Light control module, manufacturing method thereof, and vehicle

Abstract

The present application relates to a light control module and its manufacturing method, and a vehicle. The light control module includes a first transparent plate, a first adhesive layer, a light control film, a second adhesive layer and a second transparent plate, which are sequentially stacked, the first transparent plate, the first adhesive layer and the light control film are bonded by a lamination process, the second adhesive layer is formed by curing a liquid optical adhesive, and the edges of the light control film and the second adhesive layer shrink inwardly relative to the first adhesive layer, and the light control module further includes a sealing member located between the first adhesive layer and the second transparent plate and contacting the edges of the light control film and the second adhesive layer.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims priority to a Chinese patent application filed on May 13, 2022, bearing application number 2022105170427 and entitled "Dimming module and manufacturing method thereof, and vehicle," the entire contents of which are incorporated herein by reference.

[0002] The present application relates to the field of glass, in particular to a light control module and a manufacturing method thereof, and to a vehicle. [Background technology]

[0003] The light-controlling glass is a new type of photoelectric glass that combines a light-controlling film between two layers of glass and controls the light-transmitting and non-light-transmitting states of the glass by controlling the on-off of the electric current. The conventional light-controlling glass includes a first glass substrate, a first adhesive layer, a light-controlling film, a second adhesive layer and a second glass substrate, which are laminated together. The light-controlling film is bonded to the first glass substrate and the second glass substrate by the first adhesive layer and the second adhesive layer, respectively. The first adhesive layer and the second adhesive layer of the conventional light-controlling glass are usually both PVB adhesive layers or EVA adhesive layers, and are manufactured by a lamination process. The light-controlling glass manufactured by this method has defects in appearance and has an uneven (uneven) phenomenon. Summary of the Invention [Problem to be solved by the invention]

[0004] According to various embodiments of the present application, a light control module having a good appearance and no unevenness phenomenon is provided.

[0005] There is also a need to provide a method for manufacturing a dimming module and a vehicle including the dimming module. [Means for solving the problem]

[0006] The light control module includes a first transparent plate, a first adhesive layer, a light control film, a second adhesive layer, and a second transparent plate, which are stacked in order; The first light-transmitting plate, the first adhesive layer and the light-control film are bonded together by a lamination process; the second adhesive layer is formed by curing a liquid optical adhesive; the edges of the light management film and the second adhesive layer shrink inwardly relative to the first adhesive layer; The light control module further includes a sealing member positioned between the first adhesive layer and the second light-transmitting plate and in contact with edges of the light control film and the second adhesive layer.

[0007] In one embodiment, the second adhesive layer has a thickness of 0.2 mm to 1 mm.

[0008] In one embodiment, the viscosity of the liquid optical adhesive at 25° C. is 500±200 mPa·s.

[0009] In one embodiment, the liquid optical adhesive includes an acrylic-based liquid optical adhesive or a silicone-based liquid optical adhesive.

[0010] In one embodiment, the light management film includes an LC light management film.

[0011] In one embodiment, the first light-transmitting plate and the second light-transmitting plate both include single curved glass or both include hyperbolic glass.

[0012] In one embodiment, the sealing member is a sealant layer, or the sealing member includes a sealant layer and a dam adhesive layer, the dam adhesive layer contacts the edges of the light control film and the second adhesive layer, the sealant layer, the first adhesive layer and the second light-transmitting plate, and the sealant layer contacts the dam adhesive layer, the first adhesive layer and the second light-transmitting plate.

[0013] In one embodiment, the material of the first adhesive layer is one of PVB and EVA.

[0014] In one embodiment, the first adhesive layer has a thickness of 0.3 mm to 0.8 mm.

[0015] The manufacturing method of the dimming module is as follows: A step of sequentially stacking and positioning a first light-transmitting plate, a first adhesive layer, and a light-control film, and then laminating the first adhesive layer, wherein an edge of the light-control film shrinks inward relative to the first adhesive layer; A step of disposing a sealing member on the inner shrinkage area of ​​the first adhesive layer after lamination, the thickness of the sealing member being greater than the thickness of the light-regulating film, and the sealing member and the surface of the light-regulating film away from the first light-transmitting plate form a concave groove; and injecting a liquid optical adhesive into the groove, attaching a second light-transmitting plate, and curing the liquid optical adhesive to obtain a light control module.

[0016] In one embodiment, in the step of disposing a sealing member in the inner shrink region of the first adhesive layer after lamination, an adhesive injection hole communicating with the groove is left in the sealing member; The step of injecting liquid optical adhesive into the groove and laminating a second light-transmitting plate includes the steps of first laminating the second light-transmitting plate to the side of the light-control film away from the first light-transmitting plate, blocking the groove with the second light-transmitting plate, and then injecting the liquid optical adhesive into the groove through the adhesive injection port.

[0017] In one embodiment, an exhaust port is further left in the sealing member, the sealing member has opposing first and second surfaces, the adhesive injection port is located at one end of the first surface, and the exhaust port is located at the other end of the first surface away from the adhesive injection port, and when a position on the second surface facing the adhesive injection port is taken as a reference point, the adhesive injection port and the reference point are on the same horizontal plane, and the exhaust port is above the adhesive injection port, and in the step of injecting the liquid optical adhesive from the adhesive injection port into the groove, the laminate with the second light-transmitting plate bonded thereto is installed at an angle so that the distance from the adhesive injection port to the horizontal plane is greater than the distance from the reference point to the horizontal plane.

[0018] In one embodiment, the angle of inclination is between 15° and 45°.

[0019] In one embodiment, the laminating step includes a step of preliminarily laminating the first light-transmitting plate, the first adhesive layer and the light-control film, which are stacked together, under conditions where the vacuum degree is -0.1 MPa to -0.09 MPa and the temperature is 115°C or lower.

