Dimming device and dimming module, and method for manufacturing a dimming module

Abstract

The present invention provides a dimming device and a dimming module that can suitably seal the end face of the dimming layer with a sealing layer, as well as a method for manufacturing a dimming module. [Solution] A dimming device attached to a light-transmitting member, comprising: a dimming layer; a first outer support layer located on the side of the dimming layer to the light-transmitting member; a second outer support layer located on the opposite side of the dimming layer to the first outer support layer and having an overhang portion that protrudes laterally from the end face of the dimming layer; and a sealing layer located between the overhang portion and the light-transmitting member and sealing the end face of the dimming layer.

Description

Technical Field

[0001] The present invention relates to a dimming device, a dimming module, and a method for manufacturing a dimming module.

Background Art

[0002] Patent Document 1 describes a dimming device having a dimming member, a support base member, and a sealing material. The dimming member is in a flat plate shape with a liquid crystal layer encapsulated therein and has an end face on an inclined surface. The support base member has light transmissivity and mounts and fixes the dimming member in a state where the angle formed with the inclined surface of the dimming member is an obtuse angle. The sealing material seals the end face of the dimming member mounted and fixed on the support base member.

[0003] Patent Document 2 describes a dimming panel including a support member, a dimming cell disposed on one side of the support member, a sealing material disposed on the support member so as to cover an end face of the dimming cell, and a tape attached so as to cover the sealing material and straddle the support member and the dimming cell.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, according to the intensive research by the present inventor, the dimming device of Patent Document 1 has room for improvement from the viewpoint of suitably sealing the end face of the dimming member with the sealing material. Further, the dimming panel of Patent Document 2 has room for improvement from the viewpoint of suitably sealing the end face of the dimming cell with the sealing material and the tape.

[0006] The present invention was completed based on the above-mentioned concerns, and aims to provide a dimming device and dimming module that can suitably seal the end face of the dimming layer with a sealing layer, as well as a method for manufacturing a dimming module. [Means for solving the problem]

[0007] The dimming device of this embodiment is a dimming device attached to a light-transmitting member, and is characterized by comprising: a dimming layer; a first outer support layer located on the side of the dimming layer to the light-transmitting member; a second outer support layer located on the opposite side of the dimming layer to the first outer support layer and having a visor portion that protrudes laterally from the end face of the dimming layer; and a sealing layer located between the visor portion and the light-transmitting member and sealing the end face of the dimming layer.

[0008] The dimming module of this embodiment is a dimming module having a light-transmitting member and a dimming device attached to the light-transmitting member, wherein the dimming device is characterized by having a dimming layer, a first outer support layer located on the side of the dimming layer to the light-transmitting member, a second outer support layer located on the opposite side of the dimming layer to the first outer support layer and having a visor portion that protrudes laterally from the end face of the dimming layer, and a sealing layer located between the visor portion and the light-transmitting member and sealing the end face of the dimming layer.

[0009] The manufacturing method of the dimming module of this embodiment is characterized by comprising: a preparation step of preparing two laminates, each having a dimming layer, a first outer support layer located on the side of the light-transmitting member of the dimming layer, and a second outer support layer located on the opposite side of the first outer support layer of the dimming layer and having an overhang portion that protrudes laterally from the end face of the dimming layer; an attachment step of placing the two laminates adjacent to each other, with the end faces of the adjacent overhang portions facing each other, and attaching the adjacent first outer support layer to the light-transmitting member; and a filling step of filling the two adjacent laminates with a sealing layer located between the adjacent overhang portion and the light-transmitting member, and sealing the end face of the adjacent dimming layer. [Effects of the Invention]

[0010] According to the present invention, it is possible to provide a dimming device and a dimming module in which the end face of the dimming layer can be suitably sealed with a sealing layer, as well as a method for manufacturing a dimming module. [Brief explanation of the drawing]

[0011] [Figure 1] This figure shows an example of the cross-sectional structure of the dimming device of this embodiment. [Figure 2] This is a plan view showing an example of the configuration of the dimming module of this embodiment. [Figure 3] This is a cross-sectional view along line III-III in Figure 2. [Figure 4] This figure shows another example of the configuration of the dimming module in this embodiment. [Figure 5] This is a process diagram showing an example of a manufacturing method for a dimming module. [Figure 6] This is a process diagram showing another example of a manufacturing method for a dimming module. [Figure 7] This figure shows an example of the process for preparing two stacked components of a dimming device. [Modes for carrying out the invention]

[0012] <Definitions of Terms, etc.> In this specification, "first (of XX)" and "second (of XX)" may be read as interchangeable. For example, in this specification, "first outer support layer" and "second outer support layer" may be read as interchangeable, "first transparent conductive layer" and "second transparent conductive layer" may be read as interchangeable, and "first transparent substrate layer" and "second transparent substrate layer" may be read as interchangeable. Furthermore, when the "outer support layer" is constructed by laminating a "transparent conductive layer" and a "transparent substrate layer," a "functional film layer" may be further laminated on the outside of the "transparent substrate layer." In this case, the outer support layer that includes the functional film layer in addition to the transparent conductive layer and transparent substrate layer may be defined as the "second outer support layer (second transparent conductive layer, second transparent substrate layer, functional film layer)."

[0013] In this specification, the term "light-transmitting member" may be read as "light-transmitting plate" or "light-transmitting window," and is used in a concept that includes "glass member," "glass plate," or "glass window." That is, in this specification, "glass member (glass plate, glass window)" is given as an example of a "light-transmitting member (light-transmitting plate, light-transmitting window)," but a "light-transmitting member (light-transmitting plate, light-transmitting window)" may be composed of materials other than glass, such as various plastics or other materials. For example, a "light-transmitting member (light-transmitting plate, light-transmitting window)" may be made of polycarbonate.

