Light control device

Abstract

To provide a light control device capable of minimizing liquid crystal pooling, a phenomenon where a large amount of liquid crystal gathers locally.SOLUTION: A light adjustment device 10 is provided, comprising a first transparent substrate 11, a second transparent substrate 12, a light adjustment cell 20 disposed between the first transparent substrate 11 and the second transparent substrate 12, and an intermediate film 14 provided between the second transparent substrate 12 and the light adjustment cell 20. An air gap G or a fluid resin layer L is provided between the first transparent substrate 11 and the light adjustment cell 20.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to a light control device. [Background technology]

[0002] Conventionally, light control components that can be used in combination with light-transmitting components such as windows and can be used in electronic blinds to control the transmission of external light, and light control devices using such light control components have been proposed (see, for example, Patent Documents 1 and 2). One such light control component is a liquid crystal film equipped with a liquid crystal layer. This liquid crystal film is produced by sandwiching a liquid crystal material between transparent resin substrates including transparent electrodes, which are further sandwiched between linear polarizing plates. The liquid crystal film can change the orientation of the liquid crystal by changing the electric field applied between the transparent electrodes, thereby controlling the amount of transmission of external light. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6135816 [Patent Document 2] JP 2017-187810 A Summary of the Invention [Problem to be solved by the invention]

[0004] When such a liquid crystal film is used as a light control member that can be used for the roof window, side window, etc. of an automobile, it is preferable to sandwich the liquid crystal film between a pair of glasses via an interlayer to form a laminated glass. However, in laminated glass sandwiching a liquid crystal film, if the pressure applied to the surfaces when the various components are pressed together is not uniform, if the shapes of the glass or interlayer used do not match between the top and bottom, or if wrinkles occur in the interlayer or liquid crystal film, the uneven distribution of the liquid crystal is likely to cause liquid crystal pools, which is a phenomenon in which a large amount of liquid crystal is present locally, and this causes a problem of deteriorating the quality and appearance of the laminated glass with a light control function.

[0005] The present embodiment provides a light control device capable of suppressing the occurrence of liquid crystal puddles, which is a phenomenon in which a large amount of liquid crystal is present locally. [Means for solving the problem]

[0006] The dimming device of this embodiment comprises a first transparent substrate, a second transparent substrate, a dimming cell arranged between the first transparent substrate and the second transparent substrate, and an intermediate film arranged between the second transparent substrate and the dimming cell, and a void layer or a fluid resin layer is provided between the first transparent substrate and the dimming cell.

[0007] In the light control device according to the present embodiment, the first transparent substrate and the light control cell may directly face each other with the air gap layer or the fluid resin layer interposed therebetween.

[0008] In the light control device according to the present embodiment, an anti-reflection layer may be provided on a surface of the first transparent substrate or the light control cell facing the air gap layer or the flowable resin layer.

[0009] In the light control device according to the present embodiment, a region of the first transparent substrate that overlaps with the light control cell may be made thinner than other regions.

[0010] In the dimming device according to this embodiment, a third transparent substrate may be disposed on the opposite side of the first transparent substrate to the void layer or the fluid resin layer, and an additional intermediate film may be provided between the first transparent substrate and the third transparent substrate.

[0011] In the light control device according to the present embodiment, the thickness of the gap layer or the fluid resin layer may be 100 μm or more and 300 μm or less.

[0012] In the dimming device according to this embodiment, a frame-shaped intermediate film is disposed between the first transparent substrate and the second transparent substrate so as to surround the dimming cell in a planar view, and the frame-shaped intermediate film may have a groove communicating with the void layer or the fluid resin layer.

[0013] In the light control device according to the present embodiment, the first transparent substrate may have a groove communicating with the air gap layer or the fluid resin layer. Effect of the Invention

[0014] According to the embodiment of the present disclosure, it is possible to suppress the occurrence of liquid crystal puddles, which is a phenomenon in which a large amount of liquid crystal is present locally. [Brief description of the drawings]

[0015] [Figure 1] FIG. 1 is a perspective view showing a light control device according to an embodiment. [Diagram 2] FIG. 2 is a cross-sectional view showing a light control device according to an embodiment. [Diagram 3] FIG. 3 is an exploded perspective view showing a light control device according to an embodiment. [Figure 4] 4(a)-(d) are cross-sectional views illustrating a method for manufacturing a light-controlling cell according to one embodiment. [Diagram 5] 5(a)-(c) are cross-sectional views illustrating a method for manufacturing a light-control cell according to one embodiment. [Figure 6] 6(a) to 6(c) are cross-sectional views showing a method for manufacturing a light control device according to an embodiment. [Figure 7] 7(a) to 7(c) are cross-sectional views showing the action of eliminating liquid crystal pools in the light control cell after the light control device is manufactured. [Figure 8] FIG. 8 is a cross-sectional view showing a light control device according to a first modified example. [Figure 9] FIG. 9 is a cross-sectional view showing a light control device according to a second modified example. [Figure 10]10(a) and (b) are cross-sectional views showing a light control device according to a third modified example. [Figure 11] FIG. 11 is a cross-sectional view showing a light control device according to a fourth modified example. [Figure 12] FIG. 12 is a cross-sectional view showing a light control device according to a fifth modified example. [Figure 13] FIG. 13 is an exploded perspective view showing a light control device according to the fifth modified example. [Figure 14] FIG. 14 is a cross-sectional view showing a light control device according to a sixth modified example. [Figure 15] FIG. 15 is an exploded perspective view showing a light control device according to the sixth modified example. [Figure 16] FIG. 16 is a cross-sectional view showing a light control device according to a seventh modified example. [Figure 17] FIG. 17 is an exploded perspective view showing a light control device according to the seventh modified example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] Hereinafter, one embodiment will be described with reference to FIGS.

[0017] The light control device 10 described below can be applied to various technical fields that require adjustment of light transmittance, and the scope of application is not particularly limited. The light control device 10 is arranged in a portion where light control is required (a portion where external light enters, such as a front, side, rear, or roof window), such as a window glass of a building, a showcase, an indoor transparent partition, or a vehicle window, and can control the amount of light entering the inside of a building, a vehicle, or the like.

