manufacturing a laminate for a light controlling sheet, in which a light controlling sheet is cut out, comprising: forming a liquid crystal retention layer sandwiched between two transparent electrode films; the transparent electrode film includes a transparent electrode layer that constitutes the light-control sheet, the liquid crystal retention layer includes a light control layer that constitutes the light control sheet, The method further includes forming a plurality of isolated cut marks on the transparent electrode film, the cut marks being detected by visual observation, so that the outer edge of the light controlling sheet can be identified based on the relative position of one cut mark to another cut mark. A method for producing a laminate for a light-controlling sheet, comprising:

8. A method for manufacturing a laminate for a light controlling sheet, in which a light controlling sheet is cut out, comprising: forming a liquid crystal retention layer sandwiched between two transparent electrode films; the transparent electrode film includes a transparent electrode layer that constitutes the light-control sheet, the liquid crystal retention layer includes a light control layer that constitutes the light control sheet, The method further includes forming a plurality of isolated cut marks on the transparent electrode film, the cut marks being detected by visual observation, so that the outer edge of the light controlling sheet can be identified based on the relative position of the cut marks with respect to the laminate for the light controlling sheet. A method for producing a laminate for a light-controlling sheet, comprising:

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