[0014] In this specification, a "dimming module" is defined as comprising a light-transmitting member and a dimming device attached to the light-transmitting member. As its name suggests, the light-transmitting member possesses light-transmitting properties as its own characteristic. The dimming device ensures the light-transmitting properties of the light-transmitting member and thus the dimming module (making it transparent) by not activating its own dimming function, and inhibits the light-transmitting properties of the light-transmitting member and thus the dimming module (making it opaque) by activating its own dimming function. There are two types of dimming devices: a normal type (normal mode) that is transparent when powered on and opaque when not powered on, and a reverse type (reverse mode) that is transparent when not powered on and opaque when powered on. Activating the dimming function of the dimming device means when the normal type is not powered on and when the reverse type is powered on, while not activating the dimming function of the dimming device may mean when the normal type is powered on and when the reverse type is not powered on. In this way, the dimming device can switch between a transparent state and an opaque state by switching between a powered state and an unpowered state. Here, "transparent state" does not mean a visible light transmittance of 100% (it does not mean a strictly transparent state), and "opaque state" does not mean a visible light transmittance of 0% (it does not mean a strictly opaque state). Both terms may be used to include a semi-transparent state. Furthermore, in this specification, "dimming device" may mean a dimming device that is a component of a dimming module and is in its state before being attached to a light-transmitting member.

[0015] In this specification, the dimming method using a dimming module (dimmer) can, for example, be a polymer dispersed liquid crystal (PDLC) method or a polymer network liquid crystal (PNLC) method. Alternatively, the dimming method using a dimming module (dimmer) may utilize electrochromic (EC), liquid crystal (LC), or suspended particle device (SPD). In other words, the dimming method using a dimming module (dimmer) offers flexibility and allows for various design modifications.

[0016] In this specification, a dimming device has a "dimming region (dimming part, dimming surface)" that switches between a transparent state and an opaque state by switching between an energized state and an unenhanced state, and a "sealing region (sealing part, sealing surface) that seals at least a part of the periphery of the dimming region." The dimming region may mean, for example, substantially the entire area of ​​a dimming sheet (dimming film) excluding the periphery, which has a dimming layer, a pair of transparent conductive layers located on both sides of the dimming layer, and a pair of transparent substrate layers located on both sides of the pair of transparent conductive layers. Furthermore, the dimming region may be defined as the region in which the dimming function of the dimming sheet (dimming film) is activated and the visible light transmittance changes, and / or the region in the dimming sheet (dimming film) where the dimming layer exists when viewed from above. The sealing region may consist of, for example, a sealing layer or sealing member (for example, a material that can be UV cured in a short time) that seals at least a part of the periphery of the dimming sheet.

[0017] In this specification, the light-transmitting member to which the dimming device is attached may include so-called single-layer or double-layer light-transmitting members. In the case of a single-layer light-transmitting member, the dimming device may be attached to the surface of the single-layer light-transmitting member. In the case of a double-layer light-transmitting member, the dimming device may be supported by sandwiching it with an intermediate layer (intermediate film) interposed between the two light-transmitting members, or the dimming device may be attached to the surface of one of the two light-transmitting members. Thus, there is freedom in the structure for attaching the dimming device to the light-transmitting member, and various design changes are possible.

[0018] In this specification, "upper surface" and "lower surface" as well as "one surface" and "the other surface" may be defined, for example, as the upper surface (one surface) and the lower surface (the other surface) in the figure (may be defined based on the vertical direction in the figure). Also, in this specification, "outer side" and "outer support layer" may be defined as being outside a certain reference (center) layer or as a layer supported outside a certain reference (center) layer, regardless of the vertical direction in the figure. For example, assume a laminated structure in which a certain reference (center) layer A is provided, layer B is provided on both surfaces of layer A, and layer C is provided on both surfaces of layer B. In this case, layer B is an "outer support layer" supported "outside" layer A, and layer C is an "outer support layer" supported "outside" layer A and layer B. In that sense, "outer side" and "outer support layer" may be read as "upper layer" and "upper layer support layer". In this case, it is defined that the farther away from a certain reference (center) layer, the more it is on the upper layer side, and the closer to a certain reference (center) layer, the more it is on the lower layer side.

[0019] <Conventional Technical Problems> Recently, from the perspectives of ambient light adjustment and privacy protection, dimming devices that can control transparency and opacity by applying voltage have been increasingly used in partitions, residential windows, cars, etc. Considering aspects such as reliability, dimming devices generally have a structure in which the peripheral part is protected by a sealing material. For example, dimming devices used for building materials applications often change between a cloudy state and a transparent state (the color of the opaque state is white) in order to control the scattering of transmitted light by voltage and adjust transparency and opacity. On the other hand, recently, in response to environmental issues, solar control (light-shielding property), and furthermore, from the perspective of design, those that control black and transparent (or semi-transparent) (the color of the opaque state is black) are also increasing.

[0020] As described above, a dimming device is a product that can instantaneously switch between transparent and opaque by making use of the characteristics of liquid crystal, and is often used to switch between an open space and a private space. Recently, in the dimming device market for in-vehicle and bathroom applications, the demand for laminated glass is large rather than for the dimming sheet (dimming film) alone, and a design that does not cause defects in the dimming sheet (dimming film) during the laminated glass process is required.

[0021] In a dimming sheet (dimming film), in order to suppress deterioration of the dimming layer (for example, moisture absorption deterioration due to moisture), a sealing layer (sealing member) is often provided at the end (cut end) of the dimming sheet (dimming film). However, there was a risk that the sealing layer (sealing member) would be exposed in a raised form from the surface of the dimming sheet (dimming film), damaging the appearance. In addition, there was also a risk that the sealing layer (sealing member) would be damaged (broken) by an external force (for example, the pressing force during cleaning). In particular, when multiple dimming sheets (dimming films) are abutted (opposed) and pasted onto a large single piece of glass, there was a risk of being insufficient in terms of appearance and strength (durability) due to the influence of the gap at the abutting part (opposing part), non-dimming area, and sealing material coating state.

[0022] This is because, in current methods of sealing the edges of dimmable sheets (dimmable films), in order to ensure reliability, a sealing area is created by overlapping the edge surface of the dimmable sheet (dimmable film) by a predetermined height (for example, about 2 mm for larger sheets, and less than 1 mm for smaller sheets) (for example, the overlap width is about 1-2 mm). Furthermore, when sealing the edges of dimmable sheets (dimmable films) at the construction site, the non-dimmable area can be made smaller depending on the skill of the worker in adjusting (hand-painting), but it is unavoidable that the appearance will be poor due to the manual work (especially the visibility of the sealed edge when light reflects, and unevenness and waviness will be clearly visible).