[0018] The light control device 10 described below merely illustrates one embodiment. Therefore, for example, some of the elements listed below as components of the light control device 10 may be replaced with other elements or may not be included. Elements not listed below may be included as components of the light control device 10. In addition, the scale and dimensional ratios of some parts in the drawings have been appropriately changed or exaggerated from those of the actual objects for the convenience of illustration and ease of understanding.

[0019] (Light control device) FIG. 1 is a diagram showing a light control device (laminated glass) 10 according to the present embodiment. The light control device 10 according to the present embodiment is configured with a three-dimensional shape having a curved surface shape, and in FIG. 1, as an example, the light control device 10 has a shape that is convex on one side. The light control device 10 is not limited to this, and may have a planar surface shape (i.e., a flat plate shape), or may have a two-dimensional shape having a curved surface shape (for example, a shape constituting a part of a cylinder). Here, the three-dimensional shape is not a simple cylindrical surface, but a curved surface that cannot be configured by simply deforming a plane without expansion and contraction, and is distinguished from a two-dimensional shape (two-dimensional curved surface) that is two-dimensionally curved around a single axis, or a two-dimensional shape (two-dimensional curved surface) that is two-dimensionally curved with different curvatures around multiple axes that are parallel to each other. In other words, the three-dimensional shape is a shape formed by a surface that is partially or entirely curved around each of multiple axes that are inclined relative to each other. In this specification, the term "planar view" refers to a state in which the light control device 10 is viewed from a direction perpendicular to the main surface thereof.

[0020] 1, a light control device 10 according to the present embodiment includes a first glass plate 11, a light control cell 20, an intermediate film 14, and a second glass plate 12. The first glass plate 11, the light control cell 20, the intermediate film 14, and the second glass plate 12 are laminated in this order. In addition, an air gap layer G is provided between the first glass plate 11 and the light control cell 20.

[0021] Fig. 2 is a cross-sectional view showing the layer structure of the light control device 10 according to the present embodiment, and Fig. 3 is an exploded perspective view showing the layer structure of the light control device 10 according to the present embodiment. Note that the light control device 10 of the present embodiment has a three-dimensional surface shape, but Figs. 2 and 3 show a case where the surface shape of the light control device 10 is planar for easy understanding.

[0022] 2, the light control device 10 includes a first glass plate 11, a second glass plate 12, and a light control cell 20 disposed between the first glass plate 11 and the second glass plate 12. The light control cell 20 includes a first stack 21 including a first substrate 24, a first transparent electrode 25, and a first alignment layer 26, a second stack 22 including a second substrate 27, a second transparent electrode 28, and a second alignment layer 29, and a liquid crystal layer 23 disposed between the first stack 21 and the second stack 22.

[0023] The first glass plate (first transparent substrate) 11 and the second glass plate (second transparent substrate) 12 are disposed on the front and back surfaces of the light control device 10, and are plate glasses having high light transmittance. The first glass plate 11 and the second glass plate 12 have a three-dimensional shape with a curved surface shape, and are formed in advance to have a curved surface shape that is convex on one side (see FIG. 1). In this case, the first glass plate 11 and the second glass plate 12 are formed so that the first glass plate 11 side is convex with respect to the second glass plate 12 side, but this is not limited thereto, and the second glass plate 12 side may be formed so that the second glass plate 12 side is convex with respect to the first glass plate 11 side. In addition, in this embodiment, the first glass plate 11 and the second glass plate 12 have a thickness of 0.5 mm or more and 4 mm or less, and as an example, both are plate glasses having a thickness of 2 mm. The first glass plate 11 and the second glass plate 12 may be inorganic glass or resin glass. For example, polycarbonate, acrylic, etc. can be used as the resin glass. When inorganic glass is used as the first glass plate 11 and the second glass plate 12, the light control device 10 can have excellent heat resistance and scratch resistance. On the other hand, when resin glass is used as the first glass plate 11 and the second glass plate 12, the light control device 10 can be made lighter. Furthermore, the first glass plate 11 and the second glass plate 12 may be subjected to a surface treatment such as a hard coat, if necessary.

[0024] The intermediate film (first intermediate film) 14 is a member that bonds the second glass plate 12 and the dimming cell 20. In this embodiment, a sheet made of PVB (polyvinyl butyral) resin is used as the intermediate film 14. The material of the intermediate film 14 is not limited to the above-mentioned PVB, and EVA (ethylene-vinyl acetate copolymer), COP (cycloolefin polymer), etc. may also be used. The thickness of the intermediate film 14 may also be appropriately selected depending on the material, etc. Specifically, the thickness of the intermediate film 14 may be 300 μm or more and 2.5 mm or less, and as an example, a thickness of 760 μm is used.

[0025] 2 and 3, a frame interlayer film (second interlayer film) 16 is connected to the interlayer film 14. The frame interlayer film 16 is an interlayer film having a frame shape in a plan view, and more specifically, an interlayer film having a square shape (a rectangular shape with a hollowed-out center) in a plan view. The frame interlayer film 16 is disposed between the first glass plate 11 and the second glass plate 12, and bonds the first glass plate 11 and the interlayer film 14 to each other. The frame interlayer film 16 may be made of the same material as the interlayer film 14. By providing the frame interlayer film 16, it is possible to prevent the intrusion of moisture and the like from the side surface of the light control device 10, and to further improve the water-proofing property of the light control device 10.

[0026] The frame intermediate film 16 is an intermediate film formed in a thickness portion of the dimming cell 20 in a cross-sectional view when the interlayer film 14 is larger than the dimming cell 20 (in a plan view). The frame intermediate film 16 is formed so as to surround the periphery of the dimming cell 20 in a plan view, and is a frame-shaped intermediate film in which the shape of the dimming cell 20 is carved out from the shape of the interlayer film 14. In this case, the frame intermediate film 16 is formed in a portion between the first glass plate 11 and the interlayer film 14 that corresponds to the periphery of the dimming cell 20. The frame intermediate film 16 is also formed in a portion between the first glass plate 11 and the interlayer film 14 that corresponds to the periphery of the gap layer G. The width W1 (see FIG. 3) of the frame intermediate film 16 is preferably 0 mm or more and approximately ¼ or less of the glass width.