[0020] In one embodiment, after the step of curing the liquid optical adhesive, the method further includes the step of treating the cured laminate under conditions of a pressure of 0.1 MPa to 0.6 MPa and a temperature of 110°C to 140°C for 30 min to 90 min; or After the laminating step and before the step of placing a sealing member in the inner shrinkage region of the first adhesive layer after lamination, the method further includes a step of treating the laminated laminate under conditions of a pressure of 0.1 MPa to 0.6 MPa and a temperature of 110°C to 140°C for 30 min to 90 min.

[0021] In one embodiment, the sealing member is a sealant layer, and in the step of placing the sealing member on the inner shrink region of the first adhesive layer, a sealant is applied to the inner shrink region of the first adhesive layer, and in the step of curing a liquid optical adhesive, the sealant is cured to form the sealant layer.

[0022] In one embodiment, the sealing member includes a dam adhesive layer and a sealant layer, and in the step of disposing the sealing member in the inner shrink region of the first adhesive layer, after the step of disposing the dam adhesive layer in a portion of the inner shrink region of the first adhesive layer and curing the liquid optical adhesive, the method further includes the step of disposing the sealant layer in the remaining inner shrink region of the first adhesive layer.

[0023] In one embodiment, the thickness of the dam adhesive layer is between 0.2 mm and 1 mm.

[0024] The vehicle includes the above-described dimming module.

[0025] The details of one or more embodiments of the application are set forth in the drawings and description below. Other features, objects, and advantages of the application will become apparent from the description, drawings, and claims.

[0026] In order to more clearly describe the technical means in the embodiments of the present application or the prior art, the following briefly describes the drawings that need to be used in the description of the embodiments or the prior art. It is obvious that the drawings in the following description are only the embodiments of the present application, and those skilled in the art can obtain other drawings based on the disclosed drawings without creative labor. [Brief description of the drawings]

[0027] [Figure 1] 1 is a schematic diagram of a liquid optical adhesive injection process in the manufacturing process of a dimming module. [Diagram 2] 1 is a schematic diagram showing the structure of a light control glass according to Example 1. FIG. [Diagram 3]FIG. 4 is a schematic diagram showing the structure of a light control glass according to Example 2. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] Hereinafter, the technical means in the embodiments of the present application will be described clearly and completely with reference to the drawings in the embodiments of the present application. It is obvious that the described embodiments are only some of the embodiments of the present application, but not all of them. Based on the embodiments of the present application, all other embodiments that a person skilled in the art can obtain without creative labor are all within the scope of protection of the present application.

[0029] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terms used herein in the description of this application are for the purpose of describing specific examples only and are not intended to be limiting of the application.

[0030] A first aspect of the present application provides a light control module including a first light-transmitting plate, a first adhesive layer, a light control film, a second adhesive layer, and a second light-transmitting plate, which are stacked in order.

[0031] Specifically, the first light-transmitting plate is one of glass and polycarbonate plate. In one embodiment, the first light-transmitting plate is single curved glass or hyperbolic glass. Furthermore, the first light-transmitting plate is hyperbolic glass, and the dimming module may be applied to a vehicle. It should be noted that the first light-transmitting plate may be flat glass. From the viewpoint of functional glass, the first light-transmitting plate may select coated insulating glass.

[0032] Specifically, the first light-transmitting plate, the first adhesive layer and the light control film are bonded by a lamination process. The first adhesive layer is a non-liquid optical adhesive before manufacturing the light control module. In this specification, the non-liquid optical adhesive refers to an adhesive different from the liquid optical adhesive. For example, the first adhesive layer may be a solid or solidified optical adhesive OCA (full name in English is Optically Clear Adhesive) or a polymer adhesive before manufacturing the light control module. In one embodiment, the first adhesive layer is a material of one of PVB and EVA before manufacturing the light control module. In one embodiment, the thickness of the first adhesive layer is 0.3mm to 0.8mm, and in a specific example, the thickness of the first adhesive layer is 0.38mm or 0.76mm.

[0033] In one embodiment, the first adhesive layer is a PVB adhesive film, and in another embodiment, the first adhesive layer is an EVA adhesive film with a high ultraviolet shielding rate, with a UV cut wavelength range of 390 nm or more and a shielding rate of 99% or more. In a specific example, the UV cut wavelength range of the EVA adhesive film is 400 nm. The material of the first adhesive layer can be one of PVB and EVA or a combination thereof, and on the one hand, the two materials can bond the first light-transmitting plate and the light-control film by a lamination process, which is a mature process with high production efficiency, and on the other hand, the first adhesive layer formed from the two materials has a certain ultraviolet shielding effect and can protect the light-control film. In addition, the mechanical performance of the first adhesive layer is good, which can ensure the mechanical performance of the light-control module.

[0034] The edge of the light control film shrinks inward relative to the first adhesive layer. The inward shrinkage distance of the light control film relative to the adhesive layer can be adjusted according to the application of the light control module. For example, in one embodiment, the light control module is a gate glass, and the edge of the light control film is 6mm-10mm away from the edge of the first light-transmitting plate. In another embodiment, the light control module is a sunroof glass, the sunroof printing area is 30mm or more, and the light control film enters the sunroof printing area by 10mm-20mm.

[0035] In one embodiment, the light control film includes an LC light control film, in which the light control functional layer is liquid, has fluidity, and is very thin, with a thickness of 6 μm to 9 μm. In the manufacturing process, if the LC light control film receives a non-uniform force, defects such as ripples and unevenness are likely to occur. In the conventional manufacturing method of the light control module, it is difficult to ensure the appearance of the light control module, which is also a major technical problem for those skilled in the art. The light control module according to this embodiment solves the above problem. In another embodiment, the light control film may be a PDLC light control film.

[0036] Specifically, the edge of the second adhesive layer shrinks inward relative to the first adhesive layer, and further, the edge of the second adhesive layer is flush with the edge of the light management film.

[0037] Furthermore, the second adhesive layer is formed by curing the liquid optical adhesive before the light control module is manufactured. Compared with the solid or solidified optical adhesive OCA, the liquid optical adhesive is liquid before use, is manufactured by the adhesive injection and curing process, and does not require pressure during the manufacturing process, so that the light control film is subjected to as little force as possible. The process of bonding the light-transmitting plate and the light control film using the OCA adhesive is similar to the process of bonding the light-transmitting plate and the light control film using the EVA adhesive film or the PVB adhesive film, both of which use the lamination process, so if the second adhesive layer is OCA adhesive, the light control film will similarly receive uneven force and the uneven phenomenon will occur.