[0023] Furthermore, when sealing the edges of dimmable sheets (dimmable films) at the construction site, the process was often complicated, resulting in poor work efficiency and requiring considerable time and effort. More specifically, in order to uniformly apply and form the sealing material for edge sealing to the required areas, it was necessary to protect not only the dimmable sheet (dimmable film) itself, but also the mounting surfaces such as glass, sashes, and caulking, masking, application, smoothing with a spatula, removing the masking tape, and curing. Even for skilled workers, this increased the burden and difficulty.

[0024] Furthermore, existing dimmable sheets (dimmable films) are generally cut or molded to the required size at the factory before shipment, making it difficult to flexibly cut them to desired dimensions and shapes at the construction site. Although it is possible to cut the dimmable sheets (dimmable films) at the construction site with a cutter or similar tool as a non-recommended (forceful) method, it is not practical to cleanly cut long straight lines, for example, and defects at the edges, such as delamination between layers of the dimmable sheet (dimmable film) or adhesive lifting due to burrs, make it difficult to obtain a good appearance. In addition, there is a concern that if the dimmable sheet (dimmable film) lifts during bonding with the glass (transparent material), the dimming function of the dimmable sheet (dimmable film) may become insufficient.

[0025] Thus, the prior art, including the aforementioned Patent Documents 1 and 2, has made it difficult to suitably seal the end face of the dimming layer with a sealing layer, both from the perspective of objects such as dimming devices and dimming modules, and from the perspective of manufacturing methods (construction methods) such as manufacturing methods for dimming modules.

[0026] <Technical Concept of the Invention> The inventors of this invention considered the above-mentioned problems as important technical challenges and completed the present invention by conceiving a configuration and method for suitably sealing the end face of the dimming layer with a sealing layer, both from the perspective of objects such as dimming devices and dimming modules, and from the perspective of manufacturing methods (construction methods) such as manufacturing methods for dimming modules. More specifically, according to the present invention, it is possible to realize an end sealing structure that has a good appearance after construction and is resistant to damage by external forces. Furthermore, it is possible to realize a sealing method that is easy and has a low construction load even when sealing is done at the construction site. In addition, even if the sheet (film) is cut at the construction site, interlayer delamination and lifting of the adhesive layer due to burrs do not occur, and a cutting method and structure that has a good appearance and is suitable for sealing can be realized.

[0027] In this embodiment, the base material (and functional film) on the glass-bonding side (adhesive side) of the edge of the dimming sheet (dimming film) is half-cut in a minute width along the outer circumference shape. This leaves the base material (and functional film) on the front side (non-glass side) in a minute-width overhang shape, and the area below this overhang (between it and the glass) is filled with a sealing material. This structure maintains a highly reliable sealing structure while achieving a sealing structure in which the sealing material is hardly exposed on the surface.

[0028] When multiple dimming sheets (dimming films) are placed adjacent to each other on glass, at the joint (opposing) portion, the end faces of the eaves (eaves-shaped portion) of the dimming sheets (dimming films) of the same structure are brought together (opposing) to form a structure with a cavity (closed space) due to the abutting (opposing) of minute width eaves. By filling (injecting) an appropriate amount of sealant into this cavity (closed space), a sealing structure with good appearance and excellent strength (durability) can be achieved, in which the sealed portion is hardly exposed to the outside.

[0029] By using a coating machine (dispenser, etc.) with a micro-nozzle that can fill (inject) an appropriate amount of sealant into the gap formed between adjacent light-adjusting sheets (light-adjusting films) of the same structure, for example, the gap formed between the abutting end faces (opposing end faces) of the eaves (eaves-shaped parts), it is possible to eliminate the excessive masking, leveling, curing, and curing (waiting time) that are conventionally required for sealing and caulking work, thereby simplifying the work, reducing time, and further reducing the amount of materials and related supplies.

[0030] Furthermore, the light-adjusting sheet (light-adjusting film) with the awning portion (awning-shaped portion) formed on it has a structure that is suitable for cutting the outer shape and adjusting the dimensions at the construction site (the same structure can be easily realized). At the construction site, after cutting the outer shape appropriately, by manually making a small half-cut using a cutter from the glass bonding surface side (adhesive side), the awning portion (awning-shaped portion) can be formed on the light-adjusting sheet (light-adjusting film), and the edges can be cut without delamination or burrs.

[0031] <Specific Embodiments> <Dimming devices and dimming modules> Figure 1 shows an example of the cross-sectional structure (laminated structure) of the dimming device (dimming sheet, dimming film) 10 of this embodiment. Figure 1 is a simplified depiction of the minimum cross-sectional structure (laminated structure) necessary for the dimming function of the dimming device 10, and omits the "eaves portion" and the "sealing layer" that fills the filling space formed by the "eaves portion," which will be described later. The lower surface of the dimming device 10 in Figure 1 is attached (bonded, joined) to the light-transmitting member 100, which will be described later.

[0032] The dimming device (dimming sheet, dimming film) 10 has a dimming layer (liquid crystal layer) 20. The dimming layer 20 contains a liquid crystal composition. The dimming layer 20 is composed of, for example, polymer network liquid crystal (PNLC), polymer dispersed liquid crystal (PDLC), nematic curvilinear aligned phase (NCAP), etc. For example, polymer network liquid crystal has a polymer network having a three-dimensional mesh structure, and liquid crystal molecules are held in the voids of the polymer network. The liquid crystal molecules contained in the dimming layer 20 have, for example, positive dielectric anisotropy, and the dielectric constant in the long axis direction of the liquid crystal molecule is greater than the dielectric constant in the short axis direction of the liquid crystal molecule. Examples of liquid crystal molecules include Schiff base-based, azo-based, azoxy-based, biphenyl-based, terphenyl-based, benzoic acid ester-based, tran-based, pyrimidine-based, cyclohexanecarboxylic acid ester-based, phenylcyclohexane-based, and dioxane-based liquid crystal molecules.