[0027] The light control cell 20 (light control film, liquid crystal film) is a film that can control the amount of transmitted light by changing the applied voltage. The light control cell 20 is arranged so as to be sandwiched between a first glass plate 11 and a second glass plate 12. The light control cell 20 has a guest-host type liquid crystal layer that uses a dichroic dye, and is a member that changes the amount of transmitted light by an electric field applied to the liquid crystal. The light control cell 20 includes a film-like first laminate 21, a film-like second laminate 22, and a liquid crystal layer 23 arranged between the first laminate 21 and the second laminate 22.

[0028] 2, the first laminate 21 is formed by laminating a first substrate 24, a first transparent electrode 25, and a first alignment layer 26. That is, from the first glass plate 11 side, the first substrate 24, the first transparent electrode 25, and the first alignment layer 26 are laminated in this order. The second laminate 22 is formed by laminating a second substrate 27, a second transparent electrode 28, and a second alignment layer 29. That is, from the interlayer 14 side, the second substrate 27, the second transparent electrode 28, and the second alignment layer 29 are laminated in this order.

[0029] Furthermore, a plurality of bead spacers 31 are disposed between the first laminate 21 and the second laminate 22. The liquid crystal layer 23 is filled and disposed between the plurality of bead spacers 31 between the first laminate 21 and the second laminate 22. The plurality of bead spacers 31 may be disposed irregularly or regularly.

[0030] The dimming cell 20 changes the orientation of the liquid crystal material made of a guest-host liquid crystal composition provided in the liquid crystal layer 23 by driving the first transparent electrode 25 and the second transparent electrode 28 provided in the first laminate 21 and the second laminate 22, thereby changing the amount of transmitted light.

[0031] The first substrate 24 and the second substrate 27 are made of a transparent resin, and a flexible film can be used. As the first substrate 24 and the second substrate 27, it is desirable to use a transparent resin film that has small optical anisotropy and a transmittance of 80% or more in the visible wavelength range (380 nm or more and 800 nm or less). Examples of materials for the transparent resin film include acetylcellulose-based resins such as triacetylcellulose (TAC), polyester-based resins such as polyethylene terephthalate (PET) and polyethylene naphthalate (PEN), polyolefin-based resins such as polyethylene (PE), polypropylene (PP), polystyrene, polymethylpentene, and EVA, vinyl-based resins such as polyvinyl chloride and polyvinylidene chloride, acrylic resins, polyurethane-based resins, polysulfone (PEF), polyethersulfone (PES), polycarbonate (PC), polysulfone, polyether (PE), polyether ketone (PEK), (meth)acrylonitrile, cycloolefin polymer (COP), and cycloolefin copolymer. As the material of the transparent resin film, resins such as polycarbonate, cycloolefin polymer, and polyethylene terephthalate are particularly preferable. The thickness of the transparent resin film used as the first substrate 24 and the second substrate 27 depends on the material, but can be appropriately selected within a range in which the transparent resin film has flexibility. The thickness of the first substrate 24 and the second substrate 27 may be 50 μm or more and 200 μm or less. In the present embodiment, as an example of the first substrate 24 and the second substrate 27, a polyethylene terephthalate film having a thickness of 125 μm is applied.

[0032] The first transparent electrode 25 and the second transparent electrode 28 are composed of a transparent conductive film laminated on the first base material 24 and the second base material 27 (transparent resin film), respectively. As the transparent conductive film, various transparent electrode materials applicable to this type of transparent resin film can be used, and examples thereof include oxide-based transparent metal thin films having a total light transmittance of 50% or more. Examples include tin oxide-based, indium oxide-based, and zinc oxide-based materials.

[0033] Examples of tin oxide (SnO2) include NESA (tin oxide SnO2), ATO (antimony tin oxide), and fluorine-doped tin oxide. Examples of indium oxide (In2O3) include indium oxide, ITO (indium tin oxide), and IZO (indium zinc oxide). Examples of zinc oxide (ZnO) include zinc oxide, AZO (aluminum-doped zinc oxide), and gallium-doped zinc oxide. In this embodiment, the transparent conductive film constituting the first transparent electrode 25 and the second transparent electrode 28 is formed of ITO.

[0034] The bead spacer 31 is a member that determines the thickness (cell gap) of the liquid crystal layer 23 except for the outer periphery. In this embodiment, a spherical bead spacer is used as the bead spacer 31. The diameter of the bead spacer 31 may be in the range of 1 μm to 20 μm, preferably 3 μm to 15 μm. The bead spacer 31 may be made of a wide variety of materials, including inorganic materials such as silica, organic materials, and core-shell structures that combine these materials. In addition to being made of a spherical shape, the bead spacer may also be made of a rod shape such as a cylindrical shape, an elliptical cylindrical shape, or a polygonal cylindrical shape. The bead spacer 31 is made of a transparent material, but may be colored by applying a colored material as necessary.

[0035] In the present embodiment, the bead spacers 31 are provided in the second laminate 22, but this is not limiting and they may be provided in both the first laminate 21 and the second laminate 22, or only in the first laminate 21. Also, the bead spacers 31 do not necessarily have to be provided. Alternatively, instead of the bead spacers 31, or together with the bead spacers 31, columnar spacers may be used.

[0036] The first alignment layer 26 and the second alignment layer 29 are members for aligning the liquid crystal molecules contained in the liquid crystal layer 23 in a desired direction. The first alignment layer 26 and the second alignment layer 29 are formed by photo-alignment layers. As photo-alignment materials applicable to the photo-alignment layer, various materials to which a photo-alignment method can be applied can be widely applied, and examples thereof include photodecomposition type, photodimerization type, and photoisomerization type. In the present embodiment, a photodimerization type material is used. Examples of photodimerization type materials include cinnamate, coumarin, benzylidenephthalimidine, benzylideneacetophenone, diphenylacetylene, stilbazole, uracil, quinolinone, maleimide, or polymers having a cinnamylidene acetic acid derivative. Among them, a polymer having one or both of cinnamate and coumarin is preferably used because of its good alignment control force.

[0037] A rubbing alignment layer may be used instead of the photo-alignment layer. The rubbing alignment layer may not be subjected to a rubbing process, or may be subjected to a rubbing process and then subjected to a shaping process to form a fine line-shaped uneven shape to produce an alignment layer. In the present embodiment, the dimming cell 20 includes the first alignment layer 26 and the second alignment layer 29, but the present invention is not limited thereto, and the dimming cell 20 may not include the first alignment layer 26 and the second alignment layer 29.