[0038] Furthermore, in the process of manufacturing the second adhesive layer, in order to ensure that the light control film is subjected to as little force as possible and further ensure that the manufactured light control module has a good appearance, the liquid optical adhesive needs to have good fluidity. In one embodiment, the viscosity of the liquid optical adhesive at 25°C is 500±200mPa·s (GB / T 2794-1995). Furthermore, in this embodiment, the liquid optical adhesive may be an acrylic liquid optical adhesive or a silicone liquid optical adhesive. In a specific example, the liquid optical adhesive is a silicone liquid optical adhesive. The silicone liquid optical adhesive has a lower shrinkage rate than the acrylic liquid optical adhesive and is excellent in high temperature resistance performance. Specifically, the shrinkage rate of the silicone liquid optical adhesive is about 0.1%, which is much smaller than the shrinkage rate of the acrylic liquid optical adhesive, which is 3%. In addition, the silicone liquid optical adhesive can withstand a high temperature of 120°C, while the acrylic liquid optical adhesive can usually withstand temperatures of 90°C to 100°C.

[0039] Specifically, the thickness of the second adhesive layer is 0.2 mm to 1 mm. In one embodiment, the thickness of the second adhesive layer is 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, or a range consisting of any two of these values. When the thickness of the second adhesive layer is within the above thickness range, the light control film and the second light-transmitting plate can be well bonded. Note that the thickness of the second adhesive layer may be greater than 1 mm, but the price of the liquid optical adhesive is high, and if the thickness of the second adhesive layer is too large, the cost increases, which is disadvantageous for practical production. Therefore, when the cost and adhesion are considered comprehensively, the thickness of the second adhesive layer is 0.2 mm to 1 mm.

[0040] The second light-transmitting plate is one of glass and polycarbonate plate. In one embodiment, the second light-transmitting plate is single curved glass or hyperbolic glass. Furthermore, the second light-transmitting plate is hyperbolic glass, and the dimming module may be applied to a vehicle. It should be noted that the second light-transmitting plate may be flat glass. Specifically, the edge of the second light-transmitting plate is flush with the edge of the first light-transmitting plate.

[0041] Furthermore, the second adhesive layer and the second light-transmitting plate are provided on the surface of the light-transmitting film that is far from the first light-transmitting plate after laminating the first light-transmitting plate, the first adhesive layer and the light-transmitting film. In this way, during the lamination process of the first light-transmitting plate, the first adhesive layer and the light-transmitting film, only one side of the light-transmitting film receives force, which avoids the first light-transmitting plate and the second light-transmitting plate from being pressed from both sides, and further distributes the light-transmitting film evenly to avoid defects such as unevenness and poor appearance.

[0042] In addition, the light control module further includes a sealing member located between the first adhesive layer and the second transparent plate and in contact with edges of the light control film and the second adhesive layer.

[0043] In one embodiment, the sealing member is a sealant layer.

[0044] In another embodiment, the sealing member includes a dam adhesive layer and a sealant layer, and the dam adhesive layer contacts the edges of the light control film and the second adhesive layer, the sealant layer, the first adhesive layer, and the second light-transmitting plate. The sealant layer contacts the dam adhesive layer, the first adhesive layer, and the second light-transmitting plate. Specifically, the dam adhesive layer may be a butyl tape, a VHB tape, or the like. In a specific example, the dam adhesive layer and the sealant layer are stacked and installed along a direction perpendicular to the thickness direction of the light control glass, and the dam adhesive layer is closer to the light control film than the sealant layer.

[0045] The material of the sealing member is not limited to the above materials, and any sealant that does not swell with the first adhesive layer during testing, has water vapor barrier sealing properties, and has adhesive strength with glass of 600 N or more can be used as the material of the sealing member according to this embodiment. A specific adhesive strength test is performed in accordance with the test method for adhesive strength of glass adhesives.

[0046] On the one hand, because the liquid optical adhesive is liquid, in the process of manufacturing the dimming module, it is necessary to create a dam with a sealing material on the edge; on the other hand, the inventors found in their experiments that using only the liquid optical adhesive does not provide sufficient sealing; for example, in the boiling experiment, water vapor will enter and separate the dimming film from the liquid adhesive surface, so it is necessary to use a sealing material on the edge of the second adhesive layer to prevent water vapor from eroding and ensure the reliability of the product.

[0047] In some embodiments, an ink layer is provided on the surface of the first light-transmitting plate facing the second light-transmitting plate, the edge of the light-control film is shrunk inward relative to the ink layer, and the distance between the edge of the light-control film and the edge of the ink layer is 5 mm to 30 mm. Specifically, the ink layer can be manufactured by a process such as printing when forming the first light-transmitting plate.

[0048] In some embodiments, an ink layer is provided on the surface of the second light-transmitting plate facing the first light-transmitting plate or on the surface away from the first light-transmitting plate, the edge of the light-control film shrinks inward relative to the ink layer, and the distance between the edge of the light-control film and the edge of the ink layer is 5 mm to 30 mm. Specifically, the ink layer can be manufactured by a process such as printing when forming the second light-transmitting plate.

[0049] The dimming module according to this embodiment has at least the following advantages.

[0050] (1) The above-mentioned light control module includes a first transparent plate, a first adhesive layer, a light control film, a second adhesive layer and a second transparent plate, which are sequentially stacked, and the first adhesive layer is a non-liquid optical adhesive before the light control module is manufactured, and the first transparent plate, the first adhesive layer and the light control film can be bonded together by a lamination process, and in the lamination process, the light control film is only one-sided and is not pressed from both sides, and the light control film is uniformly distributed, and defects such as unevenness and poor appearance can be avoided. The second adhesive layer is a liquid optical adhesive before the light control module is manufactured, and the light control film and the second transparent plate can be bonded together by the manner of adhesive injection and curing, so that the light control film is not subjected to force during this process, and the light control module has a good appearance and no unevenness. The above-mentioned light control module is particularly applicable when the light control film is an LC light control film or other highly fluid light control film, and the first and second light transparent plates are hyperbolic glass.