[0033] A first transparent conductive layer 31 is provided on the outside of the lower surface of the dimming layer 20 (the other surface, the surface on the side of the light-transmitting member 100, which will be described later), and a first transparent substrate layer 32 is provided on the outside of the first transparent conductive layer 31. The first transparent conductive layer 31 and the first transparent substrate layer 32 constitute a first outer support layer 30 located on the side of the dimming layer 20 facing the light-transmitting member 100. Note that in Figures 3 to 7, which will be described later, the first transparent conductive layer 31 and the first transparent substrate layer 32 are sometimes depicted as a single layer without distinction. Furthermore, the first outer support layer 30 is located outside the first transparent substrate layer 32 and has an adhesive layer 33 for attaching (bonding, joining) the dimming device 10 to the light-transmitting member 100, which will be described later.

[0034] A second transparent conductive layer 41 is provided on the outer side of the upper surface of the dimming layer 20 (one side, the side opposite to the first outer support layer 30, and the side opposite to the light-transmitting member 100, which will be described later), and a second transparent substrate layer 42 is provided on the outer side of the second transparent conductive layer 41. The second transparent conductive layer 41 and the second transparent substrate layer 42 constitute the second outer support layer 40 located on the side of the dimming layer 20 opposite to the first outer support layer 30 (the side opposite to the light-transmitting member 100). Note that in Figures 3 to 7, which will be described later, the second transparent conductive layer 41 and the second transparent substrate layer 42 are sometimes depicted as a single layer without distinction. Furthermore, the second outer support layer 40 is located outside the second transparent substrate layer 42 and has a second functional film layer 43 that adds various functions to the dimming device (dimming sheet, dimming film) 10. The second functional film layer 43 can be, for example, a UV-cutting layer, an IR-cutting layer, or a hard coat layer.

[0035] Thus, the dimming device (dimming sheet, dimming film) 10 has a dimming layer 20 and a pair of outer support layers (first outer support layer 30, second outer support layer 40) located on both sides of the dimming layer 20. The first outer support layer 30 has a first transparent conductive layer 31 and a first transparent substrate layer 32, and the second outer support layer 40 has a second transparent conductive layer 41 and a second transparent substrate layer 42.

[0036] The first transparent conductive layer 31 and the second transparent conductive layer 41 are transparent layers that have conductivity. Examples of materials that make up the first transparent conductive layer 31 and the second transparent conductive layer 41 include polymers containing indium tin oxide (ITO), fluorine-doped tin oxide (FTO), tin oxide, zinc oxide, carbon nanotubes (CNTs), poly(3,4-ethylenedioxythiophene) (PEDOT), and multilayer films containing Ag alloy thin films. The first transparent substrate layer 32 and the second transparent substrate layer 42 are layers composed of materials such as PET (Polyethylene Terephthalate).

[0037] Furthermore, the first outer support layer 30 and the second outer support layer 40 may have additional / alternative layers located outside the first transparent substrate layer 32 and the second transparent substrate layer 42. In other words, there is flexibility in the number and type of "outer support layers," and various design changes are possible. For example, a transparent support layer made of a transparent substrate may be provided as the "outer support layer." As the transparent support layer, for example, a glass substrate or a silicon substrate, or a polymer film made of polyethylene, polystyrene, polyethylene terephthalate, polyvinyl alcohol, polycarbonate, polyvinyl chloride, polyimide, polysulfone, cycloolefin polymer, triacetylcellulose, etc. may be used. Furthermore, as the "outer support layer," for example, a layer for protecting the dimming layer 20, a pair of transparent conductive layers (first transparent conductive layer 31, second transparent conductive layer 41), a pair of transparent substrate layers (first transparent substrate layer 32, second transparent substrate layer 42), a layer that contributes to controlling the light transmittance in the dimming device 10, or a layer that enhances the strength, heat resistance, and other properties of the dimming device 10 may be used.

[0038] The first transparent conductive layer 31 is provided with a first electrode section (not shown) for applying a drive voltage to the dimming device 10, and a first wiring section (not shown), such as an FPC (Flexible Printed Circuits), is connected to this first electrode section. The second transparent conductive layer 41 is provided with a second electrode section (not shown) for applying a drive voltage to the dimming device 10, and a second wiring section (not shown), such as an FPC (Flexible Printed Circuits), is connected to this second electrode section.

[0039] When a drive current is passed through the first transparent conductive layer 31 and the second transparent conductive layer 41 via the first and second electrode sections and the first and second wiring sections described above, a drive voltage is applied between the first transparent conductive layer 31 and the second transparent conductive layer 41, that is, to the dimming layer 20.

[0040] When no driving voltage is applied between the first transparent conductive layer 31 and the second transparent conductive layer 41 (the dimming layer 20), the orientation of the liquid crystal molecules in the dimming layer 20 along its long axis is irregular. As a result, light incident on the dimming layer 20 is scattered, and the dimming device (dimming sheet, dimming film) 10 appears cloudy (white dimming). In other words, the dimming device 10 is opaque.

[0041] On the other hand, when a driving voltage is applied between the first transparent conductive layer 31 and the second transparent conductive layer 41 (the dimming layer 20), the liquid crystal molecules in the dimming layer 20 are oriented so that the long axis direction of the liquid crystal molecules is aligned with the direction of the electric field between the first transparent conductive layer 31 and the second transparent conductive layer 41. As a result, light is more easily transmitted through the dimming layer 20, and the dimming device (dimming sheet, dimming film) 10 becomes transparent. In this way, the dimming device 10 functions as a normal type (normal mode).

[0042] The dimming device (dimming sheet, dimming film) 10 may also include a pair of alignment layers that sandwich the dimming layer 20 between the dimming layer 20 and the first transparent conductive layer 31 and the second transparent conductive layer 41. The alignment layers are layers that control the orientation of liquid crystal molecules contained in the dimming layer 20, and when no driving voltage is applied, they orient the liquid crystal molecules along the direction normal to the alignment layer. In a configuration that includes alignment layers, when a driving voltage is applied between the first transparent conductive layer 31 and the second transparent conductive layer 41 (dimming layer 20), the dimming device 10 becomes opaque, and when no driving voltage is applied between the first transparent conductive layer 31 and the second transparent conductive layer 41 (dimming layer 20), the dimming device 10 becomes transparent (functions as a reverse type (reverse mode)). Examples of materials that constitute the alignment layers include organic compounds such as polyimide, polyamide, polyvinyl alcohol, and cyanide compounds, inorganic compounds such as silicon oxide and zirconium oxide, and silicone. Orientation treatments for forming an orientation layer include, for example, rubbing, polarized light irradiation, and microfabrication.