[0038] A guest-host liquid crystal composition and a dichroic dye composition can be widely applied to the liquid crystal layer 23. The guest-host liquid crystal composition may contain a chiral agent so that the liquid crystal material is aligned in a helical shape in the thickness direction of the liquid crystal layer 23 when aligned horizontally. In addition, a seal material 32 having a ring or frame shape in a plan view is disposed between the first laminate 21 and the second laminate 22 so as to surround the liquid crystal layer 23. The seal material 32 holds the first laminate 21 and the second laminate 22 together and prevents leakage of the liquid crystal material. The seal material 32 may be a thermosetting resin such as an epoxy resin or an acrylic resin, or an ultraviolet-curing resin.

[0039] The light control cell 20 is configured as a normally clear cell, with the first alignment layer 26 and the second alignment layer 29 being vertical alignment layers with an alignment restraining force related to the pretilt set in a certain direction so that the alignment of the guest-host liquid crystal composition during this light blocking state is the same as that during application of an electric field. Note that the light transmitting state may be configured as a normally dark state with an electric field applied. Here, normally dark is a structure in which the transmittance is at a minimum when no voltage is applied to the liquid crystal, resulting in a black screen. Normally clear is a structure in which the transmittance is at a maximum when no voltage is applied to the liquid crystal, resulting in a transparent state.

[0040] In the present embodiment, the light control cell 20 is provided with a guest-host type liquid crystal layer 23, but the present invention is not limited to this. The light control cell 20 may be provided with a liquid crystal layer 23 of a TN (Twisted Nematic) type, a VA (Vertical Alignment) type, an IPS (In-Plane-Switching) type, or the like that does not use a dichroic dye composition. When such a liquid crystal layer 23 is provided, a linear polarization layer can be further provided on each of the surfaces of the first substrate 24 and the second substrate 27 to function as a light control film.

[0041] In this embodiment, as described above, the gap layer G is provided between the first glass plate 11 and the light control cell 20. That is, the first glass plate 11 and the light control cell 20 are not joined to each other and are arranged at a certain interval in the thickness direction. The gap layer G is filled with air, but is not limited thereto and may be filled with a gas such as nitrogen or an inert gas. The planar shape of the gap layer G is approximately the same as the planar shape of the light control cell 20. The thickness of the gap layer G may be, for example, greater than 0 μm and less than 10,000 μm, and is preferably 100 μm or more and 300 μm or less. In particular, when the thickness of the gap layer G is 100 μm or more and 300 μm or less, the occurrence of interference unevenness (Newton rings) caused by the presence of the gap layer G can be suppressed. That is, when the thickness of the gap layer G is 100 μm or more and 300 μm or less, the thickness of the gap layer G is sufficiently large with respect to the wavelength of visible light (380 nm or more and 800 nm or less). Therefore, of the light incident on the light control device 10, the interference between the light reflected at the interface between the first glass plate 11 and the gap layer G and the light reflected at the interface between the gap layer G and the light control cell 20 is suppressed, and the occurrence of Newton's rings can be suppressed. As a result, the appearance of the light control device 10 can be improved. The thickness of the gap layer G refers to a value measured in a direction parallel to the normal direction of the first glass plate 11. In addition, when the thickness of the gap layer G is not uniform within the plane, the thickness of the gap layer G refers to a value at the part of the gap layer G that is thickest within the plane.

[0042] In this way, by forming the gap layer G between the first glass plate 11 and the dimming cell 20, as described below, cell gap defects in the dimming cell 20 are reduced, and it is possible to suppress the occurrence of liquid crystal puddles, which are a phenomenon in which a large amount of liquid crystal is locally present in a part of the liquid crystal layer 23. Furthermore, by providing the gap layer G between the first glass plate 11 and the dimming cell 20, the heat insulation properties of the dimming device 10 are improved, and the heat retention properties of a vehicle or building in which the dimming device 10 is installed can be improved. Furthermore, when the dimming cell 20 is in a light-shielding state, the dimming device 10 is observed to have a mirror-like appearance when viewed from the first glass plate 11 side due to reflections at the interface between the dimming cell 20 and the gap layer G and at the interface between the first glass plate 11 and the gap layer G.

[0043] Moreover, the first glass plate 11 and the dimming cell 20 directly face each other via the gap layer G. In this case, no film is provided between the first glass plate 11 and the dimming cell 20. This makes it possible to prevent the occurrence of poor appearance of the light control device 10 due to undulations in the flexible film inserted between the first glass plate 11 and the dimming cell 20. Furthermore, no bead spacer is provided between the first glass plate 11 and the dimming cell 20. That is, since the first glass plate 11 is a rigid body, the thickness of the gap layer G can be maintained almost uniform in the plane even without providing a bead spacer. In this way, the thickness of the gap layer G is prevented from varying in the plane, so the occurrence of the above-mentioned Newton rings can be reduced. Furthermore, since the light incident on the light control device 10 is not reflected by the bead spacer present in the gap layer G, the occurrence of poor appearance can be suppressed.

[0044] In this embodiment, the void layer G is provided only on one side (the first glass plate 11 side) of the dimming cell 20, but this is not limited thereto, and the void layer G may be provided only on the other side (the second glass plate 12 side) of the dimming cell 20.

[0045] 3, the light control device 10 is connected to a light control controller 91, and a sensor device 92 and a user operation unit 93 are connected to the light control controller 91. The light control controller 91 controls the dimming state of the light control device 10, and can switch between blocking and transmitting light by the light control device 10 and change the light transmittance in the light control device 10. Specifically, the light control controller 91 is connected to the external electrode substrate 35 of the light control device 10, and can switch between blocking and transmitting light by the light control device 10 and change the light transmittance by adjusting the electric field applied to the liquid crystal layer 23 of the light control device 10 to change the orientation of the liquid crystal molecules in the liquid crystal layer 23.