[0051] (2) Before the dimming module is manufactured, the first adhesive layer in the above-mentioned dimming module is made of a non-liquid optical adhesive and has good mechanical performance, so that the dimming module can meet the actual usage requirements.

[0052] (3) The above-mentioned light control module further includes a sealing member. On the one hand, since the liquid optical adhesive is liquid, in the process of manufacturing the light control module, it is necessary to create a dam on the edge by a sealing member; on the other hand, in the experiment, the inventors found that if only the liquid optical adhesive is used, the sealing property is insufficient. For example, in the boiling experiment, water vapor will enter and separate the light control film and the liquid adhesive surface, so it is necessary to use a sealing member to prevent the erosion of water vapor and ensure the reliability of the product.

[0053] A second aspect of the present application provides a method for manufacturing the light control module of the above embodiment, including the following steps S110 to S130.

[0054] In step S110, the first light-transmitting plate, the first adhesive layer, and the light-control film are sequentially stacked and placed, and then laminated.

[0055] The first adhesive layer is a non-liquid optical adhesive before manufacturing the light control module. For example, the first adhesive layer may be a solid or solidified optical adhesive OCA or a polymer adhesive before manufacturing the light control module. In one embodiment, the first adhesive layer is a material of one of PVB and EVA before manufacturing the light control module, and the edge of the light control film shrinks inward against the first light-transmitting plate and the first adhesive layer.

[0056] Specifically, the laminating step includes a step of placing the stacked first light-transmitting plate, the first adhesive layer and the light-control film in a vacuum bag, and pre-laminating the laminate by controlling the vacuum degree to -0.1 MPa to -0.09 MPa and the temperature to 115°C or less.

[0057] In the lamination step, a vacuum bag (or a vacuum bag made based on a polyester sheet) process is used to perform half lamination. Because the vacuum bag is soft, only one side of the light-control film is subjected to force, which avoids the light-control film being pressed. At the same time, after the half lamination, a liquid optical adhesive is used to process and seal the second light-transmitting plate and the light-control film. During the entire process, the light-control film is not pressed from both sides at the same time, which avoids the problem of uneven thickness of the light-control film causing appearance defects. This is especially effective for light-control films with good fluidity of liquid or functional layer.

[0058] In step S120, a sealing member is disposed in the inner shrinkage region of the first adhesive layer after lamination, and the thickness of the sealing member is greater than the thickness of the light-control film, and the sealing member and the surface of the light-control film away from the first light-transmitting plate form a concave groove.

[0059] Specifically, the thickness of the sealing member is 0.2 mm to 1 mm. The width of the sealing member is 1 mm to 3 mm. In this embodiment, the thickness direction of the sealing member is the same as the thickness direction of the light control module, and the width direction of the sealing member is perpendicular to the thickness direction, and specifically refers to the distance between the edge of the sealing member and the edge of the light control film.

[0060] In step S130, a liquid optical adhesive is poured into the groove, a second light-transmitting plate is attached, and the liquid optical adhesive is cured to obtain a light control module.

[0061] Specifically, in the step of disposing the sealing member in the inner shrinkage region of the first adhesive layer after lamination, an adhesive injection hole is left in the sealing member, and the adhesive injection hole communicates with the recessed groove. The step of injecting liquid optical adhesive into the groove and laminating a second light-transmitting plate includes the steps of first laminating a second light-transmitting plate to the side of the light-control film away from the first light-transmitting plate, covering the groove with the second light-transmitting plate, and then injecting liquid optical adhesive into the groove through the adhesive injection port.

[0062] In addition, it is necessary to leave an adhesive injection port in the sealing member and an exhaust port to facilitate evacuation and degassing. In a specific example, the sealing member has one adhesive injection port and one exhaust port. Note that the number of adhesive injection ports and exhaust ports in the sealing member is not limited thereto, and may be any number that is convenient for injecting the liquid optical adhesive into the groove and for evacuation, for example, one adhesive injection port and two exhaust ports, or two adhesive injection ports and two exhaust ports, etc.

[0063] Furthermore, as shown in FIG. 1, the sealing member has opposing first and second surfaces, the adhesive injection port is located at an end of the first surface, and the exhaust port is located at the other end of the first surface away from the adhesive injection port. When a position on the second surface opposite the adhesive injection port is taken as a reference point, the adhesive injection port and the reference point are on the same horizontal plane, and the exhaust port is located above the adhesive injection port. In the step of injecting liquid optical adhesive from the adhesive injection port into the groove, the laminate with the second light-transmitting plate attached is installed at an angle so that the distance from the adhesive injection port to the horizontal plane is greater than the distance from the reference point to the horizontal plane.

[0064] In the step of injecting the liquid optical adhesive into the groove from the adhesive inlet, the liquid optical adhesive flows and sticks to the lower surface and flows in, while the gas is exhausted from the higher surface, which is favorable for exhaust. If the surfaces where the adhesive inlet and the exhaust port are located are set horizontally or vertically, the liquid optical adhesive is likely to flow in from both sides at the same time, the liquid optical adhesive has a certain viscosity, and the gas is likely to be trapped in the groove, which is unfavorable for exhaust. In this way, the liquid optical adhesive is injected into the groove, and then the second transparent plate is attached, which is favorable for exhaust.

[0065] In this specification, the orientations or positional relationships indicated by the terms "upper", "lower", "horizontal", "vertical", etc. are all based on the orientations or positional relationships shown in the drawings, and these terms are primarily intended to provide a better explanation and are not intended to limit the elements or components shown to have a specific orientation, and are not to be understood as limiting the present application.