[0043] Furthermore, the dimming layer 20 may contain a dye having a predetermined color that does not hinder the movement of liquid crystal molecules in accordance with the magnitude of the voltage applied to the dimming layer 20. Additionally, a dichroic dye and a black spacer may be added to the dimming layer 20. With this configuration, a dimming device (dimming sheet, dimming film) 10 having a predetermined color can be realized. In other words, black dimming and colored dimming become possible.

[0044] The dimming device (dimming sheet, dimming film) 10 is, for example, cut into a desired shape from a large sheet made of a multilayer structure having each layer that constitutes the dimming device 10, and used for various purposes. For example, the dimming device 10 can be transparent glass under normal circumstances, but can be applied to various uses such as dimming films, office partitions, laminated glass, frosted glass, etc., to block the view from the inside and outside at specific times.

[0045] Figure 2 is a plan view showing an example of the configuration of the dimming module 1 of this embodiment. Figures 3A, 3B, and 3C are cross-sectional views taken along the line III-III in Figure 2.

[0046] As shown in Figures 2 and 3A to 3C, the dimming device (dimming sheet, dimming film) 10 is attached (bonded) to a light-transmitting member 100 such as glass or polycarbonate. The ends (periphery) of the light-transmitting member 100 are supported (fitted) to the sash (frame) 60 via packing (greasing channel, bead, caulking) 50.

[0047] As shown in Figures 3A to 3C, the end face of the dimming layer 20 and the end face of the first outer support layer 30 (first transparent conductive layer 31, first transparent substrate layer 32, adhesive layer 33) (the right end face in Figure 3) are on the same plane or substantially on the same plane. However, the end face of the dimming layer 20 and the end face of the first outer support layer 30 (first transparent conductive layer 31, first transparent substrate layer 32, adhesive layer 33) (the right end face in Figure 3) do not necessarily have to be on the same plane or substantially on the same plane, and the end faces may be slightly offset.

[0048] The second outer support layer 40 has a canopy portion 70 that protrudes laterally (to the right in Figure 3) from the end face (right end face in Figure 3) of the light-adjusting layer 20. The canopy portion 70 protrudes laterally (to the right in Figure 3) from the end face (right end face in Figure 3) of the first outer support layer 30 (first transparent conductive layer 31, first transparent substrate layer 32, adhesive layer 33) which are on the same or substantially the same plane as the light-adjusting layer 20.

[0049] Figure 3A shows the case where the eaves 70 are formed on the second transparent conductive layer 41 and the second transparent substrate layer 42 of the second outer support layer 40. Figure 3B shows the case where the eaves 70 are formed on the second transparent conductive layer 41, the second transparent substrate layer 42 and the second functional film layer 43 of the second outer support layer 40. Figure 3C shows the case where the eaves 70 are formed on the second functional film layer 43 of the second outer support layer 40. Thus, the eaves 70 can be formed on at least one of the layers of the second outer support layer 40: the second transparent conductive layer 41, the second transparent substrate layer 42 and the second functional film layer 43.

[0050] A sealing layer filling space is formed (defined, specified) between the lower surface of the eaves portion 70, the portion of the upper surface of the light-transmitting member 100 that faces the lower surface of the eaves portion 70, and the end face of the light-adjusting layer 20 and the end face (right end face in Figure 3) of the first outer support layer 30 (first transparent conductive layer 31, first transparent substrate layer 32, adhesive layer 33), and the sealing layer 80 is filled into this sealing layer filling space. In Figures 3A to 3C, the sealing layer 80 protrudes slightly to the side of the sealing layer filling space, but it is not necessary for the sealing layer 80 to protrude to the side of the sealing layer filling space (it is also acceptable for the sealing layer 80 to be completely contained (hidden) below the eaves portion 70 when viewed from above).

[0051] The sealing layer 80 filled in the sealing layer filling space is located between the eaves portion 70 and the light-transmitting member 100 and seals the end face of the light-adjusting layer 20 (the right end face in Figure 3). More specifically, the sealing layer 80 filled in the sealing layer filling space is located between the eaves portion 70 and the light-transmitting member 100 and seals the end face of the light-adjusting layer 20, which is on the same or substantially the same plane, and the end face of the first outer support layer 30 (first transparent conductive layer 31, first transparent substrate layer 32, adhesive layer 33) (the right end face in Figure 3).

[0052] The sealing layer 80 has the function of sealing and protecting the edges (periphery) of the dimming device (dimming sheet, dimming film) 10, particularly the edges (periphery) of the dimming layer 20 (for example, preventing moisture absorption degradation). The sealing layer 80 also plays a role in sealing and protecting the first and second electrode parts and the first and second wiring parts (not shown) described above (ensuring the electrical conductivity function). The sealing layer 80 is composed of, for example, a material that can be UV cured in a short time. In addition to UV curing, the sealing layer 80 may be composed of a material that has curing properties such as heat curing or moisture curing. The sealing layer 80 may also be a coating-type material such as epoxy resin, acrylic resin, or silicone resin.

[0053] The sealing layer 80, filled in the sealing layer filling space, can suitably seal the end face of the dimming device (dimming sheet, dimming film) 10, particularly the end face of the dimming layer 20. As described above, the sealing layer 80 is filled in a sealing layer filling space formed (defined, specified) between the lower surface of the eaves portion 70, the portion of the upper surface of the light-transmitting member 100 facing the lower surface of the eaves portion 70, and the end face of the dimming layer 20 and the end face (right end face in Figure 3) of the first outer support layer 30 (first transparent conductive layer 31, first transparent substrate layer 32, adhesive layer 33). Moreover, when viewed from above, most of the sealing layer 80 is contained (hidden) below the eaves portion 70. As a result, the sealing layer 80 is not exposed and does not spoil the appearance, making it possible to realize a good-looking dimming device 10 and, consequently, a dimming module 1. Furthermore, since the sealing layer 80 does not ride up onto the second outer support layer 40, damage (breakage) to the sealing layer 80 due to external forces (for example, pressing force during cleaning) is prevented, thereby improving its strength (durability).

