Manufacturing method of dimming unit

Abstract

To provide the electrode structure of a light control unit, manufactured with less man hour, firm, excellent in sealability to a light control layer, having a large bonding area with a transparent electrode and capable of avoiding an exothermic problem between wiring areas facing each other.SOLUTION: A light control unit includes a power supply structure having the transparent conductive film sides of a pair of transparent conductive films formed on the surface of a transparent film in the inside and for supplying the drive voltage of a light control sheet holding a light control layer having a light transmittance changed by voltage to be applied to the end part of one side of the light control sheet. The power supply structure includes a long-sized power supply member having a size of 80% or more of the length of the one side and held, bonded and sealed to the pair of transparent conduction films through a conductive adhesive by a sealing resin filled in a deep area of an opened portion between the pair of transparent conductive films peeled in parallel along the end part of the one side.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a dimming unit. Manufacturing method Regarding. [Background technology]

[0002] The light-controlling sheet used in the light-controlling unit comprises a light-controlling layer containing a liquid crystal composition and a pair of transparent electrode layers sandwiching the light-controlling layer. When a driving voltage is applied to the pair of transparent electrode layers, the orientation state of the liquid crystal molecules contained in the light-controlling layer changes, thereby changing the light transmittance of the light-controlling sheet. The light-controlling unit is composed of this light-controlling sheet and a connector for connecting the transparent electrode layer to a power source (see Patent Document 1).

[0003] An example of the structure of a light control unit will be described with reference to the drawings. As shown in Fig. 14, light control unit 100 is attached to a transparent plate 200 such as window glass. Light control sheet 110 includes a pair of electrode sheets 130A and 130B, with connection part 160A connected to electrode sheet 130A and connection part 160B connected to electrode sheet 130B.

[0004] As shown in detail in Fig. 15, which is a cross-sectional explanatory diagram illustrating the cross-sectional structure of the light-controlling sheet 110 and the connection portion 160A taken along the XII-XII' cutting line in Fig. 14, one electrode sheet 130A is a laminate of a transparent electrode layer 140A and a transparent support layer 150A. The transparent electrode layer 140A contacts one surface of the light-controlling layer 120, and the transparent support layer 150A is attached to the transparent plate 200 via an adhesive layer 210. The connection portion 160A is connected to a region of the transparent electrode layer 140A that is exposed from the light-controlling layer 120 and the other electrode sheet 130B.

[0005] 16, which is a cross-sectional explanatory diagram illustrating the cross-sectional structure of the light-controlling sheet 110 and the connection portion 160B along the XIII-XIII' cutting line in FIG. 14, the other electrode sheet 130B is a laminate of a transparent electrode layer 140B and a transparent support layer 150B, and the transparent electrode layer 140B is in contact with the other surface of the light-controlling layer 120. The connection portion 160B is connected to an area of ​​the transparent electrode layer 140B that is exposed from the light-controlling layer 120 and the other electrode sheet 130A, and faces the transparent plate 200.

[0006] The connecting portions 160A and 160B include a conductive adhesive layer 161 bonded to the transparent electrode layers 140A and 140B, and a conductive tape 162 bonded to the conductive adhesive layer 161. The conductive adhesive layer 161 is made of, for example, a conductive paste such as silver paste. The conductive tape 162 is, for example, a copper (foil) tape. The connecting portions 160A and 160B further include solder 163 located on the surface of the conductive tape 162 and a lead wire 164 connected to the conductive tape 162 by the solder 163. The lead wire 164 is connected to a drive circuit that converts a voltage supplied from a power source into a drive voltage capable of driving the light controlling sheet 110, and the drive voltage is applied to the transparent electrode layers 140A and 140B via the connecting portions 160A and 160B.

[0007] However, the power supply terminal extraction structure (connection portions 160A, 160B) as shown in Figures 14 to 16 is not only vulnerable to external forces acting on the wiring (lead wire 164), but also has other problems, such as the need to process both sides separately, i.e., connection portion 160A on the surface of transparent electrode layer 140A of electrode sheet 130A and connection portion 160B on the surface of transparent electrode layer 140B of electrode sheet 130B, which requires processing labor such as flipping the light-control sheet 110 over for processing, the formation of protrusions such as solder terminals on the light-control sheet, which may prevent it from adhering to the glass surface, and the need to separately apply a cover structure or sealing structure to the electrode formation portion to improve reliability.