[0066] In another embodiment, the step of injecting a liquid optical adhesive into the groove and attaching the second transparent plate includes the steps of first injecting a liquid optical adhesive into the groove and then attaching the second transparent plate, whereby there is no need to leave an adhesive injection hole in the sealing member.

[0067] In one embodiment, after the step of curing the liquid optical adhesive, the method further includes the step of treating the cured laminate under conditions of a pressure of 0.1 MPa to 0.6 MPa and a temperature of 110°C to 140°C for 30 min to 90 min.

[0068] In another embodiment, after the laminating step and before the step of placing a sealing member in the inner shrinkage region of the first adhesive layer after lamination, the method further includes a step of treating the laminated laminate under conditions of a pressure of 0.1 MPa to 0.6 MPa and a temperature of 110°C to 140°C for 30 min to 90 min.

[0069] Experiments have proven that the above two methods can ensure that the appearance of the dimming module is good and free of unevenness, and can firmly adhere the dimming film to the first and second light-transmitting plates.

[0070] Specifically, in one embodiment, the sealing member includes a dam adhesive layer and a sealant layer, and in the step of disposing the sealing member on the inner shrink region of the first adhesive layer, after the step of disposing the dam adhesive layer on a portion of the inner shrink region of the first adhesive layer and curing the liquid optical adhesive, the method further includes the step of disposing a sealant layer on the remaining inner shrink region of the first adhesive layer.

[0071] In another embodiment, the sealing member is a sealant layer, and in the step of disposing the sealing member on the inner shrink region of the first adhesive layer, a sealant is applied to the inner shrink region of the first adhesive layer, and in the step of curing the liquid optical adhesive, the sealant is cured to form the sealant layer.

[0072] The first and second adhesive layers of the conventional light control module are both PVB adhesive film or EVA adhesive film, and are manufactured by lamination process. In the lamination process, high temperature and high pressure treatment is required, which causes defects in appearance and is prone to unevenness. In addition, the first and second adhesive layers of the light control module may be liquid optical adhesive before manufacturing the light control module, and the liquid adhesive injection process is used, and the appearance of the manufactured light control module is fine, but the method is complicated, the efficiency is low, and it is difficult to ensure the bonding of the flat light control film to the hyperbolic transparent plate. In addition, the liquid optical adhesive does not have the function of blocking ultraviolet light, cannot protect the light control film, and the mechanical performance of the liquid optical adhesive is low, so the performance of the manufactured light control module is difficult to meet the requirements.

[0073] The method for manufacturing the light control module according to this embodiment has at least the following advantages.

[0074] (1) The manufacturing method of the light control module according to the present embodiment is to first laminate the first light-transmitting plate, the first adhesive layer and the light-control film by lamination process, and in the lamination process, the light-control film is only subjected to one side force, avoiding being pressed from both sides, and further distributing the light-control film evenly, avoiding defects such as unevenness and poor appearance. Next, a sealing member is arranged on the edge of the light-control film, leaving an adhesive injection port and an exhaust port, and the second light-transmitting plate is laminated, and the light-control film and the second light-transmitting plate are bonded by the method of injecting and curing adhesive, so that the light-control film is not subjected to force in this process, and it is ensured that the appearance of the light-control module is good and there is no unevenness.

[0075] (2) In the manufacturing method of the dimming module of this embodiment, first, PVB or EVA is used to perform half lamination processing, and the processing efficiency is much higher than that of liquid optical adhesive. In addition, the half lamination process (vacuum bag process) is easier to perform in the processing method of the vehicle industry, which makes the lamination of the flat light control film to the hyperbolic light-transmitting plate more reliable. Next, when the liquid optical adhesive is laminated, only one adhesive injection is required, which improves production efficiency and ensures the lamination of the flat light control film to the hyperbolic light-transmitting plate.

[0076] (3) In the manufacturing method of the light control module according to the present embodiment, a sealing member is placed on the edge of the light control film. On the one hand, since the liquid optical adhesive is liquid, it is necessary to create a dam on the edge using a sealing member in the process of manufacturing the light control module. On the other hand, the inventors have found in their experiments that using only the liquid optical adhesive does not provide sufficient sealing. For example, in the boiling experiment, water vapor enters and separates the light control film from the liquid adhesive surface, so it is necessary to use a sealing member to prevent water vapor erosion and ensure the reliability of the product.

[0077] (4) The manufacturing method of the dimming module of this embodiment is integrated by combining two packaging processes, which not only ensures the appearance of the product, but also improves the mechanical performance and sealing properties of the dimming module, making the performance of the product more reliable.

[0078] A third aspect of the present application further provides a vehicle including the dimming module of the above embodiment.

[0079] In order to clarify the purpose and advantages of the present application, the dimming module of the present application and its effects will be described in more detail below with reference to specific examples. Note that the specific examples described herein are only for the purpose of explaining the present application and are not intended to limit the present application. Example 1

[0080] As shown in FIG. 2, this embodiment provides a light control module, specifically, a light control glass 100, which includes a first light-transmitting plate 110, a first adhesive layer 120, a light control film 130, a second adhesive layer 140, and a second light-transmitting plate 150, which are stacked in order. The first light-transmitting plate 110 and the second light-transmitting plate 150 are both hyperbolic glass (with a principal curvature of 2293-4900 mm, a minor curvature of 4887-475778 mm, and a thickness of 2.1 mm). The first adhesive layer 120 is a PVB adhesive film with a thickness of 0.38 mm. Before the light control module is manufactured, the material of the second adhesive layer 140 is a liquid optical adhesive (specifically, US108 liquid optical adhesive), and the thickness is 0.4 mm. The light control film 130 is an LC light control film. The light-control film 130 and the second adhesive layer 140 shrink inward relative to the first light-transmitting plate 110 and the second light-transmitting plate 150, and a sealant layer 160 (specifically, a polyurethane adhesive) is applied to the edges of the light-control film 130 and the second adhesive layer 140.

[0081] The manufacturing steps of the light control glass according to this embodiment specifically include the following steps (1) to (5).