[0054] The dimming module 1 is manufactured (assembled) as follows: A small width is half-cut from the side surface of the adhesive layer 33 of the dimming device (dimming sheet, dimming film) 10 along the outer edge to form a canopy portion 70, and then it is bonded to a light-transmitting member 100 such as glass (transparent substrate). After that, a sealing material is filled (injected) through the surface side of the dimming device (dimming sheet, dimming film) 10 with the canopy portion 70 formed thereon (the space immediately next to the canopy portion 70 of the second outer support layer 40), dried, and cured to form a sealing layer 80. Since the sealing layer 80 is hardly exposed on the surface side, the appearance of the edges (end faces) is not impaired, and sealing can be performed without scratches or peeling caused by external forces. At the same time, it also fixes the edges of the sheet (film), which helps prevent peeling from the edges.

[0055] The width of the half-cut, that is, the amount of protrusion of the eaves portion 70 from the end face of the dimming layer 20 and the end face of the first outer support layer 30 (first transparent conductive layer 31, first transparent substrate layer 32, adhesive layer 33) (right end face in Figure 3), is preferably, for example, 0.5 mm or more and 5 mm or less, more preferably 0.5 mm or more and 2 mm or less, and even more preferably 0.5 mm or more and 1 mm or less.

[0056] Figure 4 is a diagram (plan view, cross-sectional view) showing another example of the configuration of the dimming module 1 of this embodiment. In Figure 4, the dimming device 10 has two adjacent laminates of a dimming layer 20, a first outer support layer 30, and a second outer support layer 40, and these two adjacent laminates are attached to a single large light-transmitting member 100.

[0057] As shown in Figure 4, in two adjacent laminates, the end faces of two adjacent eaves 70 face each other. The sealing layer 80 is located between the two adjacent eaves 70 and the light-transmitting member 100 in the two adjacent laminates, and seals the end faces of the two adjacent light-adjusting layers 20. More specifically, below the two adjacent eaves 70, there is a sealing layer-filled space formed (defined, specified) between the upper surface of the light-transmitting member 100, the end face of the light-adjusting layer 20 of the left laminate and the end face of the first outer support layer 30 (first transparent conductive layer 31, first transparent substrate layer 32, adhesive layer 33) (right end face in Figure 4), and the end face of the light-adjusting layer 20 of the right laminate and the end face of the first outer support layer 30 (first transparent conductive layer 31, first transparent substrate layer 32, adhesive layer 33) (left end face in Figure 4), and the sealing layer 80 is filled into this sealing layer-filled space. Furthermore, the sealing layer 80 is also filled between the opposing end faces of two adjacent eaves portions 70. In Figure 4, the sealing layer 80 protrudes slightly upward from between the opposing end faces of the two adjacent eaves portions 70, but it may also be contained within the space between the opposing end faces of the two adjacent eaves portions 70.

[0058] As shown in Figure 4, the sealing performance of the end cross-section of the dimming device (dimming sheet, dimming film) 10 is sufficiently ensured, while there is almost no surface exposure of the sealing layer 80 (only between the opposing end faces of two adjacent eaves 70), and the sealing edge and uneven coating are not visible from the surface, resulting in a superior appearance (good looks). Incidentally, the gap between the half-cut (eaves 70) and its abutting (opposite) becomes a non-illuminated area (non-dimming area), but this can be minimized by devising the manufacturing method and conditions. This reduces the risk of sealing peeling or sheet (film) peeling in the gap between the half-cut (eaves 70) and its abutting (opposite)

[0059] <Manufacturing method (installation method) for dimming modules> Next, we will explain in detail the manufacturing method (installation method) of the dimming module 1 configured as described above.

[0060] Figures 5A to 5E are process diagrams showing an example of a manufacturing method (installation method) for the dimming module 1.

[0061] ≪Preparation process≫ First, two laminates of the dimming device (dimming sheet, dimming film) 10 are prepared. Each of the two laminates has a dimming layer 20, a first outer support layer 30 located on the side of the light-transmitting member 100 of the dimming layer 20, and a second outer support layer 40 located on the opposite side of the first outer support layer 30 of the dimming layer 20. The second outer support layer 40 also has an overhang portion 70 that protrudes laterally from the end face of the dimming layer 20 (and the first outer support layer 30).

[0062] Installation Process Next, as shown in Figure 5A, the two laminates of the dimming device (dimming sheet, dimming film) 10 are placed adjacent to each other, so that the end faces of the two adjacent eaves portions 70 face each other, and the two adjacent first outer support layers 30 are attached to the light-transmitting member 100 (bonded and joined by the adhesive layer 33).

[0063] ≪Mask application process≫ Next, as shown in Figure 5B, before the filling process described later (Figure 5C), a mask (masking tape) 90 is applied to the side of the two adjacent eaves portions 70 opposite to the filling space of the sealing layer 80, in the two adjacent laminates. In the example in Figure 5B, the mask 90 is applied across the entire upper surface of the second outer support layer 40, specifically the portion corresponding to the eaves portion 70 and a portion continuous with the eaves portion 70 (the portion near the joint).

[0064] ≪Filling process≫ Next, as shown in Figure 5C, in two adjacent laminates, a sealing layer 80 (more precisely, a sealing material which is the material of the sealing layer 80) is filled so as to be located between the two adjacent eaves 70 and the light-transmitting member 100, and to seal the end faces of the adjacent light-adjusting layer 20 (and the first outer support layer 30). More specifically, a coating machine (dispenser) 95 with a micro-nozzle is inserted from between the opposing end faces of the two adjacent eaves 70 to fill (inject) the sealing layer 80 (sealing material). As a result, the sealing layer 80 (sealing material) is filled (injected) into the sealing layer filling space formed (defined, specified) below the two adjacent eaves 70, between the upper surface of the light-transmitting member 100, the end face of the light-adjusting layer 20 of the left laminate and the end face of the first outer support layer 30 (right end face in the figure), and the end face of the light-adjusting layer 20 of the right laminate and the end face of the first outer support layer 30 (left end face in the figure). Furthermore, a sealing layer 80 (sealing material) is also filled (injected) between the opposing end faces of two adjacent eaves portions 70.