[0046] The light control controller 91 can adjust the electric field applied to the liquid crystal layer 23 based on an arbitrary method. The light control controller 91 can adjust the electric field applied to the liquid crystal layer 23 in response to, for example, the measurement result of the sensor device 92 or an instruction (command) input by the user via the user operation unit 93, and can switch between blocking and transmitting light by the light control device 10 or change the light transmittance. Therefore, the light control controller 91 may automatically adjust the electric field applied to the liquid crystal layer 23 in response to the measurement result of the sensor device 92, or may manually adjust the electric field in response to an instruction from the user via the user operation unit 93. Note that the object to be measured by the sensor device 92 is not particularly limited, and for example, the brightness of the usage environment may be measured. In this case, the light control device 10 switches between blocking and transmitting light or changes the light transmittance in response to the brightness of the usage environment. In addition, it is not necessary to connect both the sensor device 92 and the user operation unit 93 to the light control controller 91, and only one of the sensor device 92 and the user operation unit 93 may be connected.

[0047] The external electrode substrate 35 is sandwiched between the first laminate 21 and the second laminate 22. In the region where the external electrode substrate 35 is formed, the first laminate 21 and the second laminate 22 have electrode protruding pieces 36 that protrude outward in the planar direction. The external electrode substrate 35 is embedded inside the electrode protruding pieces 36. The external electrode substrate 35 and the electrode protruding pieces 36 are sandwiched between the frame intermediate film 16 and the intermediate film 14, and protrude outward from the frame intermediate film 16 and the intermediate film 14.

[0048] (Manufacturing method of light control cell) Next, a method for manufacturing the dimming cell 20 of the dimming device 10 according to the present embodiment will be described with reference to Figures 4(a)-(d) and 5(a)-(c). Figures 4(a)-(d) and 5(a)-(c) are cross-sectional views showing the method for manufacturing the dimming cell 20 according to the present embodiment.

[0049] First, as shown in Fig. 4(a), a second substrate 27 supplied in a roll form is prepared. Then, as shown in Fig. 4(b), a second transparent electrode 28 made of, for example, ITO is formed on the second substrate 27 by sputtering using a sputtering device. At this time, the transparent electrode may be patterned to have a predetermined pattern shape.

[0050] 4(c), a coating liquid for the second alignment layer 29 is applied onto the second substrate 27 on which the second transparent electrode 28 has been formed, and then exposed to light to produce the second alignment layer 29. In this manner, the second laminate 22 in which the second substrate 27, the second transparent electrode 28, and the second alignment layer 29 are laminated is prepared.

[0051] In addition, a first laminate 21 in which a first substrate 24, a first transparent electrode 25, and a first alignment layer 26 are laminated is also prepared in the same manner as in the steps shown in FIGS. 4(a)-(c).

[0052] Next, as shown in FIG. 4(d), bead spacers 31 are arranged on the second alignment layer 29 of the second laminate 22. In addition to wet / dry spraying, various arrangement methods can be widely applied to arrange the bead spacers 31. For example, the bead spacers 31 may be arranged randomly on the second alignment layer 29 and held in a difficult-to-move manner by partially applying a coating liquid prepared by dispersing the bead spacers 31 together with a resin component in a solvent, and then sequentially performing drying and baking processes. Although not shown, the outer periphery of the bead spacers 31 may be covered with the second alignment layer 29. Specifically, the bead spacers 31 are mixed with the coating liquid for the second alignment layer 29 to form the second alignment layer 29, so that the bead spacers 31 can be thinly covered and held by the second alignment layer 29.

[0053] 5(a), a dispenser is used to apply a sealant 32 onto the second alignment layer 29 of the second laminate 22. The sealant 32 is applied in a frame shape so as to surround the area where the liquid crystal layer 23 is to be formed.

[0054] 5(b) and (c), the second laminate 22 and the first laminate 21 are laminated together, and the liquid crystal layer 23 is disposed. During this process, liquid crystal that constitutes the liquid crystal layer 23 is first dripped into the area surrounded by the sealant 32, as shown in FIG. 5(b). At this time, the liquid crystal layer 23 is filled inside the sealant 32 and around the bead spacers 31.

[0055] 5(c), the second laminate 22 on which the liquid crystal layer 23 is arranged and the first laminate 21 prepared in advance are laminated and pressed against each other. After that, the sealant 32 is semi-cured by irradiating it with ultraviolet light, and then heated to integrate the first laminate 21 and the second laminate 22. Thereafter, the laminate of the first laminate 21 and the second laminate 22 thus prepared is cut to a desired size by trimming.

[0056] As described above, it is preferable to laminate the second stack 22 and the first stack 21 together after disposing the liquid crystal layer 23, but this is not limiting, and the second stack 22 and the first stack 21 may be laminated together and then the liquid crystal layer 23 may be disposed. Thereafter, an external electrode substrate 35 (see FIG. 3) is attached between the first stack 21 and the second stack 22 to obtain the dimming cell 20 according to this embodiment.

[0057] (Manufacturing method of light control device) Next, a method for manufacturing the light control device 10 according to the present embodiment (a method for processing laminated glass) will be described with reference to Figures 6(a) to 6(c). Figures 6(a) to 6(c) are cross-sectional views showing the method for manufacturing the light control device 10.

[0058] 6(a), a first glass plate 11 and a second glass plate 12 are prepared. Next, a frame interlayer film 16, a dimming cell 20, and an interlayer film 14 are sandwiched between the first glass plate 11 and the second glass plate 12 to produce a laminated glass laminate 30. Here, the first glass plate 11 and the second glass plate 12 are each previously formed into a curved shape, which is a three-dimensional surface shape.

[0059] Next, as shown in FIG. 6(b), the laminated glass laminate 30 is sealed in a bag 51. The bag 51 is preferably made of rubber or silicone, which is flexible and airtight. A vent pipe 52 is connected to the bag 51, and air in the bag 51 is sucked through the vent pipe 52 by a pump (not shown). This allows the air remaining between the members of the laminated glass laminate 30 to be sucked, and pressure failure due to air bubbles remaining inside the light control device 10 can be suppressed. In this embodiment, an example is described in which the inside of the bag 51 and the inside of the laminated glass laminate 30 are sucked to create a vacuum state, and a pressure of about atmospheric pressure (0.1 MPa) is applied to the laminated glass laminate 30 due to a pressure difference. However, this is not limited to this, and for example, the suction force of the pump (not shown) may be adjusted to create a state in which the inside of the bag 51 is not completely vacuum, but the air between the members of the laminated glass laminate 30 is sufficiently sucked, and a pressure smaller than atmospheric pressure is applied to the laminated glass laminate 30 due to a pressure difference.