[0082] In step (1), the first light-transmitting plate is cleaned, a cut PVB adhesive film (the edge of the PVB adhesive film is 2 to 3 mm larger than the edge of the first light-transmitting plate) is placed on it, and then the light-control film is placed and aligned to obtain a half-laminated glass.

[0083] In step (2), the half laminated glass was placed in a vacuum bag and cold evacuated and pre-laminated, with the vacuum degree controlled at -0.09 MPa and the maximum temperature at 115 °C.

[0084] In step (3), polyurethane adhesive is applied within an area of ​​2 mm from the edge of the light-control film of the half laminated glass after pre-lamination, and the thickness of the polyurethane adhesive is 0.8 mm. In some areas, polyurethane adhesive is not applied, and two holes are left, one for adhesive injection and the other for exhaust, and then the second light-transmitting plate is laminated.

[0085] In step (4), the laminate obtained in step (3) was tilted to an inclination angle of 20° and left as it was, and a liquid optical adhesive was injected into the laminate and simultaneously evacuated, and then the laminate was cured at room temperature.

[0086] In step (5), the laminate cured in step (4) was placed in an autoclave and subjected to high pressure and high temperature treatment at a pressure of 0.8 MPa and a temperature of 110° C. for 70 minutes to obtain a light control glass. Example 2

[0087] As shown in FIG. 3, this embodiment provides a light control module, specifically a light control glass 200, which includes a first light-transmitting plate 210, a first adhesive layer 220, a light control film 230, a second adhesive layer 240 and a second light-transmitting plate 250, which are sequentially stacked. The first light-transmitting plate 210 and the second light-transmitting plate 250 are both hyperbolic glass (with a principal curvature of 2293-4900 mm, a minor curvature of 4887-475778 mm, and a thickness of 2.1 mm). The first adhesive layer 220 is a PVB adhesive film with a thickness of 0.38 mm. Before the light control module is manufactured, the material of the second adhesive layer 240 is a liquid optical adhesive (specifically, US108 liquid optical adhesive), and the thickness is 0.4 mm. The light control film 230 is an LC light control film. The light-control film 230 and the second adhesive layer 240 shrink inwardly relative to the first light-transmitting plate 210 and the second light-transmitting plate 250, and a sealing member 260 is installed on the edges of the light-control film 230 and the second adhesive layer 240, the sealing member 260 including a dam adhesive layer 262 (e.g., butyl tape) and a sealant layer 264 (e.g., Sika adhesive), and the dam adhesive layer 262 is closer to the light-control film 230 than the sealant layer 264.

[0088] The manufacturing steps of the light control glass according to this embodiment specifically include the following steps (1) to (6).

[0089] In step (1), the first light-transmitting plate is cleaned, a cut PVB adhesive film (the edge of the PVB adhesive film is 1 to 3 mm larger than the edge of the first light-transmitting plate) is placed on it, a light-control film is placed on it, and the position is adjusted to obtain a half-laminated glass.

[0090] In step (2), the half laminated glass was placed in a vacuum bag and cold evacuated and pre-laminated, with the vacuum degree controlled at -0.09 MPa and the maximum temperature at 115 °C.

[0091] In step (3), a butyl tape was placed within an area of ​​2 mm from the edge of the light-control film of the half laminated glass after pre-lamination, and the thickness of the butyl tape was 0.4 mm. Two holes were left on the butyl tape, one for injecting adhesive and the other for exhausting, and then a second light-transmitting plate was laminated.

[0092] In step (4), the laminate obtained in step (3) was tilted to an inclination angle of 30° and left as it was, and a liquid optical adhesive was injected into the laminate and simultaneously evacuated, and then the laminate was cured at room temperature.

[0093] In step (5), the laminate cured in step (4) was placed in an autoclave and subjected to high-pressure and high-temperature treatment at a pressure of 0.3 MPa and a temperature of 115° C. for 70 minutes.

[0094] In step (6), a Sika adhesive was applied to the edge of the laminate after the high temperature and high pressure treatment, and cured at room temperature to obtain light-control glass. Example 3

[0095] The light control glass of this embodiment has the same structure as the light control glass of Example 2, but is manufactured using a different method. Specifically, the manufacturing steps of the light control glass of this embodiment include the following steps (1) to (6).

[0096] In step (1), the first light-transmitting plate is cleaned, a cut PVB adhesive film (the edge of the PVB adhesive film is 1 to 3 mm larger than the edge of the first light-transmitting plate) is placed on it, a light-control film is placed on it, and the position is adjusted to obtain a half-laminated glass.

[0097] In step (2), the half laminated glass was placed in a vacuum bag and cold evacuated and pre-laminated, with the vacuum degree controlled at -0.09 MPa and the maximum temperature at 115 °C.

[0098] In step (3), the half laminated glass after pre-lamination is put into an autoclave to undergo high pressure and high temperature treatment, the pressure is 0.6 MPa, the temperature is 135° C., and the temperature is kept constant for 40 minutes.

[0099] In step (4), butyl tape was placed within an area of ​​2 mm from the edge of the light-control film of the half laminated glass treated in step (3), the thickness of the butyl tape was 0.4 mm, two holes were left in the butyl tape, one for injecting adhesive and the other for exhaust, and then a second light-transmitting plate was laminated.

[0100] In step (5), the laminate obtained in step (4) was tilted to an inclination angle of 20° and left as it was, and a liquid optical adhesive was injected into the laminate and simultaneously evacuated, and then the laminate was cured at room temperature.

[0101] In step (6), a Sika adhesive was applied to the edge of the laminate cured in step (5) and cured at room temperature to obtain a light-control glass.

[0102] Comparative Example 1 Comparative Example 1 provides a light-control glass including a first light-transmitting plate, a first adhesive layer, a light-control film, a second adhesive layer, and a second light-control plate, which are laminated in this order. The first light-transmitting plate and the second light-transmitting plate are both hyperbolic glass (with a principal curvature of 2293 to 4900 mm, a minor curvature of 4887 to 475778 mm, and a thickness of 2.1 mm). The first adhesive layer and the second adhesive layer are both PVB adhesive films with a thickness of 0.38 mm. The light-control film is an LC light-control film. The light-control film shrinks inward relative to the first light-transmitting plate and the second light-transmitting plate.