[0065] ≪Mask Removal Process≫ Next, as shown in Figure 5D, after the filling process described above (Figure 5C), the mask (masking tape) 90 is removed from the side of the two adjacent eaves portions 70 opposite to the filling space of the sealing layer 80 (sealant) in the two adjacent laminates. Before removing the mask 90, any excess sealing layer 80 (sealant) remaining near the space between the opposing end faces of the two adjacent eaves portions 70 (the insertion space for the coating machine 95) (especially any material that has risen above the mask 90) is removed using a rubber spatula or the like.

[0066] ≪Curing process≫ Finally, as shown in Figure 5C, after the filling process described above (Figure 5C), the sealing layer 80 (sealant) filled (injected) into the sealing layer filling space is cured. For example, in the case of a UV-curable sealing layer 80 (sealant), UV light can be irradiated from the upper side of the dimming device 10 (above the eaves portion 70). In this embodiment, since the sealing layer filling space is defined as a nearly closed space, once the sealing layer 80 (sealant) is filled (injected) into the sealing layer filling space, curing with natural light is also possible (it can be cured in a short time).

[0067] The manufacturing method (construction method) for the dimming module 1, as described with reference to Figures 5A to 5E, can be modified as appropriate. For example, by using a nozzle with a narrow tip or a tool (coating machine, dispenser) that allows control of minute liquid discharge, it becomes possible to fill (inject) the sealing layer (sealant) into the sealing layer filling space without masking or smoothing with a spatula (removal of unwanted material). Furthermore, by setting the distance (gap) between the opposing end faces of two adjacent eaves to 1 mm or less, and by filling (injecting) the sealing layer (sealant) so that it does not protrude from the surface (eaves), it becomes possible to apply natural light curing without any special curing acceleration process. In this case, there is the advantage of reducing the amount of various materials used and reducing related components (masking tape, UV light, etc.).

[0068] Figure 6 is a process diagram showing another example of the manufacturing method (construction method) of the dimming module 1. In the filling process of Figure 5C, a micro-nozzle coating machine (dispenser) 95 is inserted into the gap between the opposing end faces of two adjacent eaves portions 70 to fill (inject) the sealing layer 80 (sealant). In contrast, in Figure 6, the gap between the opposing end faces of two adjacent eaves portions 70 is sealed with a mask (masking tape) 90, and then a micro-nozzle coating machine (dispenser) 95 is inserted into the gap between the end faces of two adjacent dimming layers 20 (and the first outer support layer 30) to fill (inject) the sealing layer 80 (sealant). Alternatively, the filling processes of Figure 5C and Figure 6 may be combined. In other words, the filling process may include at least one of the following steps: filling the gap between the end faces of two adjacent eaves portions 70 with a sealing layer 80 (sealing material); and filling the gap between the end faces of two adjacent light-regulating layers 20 (and the first outer support layer 30) with a sealing layer 80 (sealing material).

[0069] In the alternative method shown in Figure 6, masking tape is applied to cover the space (gap) between the end faces (butt joints) of the two canopy sections 70, and a sealing layer (sealant) is poured in from one end of the sheet (film) butt joint (in the vertical direction in the plan view of Figure 6, and in the direction perpendicular to the plane of the paper in the cross-sectional view of Figure 6). After the filling (injection) has hardened, the masking tape is removed. By adopting this method, a sealed structure for the butt joint ends can be achieved without requiring advanced techniques.

[0070] The manufacturing method (construction method) of the dimming module 1 shown in Figures 5 and 6 above involved attaching (sticking) the dimming device (dimming sheet, dimming film) 10 to the light-transmitting member 100, and then filling and curing the sealing layer 80 (sealant). In contrast, it is also possible to fill and cure the sealing layer 80 (sealant) into the dimming device (dimming sheet, dimming film) 10 before attaching (sticking) the dimming device (dimming sheet, dimming film) 10 to the light-transmitting member 100. In this case, a dummy member may be placed in the position corresponding to the light-transmitting member 100 in Figures 5 and 6, and after filling and curing the sealing layer 80 (sealant) into the dimming device (dimming sheet, dimming film) 10 to integrate it, the dummy member may be removed.

[0071] Furthermore, instead of filling and curing the sealing layer 80 (sealant) between two adjacent (facing) dimming devices (dimming sheets, dimming films) 10 as shown in Figure 4, the sealing layer 80 (sealant) may be filled and cured at one end of a single dimming device (dimming sheet, dimming film) 10, as shown in Figures 3A to 3C. In this case, a dummy member may be placed adjacent (facing) to one end of the single dimming device (dimming sheet, dimming film) 10, and after filling and curing the sealing layer 80 (sealant) into the dimming device (dimming sheet, dimming film) 10 to integrate it, the dummy member may be removed.

[0072] Figures 7A to 7D show an example of the process for preparing (manufacturing) the two laminates of the dimming device (dimming sheet, dimming film) 10. In this preparation process, the following first cutting process and second cutting process are performed on each of the two laminates of the dimming device (dimming sheet, dimming film) 10.

[0073] In the first cutting process, as shown in Figure 7A, the end faces of the dimming layer 20, the first outer support layer 30, and the second outer support layer 40 are aligned, and the cut (full cut) is performed from the side of the second outer support layer 40 using a cutter 96. As a result, as shown in Figure 7B, interfacial delamination and burr generation are induced between the second outer support layer 40 and the dimming layer 20, and between the dimming layer 20 and the first outer support layer 30. In the example in Figure 7B, interfacial delamination has occurred at the cut end between the second outer support layer 40 and the dimming layer 20, and burrs have been generated at the cut end between the dimming layer 20 and the first outer support layer 30.

[0074] In the second cutting step, as shown in Figure 7C, the first outer support layer 30 (adhesive layer 33) is cut from the side of the first outer support layer 30 and the dimming layer 20 with a cutter 97 (this is a half-cut, and the second outer support layer 40 is not cut). As a result, as shown in Figure 7D, interfacial delamination and burr formation between the second outer support layer 40 and the dimming layer 20 and between the dimming layer 20 and the first outer support layer 30 are removed, and an overhang portion 70 is formed in which the second outer support layer 40 protrudes laterally from the end face of the dimming layer 20 (and the first outer support layer 30).