[0060] Next, as shown in FIG. 6(c), the laminated glass laminate 30 is sealed in a bag 51, and then the bag 51 is placed in a heating and pressurizing device 53. The laminated glass laminate 30 is heated in the bag 51 at a predetermined temperature for a predetermined time. In this embodiment, the laminated glass laminate 30 is heated for a predetermined time at a temperature equal to or higher than the softening temperature of the interlayer 14 and the frame interlayer 16. At this time, it is preferable to suck air from the bag 51 by a pump (not shown) through the vent pipe 52. The device used as the heating and pressurizing device 53 is not particularly limited as long as it can sufficiently heat and pressurize the laminated glass laminate 30, and examples of the device include an oven and an autoclave device. This heating melts the interlayer 14 and the frame interlayer 16, and the first glass plate 11, the frame interlayer 16, the light control cell 20, the interlayer 14, and the second glass plate 12 of the laminated glass laminate 30 are pressure-bonded together to obtain the light control device 10. At this time, the first glass plate 11 and the dimming cell 20 are not directly joined to each other, so that an air gap layer G is formed between them. By providing such an air gap layer G, the pressure applied to the liquid crystal layer 23 of the dimming cell 20 is released after the manufacture of the dimming device 10, so that even if the liquid crystal layer 23 is unevenly distributed within the dimming cell 20, the uneven distribution of the liquid crystal layer 23 is naturally eliminated.

[0061] Thereafter, a process of making the cell gap (the thickness of the liquid crystal layer 23) uniform (leveling process) may be performed by heating the laminated glass laminate 30 (the light control device 10) for a predetermined time at a temperature equal to or higher than the softening temperature of the interlayer 14 and the frame interlayer 16.

[0062] During the laminated glass processing for manufacturing the light control device 10 in this manner, pressure is applied to each component of the laminated glass laminate 30. At this time, the original cell gap (thickness of the liquid crystal layer 23) is maintained in the portion where the spacer (bead spacer 31) is located, but the original cell gap value becomes smaller away from the bead spacer 31. If such unevenness occurs in the cell gap, the light control device 10 may have a poor appearance, the light control function may become non-uniform, or the quality of the light control device 10 may be degraded.

[0063] In contrast, according to the present embodiment, an air gap layer G is provided between the first glass plate 11 and the dimming cell 20. As a result, even if liquid crystal puddles (a phenomenon in which a large amount of liquid crystal is present locally) occur in the liquid crystal layer 23 of the dimming cell 20, when the pressure applied to the liquid crystal layer 23 is released after the manufacture of the dimming device 10, the dimming cell 20 moves naturally within the air gap layer G so that the cell gap (the thickness of the liquid crystal layer 23) becomes uniform (see FIGS. 7(a)-(c)). As a result, the liquid crystal puddles in the dimming cell 20 are eliminated, and the liquid crystal layer 23 of the dimming cell 20 can be distributed uniformly within the plane, thereby improving the quality and appearance of the dimming device 10.

[0064] Furthermore, according to this embodiment, since the first glass plate 11 is a rigid body, it is possible to maintain the thickness of the gap layer G approximately uniform within the plane. In this manner, since the thickness of the gap layer G is prevented from varying within the plane, it is possible to prevent interference unevenness (Newton rings) caused by the presence of the gap layer G.

[0065] Furthermore, according to this embodiment, the first glass plate 11 and the dimming cell 20 directly face each other via the air gap layer G. This prevents poor appearance caused by waviness of the film between the first glass plate 11 and the dimming cell 20. Furthermore, since light incident on the light control device 10 is not reflected by the bead spacers between the first glass plate 11 and the dimming cell 20, it is possible to prevent poor appearance.

[0066] Furthermore, according to this embodiment, an air gap layer G is provided between the first glass plate 11 and the dimming cell 20, thereby improving the insulating properties of the dimming device 10 and enhancing the heat retention inside the vehicle or building in which the dimming device 10 is installed.

[0067] Furthermore, according to this embodiment, the frame interlayer film 16 is formed in a frame shape so as to surround the periphery of the dimming cell 20, and the frame interlayer film 16 connects the first glass plate 11 and the interlayer film 14. This makes it possible to prevent the intrusion of moisture and the like from the side surface of the dimming device 10, and to further improve the water-proofing property of the dimming device 10.

[0068] (Modification) Next, various modified examples of the present disclosure will be described with reference to Fig. 8 to Fig. 17. Fig. 8 to Fig. 17 are diagrams showing light control devices according to modified examples of the present disclosure. In Fig. 8 to Fig. 17, the same parts as those shown in Fig. 1 to Fig. 7 are denoted by the same reference numerals, and detailed description thereof will be omitted.

[0069] (First Modification) FIG. 8 shows a light control device 10A according to a first modified example. In the light control device 10A shown in FIG. 8, a fluid resin layer L is provided between the first glass plate 11 and the light control cell 20. This fluid resin layer L is filled in the space between the first glass plate 11 and the light control cell 20. The fluid resin layer L is, for example, a transparent resin that softens at a temperature lower than that of the intermediate film 14, and may be an uncured liquid or a gel. The first glass plate 11 and the light control cell 20 directly face each other via the fluid resin layer L. For example, glycerin or the like can be used as the fluid resin layer L. The fluid resin layer L may be a fluid liquid layer. The thickness of the fluid resin layer L may be greater than 0 μm and less than 10,000 μm, and is preferably greater than 100 μm and less than 300 μm. When the thickness of the fluid resin layer L is greater than 100 μm and less than 300 μm, the occurrence of interference unevenness (Newton rings) caused by the presence of the fluid resin layer L can be suppressed. In this way, by providing the fluid resin layer L between the first glass plate 11 and the light control cell 20, the fluid resin layer L can be made to flow after the laminated glass is processed. This makes it possible to make the thickness of the liquid crystal layer 23 of the light control cell 20 uniform and prevent liquid crystal pools from occurring. Note that the fluid resin layer L may be provided instead of the gap layer G in the examples shown in Figs. 9 to 11, which will be described later.