[0103] The manufacturing steps of the light control glass according to Comparative Example 1 specifically include the following steps (1) and (2).

[0104] In step (1), the first light-transmitting plate was cleaned, and the cut PVB adhesive film (the edge of the PVB adhesive film was 2 to 3 mm larger than the edge of the first light-transmitting plate), the LC light-control film, the cut PVB adhesive film, and the second light-transmitting plate were placed in that order and aligned to obtain a laminate.

[0105] In step (2), the laminate was placed in a vacuum bag and subjected to cold vacuuming and pre-lamination, and the degree of vacuum was controlled to -0.09 MPa and the maximum temperature to 115°C. Then, the laminate was placed in an autoclave and subjected to high pressure and high temperature treatment at a pressure of 0.6 MPa and a temperature of 135°C for 40 minutes to obtain a light-control glass.

[0106] Comparative Example 2 Comparative Example 2 provides a light control glass including a first light-transmitting plate, a first adhesive layer, a light control film, a second adhesive layer and a second light-transmitting plate, which are laminated in order. The first light-transmitting plate and the second light-transmitting plate are both hyperbolic glass (principal curvature is 2293-4900 mm, minor curvature is 4887-475778 mm, and thickness is 2.1 mm). Before manufacturing the light control module, the first adhesive layer and the second adhesive layer are both made of liquid optical adhesive (specifically, US108 liquid optical adhesive) and have a thickness of 0.8 mm. The light control film is an LC light control film. The first adhesive layer, the light control film and the second adhesive layer shrink inwardly relative to the first light-transmitting plate and the second light-transmitting plate, and a dam adhesive layer (specifically, butyl tape) and a sealant layer (specifically, Sika adhesive) are installed on the edges of the first adhesive layer, the light control film and the second adhesive layer.

[0107] The manufacturing steps of the light control glass according to Comparative Example 2 specifically include the following steps (1) to (3).

[0108] In step (1), the first light-transmitting plate was cleaned and scribed on one side of the first light-transmitting plate, and the scribed area matched the outer dimensions of the LC light-control film (including the PET dimensions around the light-control film).

[0109] In step (2), butyl tape was attached to the unscribed surface, and the edge of the tape was made flush with the scribe line. One adhesive injection port and four exhaust ports were left on the butyl tape. The planar LC liquid crystal film and the butyl tape were aligned and attached, and the edge of the LC liquid crystal film and the edge of the butyl tape were made flush with each other to form a planar box. In combination with an adhesive injection device, a needle was inserted into the adhesive injection port to inject liquid optical adhesive, and after the injection was completed, it was left horizontally for 5 minutes, and a sheet of release film was placed on the top surface of the LC liquid crystal film, after which 2 to 3 sheets of white glass of the same size were pressed against the release film, tied with tape, and left horizontally for 10 minutes. It was then cured at room temperature for 30 minutes, and the pressed white glass and release film were removed, and the overflowing adhesive was removed.

[0110] In step (3), a layer of butyl rubber tape is applied along the original position of the butyl tape in the first layer, and similarly, one adhesive injection port and four exhaust ports are left, and the second light-transmitting plate and the butyl tape are aligned and bonded together to form a flat box of the second layer, and a second adhesive injection is performed. After the injection is completed, the product is left horizontally for 5 minutes, and then cured at room temperature. After curing, the remaining adhesive is removed, and Sika adhesive is applied around it to obtain a light-control glass. Comparative Example 3

[0111] Comparative Example 3 provides a light-control glass having a structure similar to that of the light-control glass of Example 2, except that no dam adhesive or sealant is installed on the edges of the LC light-control film and the second adhesive layer.

[0112] The manufacturing steps of the light control glass according to Comparative Example 3 specifically include the following steps (1) to (5).

[0113] In step (1), the first light-transmitting plate is cleaned, a cut PVB adhesive film (the edge of the PVB adhesive film is 2 to 3 mm larger than the edge of the first light-transmitting plate) is placed on it, and then the light-control film is placed and aligned to obtain a half-laminated glass.

[0114] In step (2), the half laminated glass was placed in a vacuum bag and cold evacuated and pre-laminated, with the vacuum degree controlled at -0.09 MPa and the maximum temperature at 115 °C.

[0115] In step (3), a butyl tape was placed within an area of ​​2 mm from the edge of the light-control film of the half laminated glass after pre-lamination, and the thickness of the butyl tape was 0.8 mm. Two holes were left on the butyl tape, one for injecting adhesive and the other for exhausting, and then a second light-transmitting plate was laminated.

[0116] In step (4), the laminate obtained in step (3) was tilted to an inclination angle of 20° and left as it was, and a liquid optical adhesive was injected into the laminate and simultaneously evacuated. Thereafter, the laminate was cured at room temperature, and after the curing was completed, the butyl tape was removed.

[0117] In step (5), the laminate cured in step (4) was placed in an autoclave and subjected to high-pressure and high-temperature treatment at a pressure of 0.3 MPa and a temperature of 110° C. for 60 minutes to obtain a light-control glass.

[0118] The performance of the light control glass of the examples and comparative examples was tested. Specific test methods included a sealability test (boiling experiment, 100°C boiling water, left for 2 hours, judged according to the method of GB9656-2021) and a mechanical performance test (using a 226g steel ball, free-fall from a height of 9m to impact, judged according to the method of GB9656-2021), and the data shown in Table 1 below was obtained.

[0119] [Table 1]

[0120] The technical features of the above embodiments can be combined in any combination. For the sake of brevity, all possible combinations of the technical features in the above embodiments are not described, but these combinations should all be considered to fall within the scope of the present specification unless there is a contradiction.

[0121] The above examples are merely some embodiments of the present application, and the descriptions thereof are specific and detailed, but should not be construed as limiting the scope of the patent of the present application. It should be noted that those skilled in the art can make various modifications and improvements to the present application without departing from the spirit of the present application, and these modifications and improvements belong to the scope of protection of the present application. Therefore, the scope of protection of the patent of the present application should be based on the scope of the attached claims.