[0075] Conventionally, in general construction processes, it was often difficult (and impossible to do neatly and safely) to cut or change the dimensions of the long side of dimmable sheets (dimmable films) on-site. However, by using the construction process shown in Figures 7A to 7D, it is possible to make edge cuts that are aesthetically pleasing and also convenient for sealing (i.e., it is possible to prepare (manufacture) dimmable sheets (dimmable films) with an overhang).

[0076] The present invention is not limited to the embodiments described above, and can be modified in various ways during implementation without departing from its essence. Furthermore, each embodiment may be combined as appropriate, and in that case, the combined effects can be obtained. Moreover, the above embodiments include various inventions, and various inventions can be extracted by selecting combinations from the multiple constituent elements disclosed. For example, if the problem can be solved and effects obtained even if some constituent elements are deleted from all the constituent elements shown in the embodiment, then the configuration with these constituent elements deleted can be extracted as an invention. [Explanation of Symbols]

[0077] 1. Dimming module 10. Dimming devices (dimming sheets, dimming films) 20. Dimming layer (liquid crystal layer) 30. First outer support layer 31 First transparent conductive layer 32 First transparent substrate layer 33 Adhesive layer 40. Second outer supporting layer 41 Second transparent conductive layer 42 Second transparent substrate layer 43. Second functional film layer 50 Packing (Grating channel, bead, caulking) 60 sash (frame) 70 Eaves 80 sealing layer 90 Masks (Masking Tape) 95 Coating machine (dispenser) 96 Cutter 97 Cutter 100 Light-transmitting member

Claims

1. A dimming device attached to a light-transmitting member, Dimming layer, A first outer support layer located on the side of the light-transmitting member of the light-adjusting layer, A second outer support layer is located on the opposite side of the first outer support layer of the dimming layer and has an overhang portion that protrudes laterally from the end face of the dimming layer, A sealing layer located between the eaves portion and the light-transmitting member and sealing the end face of the light-adjusting layer, A dimming device characterized by having the following features.

2. The end face of the dimming layer and the end face of the first outer support layer constitute the same or substantially the same surface. The eaves portion protrudes laterally from the end face of the light-regulating layer and the end face of the first outer support layer, which form the same or substantially the same plane. The sealing layer is located between the eaves portion and the light-transmitting member and seals the end face of the light-regulating layer and the end face of the first outer support layer, which are on the same plane or substantially the same plane. The dimming device according to feature 1.

3. The second outer support layer comprises a second transparent conductive layer located outside the light-adjusting layer, a second transparent substrate layer located outside the second transparent conductive layer, and a second functional film layer located outside the second transparent substrate layer. The eaves portion is formed in at least one of the layers of the second transparent conductive layer, the second transparent substrate layer, and the second functional film layer. The dimming device according to feature 1.

4. The laminate of the light-adjusting layer, the first outer support layer, and the second outer support layer is provided in two adjacent units. In the two adjacent laminates, the end faces of the adjacent eaves portions face each other. The sealing layer is located between the adjacent eaves portion and the light-transmitting member in the two adjacent laminates, and seals the end face of the adjacent light-regulating layer. The dimming device according to feature 1.

5. The first outer support layer has an adhesive layer for attaching the dimming device to the light-transmitting member. The dimming device according to feature 1.

6. Light-transmitting member, A dimming device attached to the light-transmitting member, A dimming module having, The dimming device is Dimming layer, A first outer support layer located on the side of the light-transmitting member of the light-adjusting layer, A second outer support layer is located on the opposite side of the first outer support layer of the dimming layer and has an overhang portion that protrudes laterally from the end face of the dimming layer, A sealing layer located between the eaves portion and the light-transmitting member and sealing the end face of the light-adjusting layer, A dimming module characterized by having the following features.

7. A preparation step of preparing two laminates, each having a light-regulating layer, a first outer support layer located on the side of the light-transmitting member of the light-regulating layer, and a second outer support layer located on the opposite side of the first outer support layer of the light-regulating layer and having an overhang portion that protrudes laterally from the end face of the light-regulating layer. The mounting step involves placing the two laminates adjacent to each other, so that the end faces of the adjacent eaves portions face each other, and attaching the adjacent first outer support layer to the light-transmitting member, A filling step is performed in which a sealing layer is filled in the two adjacent laminates, the sealing layer being located between the adjacent eaves portion and the light-transmitting member, and sealing the end face of the adjacent light-adjusting layer. A method for manufacturing a dimming module, characterized by having the following features.

8. The filling step comprises at least one of the steps of filling the sealing layer into the gap between the end faces of adjacent eaves portions and filling the sealing layer into the gap between the end faces of adjacent light-adjusting layers. A method for manufacturing a dimming module according to feature 7.

9. Prior to the filling step, a mask application step is performed in which a mask is attached to the side of the adjacent overhang portion of the two adjacent laminates that is opposite to the filling space of the sealing layer, After the filling step, a mask removal step is performed in which, in the two adjacent laminates, the mask is removed from the side of the adjacent overhang portion opposite to the filling space of the sealing layer, A method for manufacturing a dimming module according to claim 7, characterized by having the following:

10. The process includes a curing step after the filling step, in which the filled sealing layer is cured. A method for manufacturing a dimming module according to feature 7.

11. The preparation step described above is performed for each of the two laminates, A first cutting step is performed by cutting from the side of the second outer support layer so that the end faces of the dimming layer, the first outer support layer, and the second outer support layer are aligned, thereby inducing interfacial delamination and burr generation between the second outer support layer and the dimming layer and between the dimming layer and the first outer support layer. A second cutting step involves cutting the first outer support layer and the dimming layer from the side of the first outer support layer to remove interfacial delamination and burr formation between the second outer support layer and the dimming layer and between the dimming layer and the first outer support layer, and forming the eaves portion in which the second outer support layer protrudes laterally beyond the end face of the dimming layer. A method for manufacturing a dimming module according to claim 7, characterized by having the following:

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