[0070] (Second Modification) FIG. 9 shows a light control device 10B according to a second modified example. In the light control device 10B shown in FIG. 9, an antireflection layer 37 is provided on the surface of the light control cell 20 facing the gap layer G. For example, an AR (Anti Reflection) film, a LR (Low Reflection) film, an AG (Anti Glare) film, or a moth-eye film may be used as the antireflection layer 37. The AR film is a film that suppresses regular reflection by utilizing the interference of reflected light. The LR film is a film made of a low-reflection material with a low reflectance. The AG film is a film that reduces regular reflection by diffusing incident light. The moth-eye film is a film that includes an uneven structure in which a large number of minute protrusions are regularly arranged at intervals equal to or less than the shortest wavelength of the wavelength range of light to be prevented from being reflected, as a structure for reducing reflected light. The thickness of the antireflection layer 37 may be 30 μm or more and 200 μm or less. The antireflection layer 37 may be attached to the light control cell 20 via an optically transparent adhesive film. Such an optically transparent adhesive film may be, for example, an optically transparent adhesive film called OCA (Optical Clear Adhesive Film) made of an acrylic adhesive. The antireflection layer 37 may be provided on the surface of the first glass plate 11 facing the air gap layer G (phantom line in FIG. 9). The antireflection layer 37 may be provided on both the surface of the light control cell 20 facing the air gap layer G and the surface of the first glass plate 11 facing the air gap layer G.

[0071] In this way, by providing the anti-reflection layer 37 on the surface of the dimming cell 20 or the first glass plate 11 facing the air gap layer G, light incident on the light control device 10B is prevented from being reflected at the interface between the first glass plate 11 and the air gap layer G, or at the interface between the air gap layer G and the dimming cell 20. This reduces interference between the light reflected at the interface between the first glass plate 11 and the air gap layer G and the light reflected at the interface between the air gap layer G and the dimming cell 20, making it possible to suppress the occurrence of Newton's rings.

[0072] (Third Modification) 10(a) and 10(b) show a light control device 10C according to a third modified example. In the light control device 10C shown in FIG. 10(a) and 10(b), a region (thin region 11a) of the first glass plate 11 that overlaps with the light control cell 20 in a plan view is made thinner than the other region (peripheral region 11b). Specifically, a region of the first glass plate 11 that overlaps with the light control cell 20 in a plan view is made thinner to form the thin region 11a. The thin region 11a may be formed, for example, by cutting a flat glass substrate before processing. A peripheral region 11b having substantially the same planar shape as the frame intermediate film 16 is formed on the periphery of the thin region 11a. The peripheral region 11b is not thinned and is thicker than the thin region 11a. The peripheral region 11b is also joined to the frame intermediate film 16. The thickness of the thin region 11a may be 85% or more and 95% or less of the thickness of the peripheral region 11b.

[0073] 10(a), the bonding surface between the peripheral region 11b and the frame intermediate film 16 may be separated in the thickness direction of the light control device 10C from the surface (the surface on the gap layer G side) of the light control cell 20. This makes it possible to increase the volume of the gap layer G, and to further prevent liquid crystal accumulation in the light control cell 20.

[0074] 10(b), the joint surface between the peripheral region 11b and the frame intermediate film 16 may be located on the same plane as the surface (surface on the air gap layer G side) of the dimming cell 20. In this case, the air gap layer G is formed in the space surrounded by the thin region 11a and the peripheral region 11b of the first glass plate 11. The thickness of the frame intermediate film 16 is approximately the same as the thickness of the dimming cell 20. This makes it possible to reduce the overall thickness of the dimming device 10C while suppressing the occurrence of liquid crystal accumulation in the dimming cell 20.

[0075] (Fourth Modification) FIG. 11 shows a light control device 10D according to a fourth modified example. In the light control device 10D shown in FIG. 11, a third glass plate (third transparent substrate) 46 is disposed on the opposite side of the gap layer G of the first glass plate 11. In addition, an additional intermediate film (third intermediate film) 47 is provided between the first glass plate 11 and the third glass plate 46. The third glass plate 46 is located on the outermost surface of the light control device 10D and is a plate glass having high light transmittance. The material of the third glass plate 46 can be the same as that of the first glass plate 11 and the second glass plate 12 described above. The additional intermediate film 47 is a member that bonds the first glass plate 11 and the third glass plate 46. The material of the additional intermediate film 47 can be the same as that of the intermediate film 14 described above.

[0076] The first glass plate 11 and the third glass plate 46 may have the same thickness as the second glass plate 12, or may have a different thickness. In particular, the first glass plate 11 and the third glass plate 46 may be made of glass thinner than the second glass plate 12, for example, glass having a thickness of 0.5 mm or more and 1 mm or less. As an example, the first glass plate 11 and the third glass plate 46 may have a thickness of 0.5 mm, 0.7 mm, or 1 mm. This makes it possible to reduce the overall thickness of the light control device 10D. In addition, the size of the first glass plate 11 is the same as the size of the third glass plate 46, but is not limited thereto, and may be the same as the size of the light control cell 20, or may be an intermediate size between the first glass plate 11 and the light control cell 20.

[0077] In this way, it is possible to improve the impact resistance of the light control device 10D by providing the additional intermediate film 47 and the third glass plate 46 on the first glass plate 11. Since the third glass plate 46 is bonded to the additional intermediate film 47 over the entire surface, even if the third glass plate 46 or the first glass plate 11 is broken, it is possible to prevent fragments of the third glass plate 46 or the first glass plate 11 from scattering.

[0078] (Fifth Modification) 12 and 13 show a light control device 10E according to a fifth modified example. In the light control device 10E shown in FIG. 12 and FIG. 13, a fluid resin layer L is provided between the first glass plate 11 and the light control cell 20. In addition, the frame intermediate film 16 has a groove 48 that communicates with the fluid resin layer L. The groove 48 is formed by cutting a part of the periphery of the frame intermediate film 16 along the width direction. The groove 48 is formed in a part of the frame intermediate film 16 in the thickness direction (on the first glass plate 11 side). The groove 48 is used as an injection port when injecting the fluid resin layer L into the space between the first glass plate 11 and the light control cell 20 after the laminated glass processing. In this case, since the first glass plate 11 is a rigid body, a space between the first glass plate 11 and the light control cell 20 is secured, and the operation of injecting the fluid resin layer L from the groove 48 becomes easy. Moreover, it is preferable to fill the grooves 48 with the material of the frame interlayer 16 or a sealing material after injecting the fluid resin layer L. In the light control device 10E, a gap layer G may be used instead of the fluid resin layer L. In this case, even if air escapes from the gap layer G between the first glass plate 11 and the dimming cell 20 during processing of the laminated glass, the gap layer G can be restored by injecting air or a gas such as nitrogen through the grooves 48.