Claims

1. The light-transmitting device includes a first light-transmitting plate, a first adhesive layer, a light-control film, a second adhesive layer, and a second light-transmitting plate, which are stacked in this order; The first light-transmitting plate, the first adhesive layer and the light-control film are bonded together by a lamination process; the second adhesive layer is formed by curing a liquid optical adhesive; the edges of the light management film and the second adhesive layer shrink inwardly relative to the first adhesive layer; The light control module further comprises a sealing member positioned between the first adhesive layer and the second light-transmitting plate and in contact with edges of the light control film and the second adhesive layer.

2. The light control module according to claim 1 , wherein the second adhesive layer has a thickness of 0.2 mm to 1 mm.

3. The light control module according to any one of claims 1 to 2, characterized in that the viscosity of the liquid optical adhesive at 25°C is 500±200 mPa·s.

4. The light control module according to any one of claims 1 to 3, characterized in that the liquid optical adhesive comprises an acrylic-based liquid optical adhesive or a silicone-based liquid optical adhesive.

5. The light control module of any one of claims 1 to 4, wherein the light control film comprises an LC light control film.

6. The dimming module according to any one of claims 1 to 5, characterized in that the first light-transmitting plate and the second light-transmitting plate both include single-curved glass or both include hyperbolic glass.

7. The light control module described in any one of claims 1 to 6, characterized in that the sealing member is a sealant layer, or the sealing member includes a sealant layer and a dam adhesive layer, the dam adhesive layer contacts the edges of the light control film and the second adhesive layer, the sealant layer, the first adhesive layer and the second light-transmitting plate, and the sealant layer contacts the dam adhesive layer, the first adhesive layer and the second light-transmitting plate.

8. The light control module according to any one of claims 1 to 7, characterized in that the material of the first adhesive layer is one of PVB and EVA.

9. The dimming module according to any one of claims 1 to 8, characterized in that the first adhesive layer has a thickness of 0.3 mm to 0.8 mm.

10. A step of sequentially stacking and positioning a first light-transmitting plate, a first adhesive layer, and a light-control film, and then laminating the first adhesive layer, wherein an edge of the light-control film shrinks inward relative to the first adhesive layer; A step of disposing a sealing member on the inner shrinkage region of the first adhesive layer after lamination, the thickness of the sealing member being greater than the thickness of the light-regulating film, and the sealing member and the surface of the light-regulating film away from the first light-transmitting plate form a concave groove; A method for manufacturing a dimming module, comprising the steps of injecting a liquid optical adhesive into the groove, bonding a second light-transmitting plate, and hardening the liquid optical adhesive to obtain a dimming module.

11. In the step of disposing a sealing member in the inner shrink region of the first adhesive layer after lamination, an adhesive injection port communicating with the groove is left in the sealing member; The method for manufacturing a light control module as described in claim 10, characterized in that the step of injecting liquid optical adhesive into the groove and bonding a second light-transmitting plate includes the steps of first bonding the second light-transmitting plate to the side of the light control film away from the first light-transmitting plate, blocking the groove with the second light-transmitting plate, and then injecting the liquid optical adhesive into the groove from the adhesive injection port.

12. The method for manufacturing a dimming module described in claim 11, characterized in that the sealing member further has an exhaust port, the sealing member has opposing first and second surfaces, the adhesive injection port is located at one end of the first surface, the exhaust port is located at the other end of the first surface away from the adhesive injection port, and when a position on the second surface opposite the adhesive injection port is taken as a reference point, the adhesive injection port and the reference point are on the same horizontal plane, the exhaust port is above the adhesive injection port, and in the step of injecting the liquid optical adhesive from the adhesive injection port into the groove, the laminate in which the second light-transmitting plate is bonded is installed at an angle so that the distance from the adhesive injection port to the horizontal plane is greater than the distance from the reference point to the horizontal plane.

13. The method for manufacturing a light control module according to claim 12, characterized in that the inclination angle is 15° to 45°.

14. The manufacturing method of the light control module described in any one of claims 10 to 13, characterized in that the laminating step includes a step of preliminarily laminating the first light-transmitting plate, the first adhesive layer and the light control film that are stacked together under conditions of a vacuum degree of -0.1 MPa to -0.09 MPa and a temperature of 115°C or less.

15. After the step of curing the liquid optical adhesive, the cured laminate is subjected to a pressure of 0.1 MPa to 0.6 MPa and a temperature of 110° C. to 140° C. for 30 min to 90 min. Alternatively, The method for manufacturing a light control module as described in claim 14, characterized in that after the laminating step, before the step of placing a sealing member in the inner shrinkage area of ​​the first adhesive layer after lamination, the method further includes a step of treating the laminated stack for 30 min to 90 min under conditions of a pressure of 0.1 MPa to 0.6 MPa and a temperature of 110 ° C to 140 ° C.

16. The method for manufacturing a dimming module described in any one of claims 10 to 15, characterized in that the sealing member is a sealant layer, and in the step of placing the sealing member in the inner shrinkage region of the first adhesive layer, a sealant is applied to the inner shrinkage region of the first adhesive layer, and in the step of hardening a liquid optical adhesive, the sealant is hardened to form the sealant layer.

17. The method for manufacturing a dimming module described in any one of claims 10 to 16, characterized in that the sealing member includes a dam adhesive layer and a sealant layer, and in the step of placing the sealing member in the inner shrinkage area of ​​the first adhesive layer, the method further includes a step of placing the dam adhesive layer in a portion of the inner shrinkage area of ​​the first adhesive layer, and after a step of hardening the liquid optical adhesive, placing the sealant layer in the remaining inner shrinkage area of ​​the first adhesive layer.

18. The method for manufacturing a light control module according to claim 17, wherein the thickness of the dam adhesive layer is 0.2 mm to 1 mm.

19. A vehicle comprising the light control module according to any one of claims 1 to 9.

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