[0079] (Sixth Modification) 14 and 15 show a light control device 10F according to a sixth modified example. In the light control device 10F shown in FIG. 14 and FIG. 15, a fluid resin layer L is provided between the first glass plate 11 and the light control cell 20. The first glass plate 11 has a groove 49 communicating with the fluid resin layer L. The groove 49 is formed by cutting a part of the periphery of the first glass plate 11 along the surface direction of the first glass plate 11. The groove 49 is formed in a part of the thickness direction of the first glass plate 11 (on the frame interlayer 16 side). The groove 49 is used as an injection port when injecting the fluid resin layer L into the space between the first glass plate 11 and the light control cell 20 after the laminated glass processing. In this case, since the first glass plate 11 is a rigid body, a space between the first glass plate 11 and the light control cell 20 is secured, and the operation of injecting the fluid resin layer L from the groove 49 becomes easy. Moreover, it is preferable that the groove 49 is sealed with the material of the frame interlayer 16 or a sealing material after the fluid resin layer L is injected. Note that in the light control device 10F, a gap layer G may be used instead of the fluid resin layer L. In this case, even if air escapes from the gap layer G between the first glass plate 11 and the dimming cell 20 during the laminated glass processing, the gap layer G can be restored by injecting air or a gas such as nitrogen through the groove 49. Note that both the groove 49 in the first glass plate 11 and the groove 48 in the frame interlayer 16 (FIGS. 12 and 13) may be formed.

[0080] (Seventh Modification) 16 and 17 show a light control device 10G according to a seventh modified example. In the light control device 10G shown in FIG. 16 and FIG. 17, a fluid resin layer L is provided between the first glass plate 11 and the light control cell 20. The frame intermediate film 16 has a groove 48A communicating with the fluid resin layer L. The groove 48A is formed by cutting a part of the periphery of the frame intermediate film 16 along the width direction. The groove 48A is formed in a part of the frame intermediate film 16 in the thickness direction (on the first glass plate 11 side). The groove 48A is used as an injection port when injecting the fluid resin layer L into the space between the first glass plate 11 and the light control cell 20 after the laminated glass processing. In this case, since the first glass plate 11 is a rigid body, the space between the first glass plate 11 and the light control cell 20 is easily secured, and the operation of injecting the fluid resin layer L from the groove 48A becomes easy. Moreover, it is preferable to fill the groove 48A with the material of the frame interlayer 16 or a sealing material after injecting the fluid resin layer L. In the light control device 10G, a gap layer G may be used instead of the fluid resin layer L. In this case, even if air escapes from the gap layer G between the first glass plate 11 and the dimming cell 20 during processing of the laminated glass, the gap layer G can be restored by injecting a gas such as air or nitrogen through the groove 48A.

[0081] 16 and 17, an extension 61 is formed by a part of the dimming cell 20. The extension 61 protrudes from the dimming device 10G toward the outside in the planar direction. The extension 61 is provided to be accommodated in the groove 48A, and is in contact with the first glass plate 11. The extension 61 has a substantially rectangular shape in a plan view, and extends outward from the first glass plate 11 and the second glass plate 12. In this case, the extension 61 is formed by a part of the first base material 24 of the dimming cell 20. In this way, the extension 61 is formed in the dimming cell 20, which makes it easier to inject the fluid resin layer L from the groove 48A located above the extension 61. Also, in FIG. 16 and FIG. 17, only the extension 61 may be provided without providing the groove 48A.

[0082] It is also possible to combine the multiple components disclosed in the above embodiments and modifications as necessary. Alternatively, some components may be deleted from all the components shown in the above embodiments and modifications. [Explanation of symbols]

[0083] 10 Dimmer 11 First glass plate 12 Second Glass Pane 14 Interlayer 16 Frame Interlayer 20 Dimming cell 21 First laminate 22 Second laminate 23 Liquid crystal layer 24 First base material 25 1st transparent electrode 26 First alignment layer 27 Second base material 28 Second transparent electrode 29 Second alignment layer 31 Bead Spacer 32 Sealing material

Claims

1. A first transparent substrate; A second transparent substrate; a light-controlling cell disposed between the first transparent substrate and the second transparent substrate; a first intermediate film disposed between the second transparent substrate and the light control cell; a second intermediate film disposed between the first transparent substrate and the second transparent substrate and formed so as to surround the periphery of the light control cell in a plan view; a gap layer or a fluid resin layer is provided between the first transparent substrate and the light-controlling cell; the dimming cell includes a first stack, a second stack, a liquid crystal layer disposed between the first stack and the second stack, and an external electrode substrate sandwiched between the first stack and the second stack; the external electrode substrate is sandwiched between the first intermediate film and the second intermediate film and protrudes outward from the first intermediate film and the second intermediate film; The first intermediate film contains polyvinyl butyral, ethylene-vinyl acetate copolymer, or cycloolefin polymer, and the second intermediate film is made of the same material as the first intermediate film; A light control device, wherein a thin region of the first transparent substrate that overlaps with the dimming cell is thinner than a peripheral region located on the periphery of the thin region, and the peripheral region has the same planar shape as the second intermediate film.

2. The light control device according to claim 1 , wherein the first transparent substrate and the light control cell directly face each other with the air gap layer or the fluid resin layer interposed therebetween.

3. The light control device according to claim 1 , further comprising an anti-reflection layer provided on a surface of the first transparent substrate or the light control cell facing the air gap layer or the flowable resin layer.

4. A dimming device according to any one of claims 1 to 3, wherein a third transparent substrate is disposed on the opposite side of the first transparent substrate from the void layer or the fluid resin layer, and an additional intermediate film is provided between the first transparent substrate and the third transparent substrate.

5. The light control device according to claim 1 , wherein the thickness of the gap layer or the fluid resin layer is 100 μm or more and 300 μm or less.

6. The light control device according to claim 1 , wherein the second intermediate film has a groove communicating with the void layer or the fluid resin layer.

7. The light control device according to claim 1 , wherein the first transparent substrate has a groove communicating with the air gap layer or the fluid resin layer.

Images