[0008] Furthermore, when the connection area (wiring area) with the transparent electrode is small (short in width in the direction perpendicular to the current supply direction), current concentrates on the transparent electrode, causing voltage drops, heat generation, and reduced reliability around the wiring area. Also, when one wiring area is made somewhat long to improve current injection, as shown in Figure 14, there is a problem that current concentrates in the area where the distance between the wiring areas on each of the opposing transparent electrodes is short, causing heat generation in that area. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] Patent No. 4387931 Summary of the Invention [Problem to be solved by the invention]

[0010] In view of the above circumstances, the present invention provides a light control unit that can be manufactured with a small number of steps, is robust, has good sealing properties for a light control layer, has a large bonding area with a transparent electrode, and avoids the problem of heat generation between opposing wiring areas. Manufacturing method The objective is to provide the following. [Means for solving the problem]

[0011] As a means for solving the above problems , th One aspect is a light-controlling unit including a pair of transparent conductive films each having a transparent conductive film formed on the surface of the transparent film, with the transparent conductive film side of the pair of transparent conductive films facing inward, and a light-controlling layer whose light transmittance changes depending on the applied voltage sandwiched between the pair of transparent conductive films, the light-controlling unit including a power supply structure that supplies a driving voltage to the light-controlling sheet at an end of one side of the light-controlling sheet, the light-controlling sheet having a light-controlling layer whose light transmittance changes depending on the applied voltage, the power supply structure is formed by sandwiching and bonding, at an end of the one side, a long power supply member having a length of 80% or more of the length of the one side to each transparent conductive film of a pair of transparent conductive films peeled off in parallel along the end, between the pair of transparent conductive films via a conductive adhesive, the power supply member is a double-sided conductive tape having a long insulating layer, the double-sided conductive tape including a first conductive layer on one side and a second conductive layer on the other side; the first conductive layer and the second conductive layer are covered with a first insulating layer and a second insulating layer, respectively; the first conductive layer and one of the transparent conductive films are bonded to each other via a conductive adhesive provided in an opening formed in the first insulating layer; the second conductive layer and the other transparent conductive film are bonded to each other via a conductive adhesive provided in an opening formed in the second insulating layer at a position overlapping the opening in a plan view, This dimming unit is characterized in that in the power supply structure, the power supply member is embedded with a sealing resin filled in a space surrounded by one of the transparent conductive films, the other transparent conductive film, and the surface of the dimming layer that is not in contact with the transparent conductive film, and the surface of the dimming layer that is not in contact with the transparent conductive film is sealed.

[0012] In addition, a second aspect is a light-controlling unit including a pair of transparent conductive films each having a transparent conductive film formed on the surface of a transparent film, with the transparent conductive film side of the pair of transparent conductive films facing inward, and a light-controlling layer whose light transmittance changes depending on the applied voltage sandwiched between the pair of transparent conductive films, and a power supply structure that supplies a drive voltage to the light-controlling sheet at an end of one side of the light-controlling sheet, the power supply structure is formed by bonding, via a conductive adhesive, an elongated power supply member having a length of 80% or more of the length of the one side to each transparent conductive film of a pair of transparent conductive films that have been peeled off in parallel along the one side, the power supply member is a double-sided conductive tape having a long insulating layer, the double-sided conductive tape including a first conductive layer on one side and a second conductive layer on the other side; the first conductive layer and the second conductive layer are covered with a first insulating layer and a second insulating layer, respectively; the first conductive layer and one of the transparent conductive films are bonded to each other via a conductive adhesive provided in an opening formed in the first insulating layer; the second conductive layer and the other transparent conductive film are bonded to each other via a conductive adhesive provided in an opening formed in the second insulating layer at a position that does not overlap with the opening in a plan view, This dimming unit is characterized in that in the power supply structure, the power supply member is embedded with a sealing resin filled in a space surrounded by one of the transparent conductive films, the other transparent conductive film, and the surface of the dimming layer that is not in contact with the transparent conductive film, and the surface of the dimming layer that is not in contact with the transparent conductive film is sealed.

[0013] A third aspect is a dimming unit according to the first or second aspect, characterized in that in the power supply structure, at least one end of the power supply member has a wiring area that protrudes from the end of the side adjacent to the one side and can be connected to a power source that supplies the driving voltage.

[0014] A fourth aspect is a dimming unit according to any one of the first to third aspects, characterized in that the openings formed in the first insulating layer are openings of the same shape and size that are arranged parallel to and at equal intervals along the one side.

[0015] A fifth aspect is the light control unit according to any one of the first to fourth aspects, wherein the double-sided conductive tape is made of a double-sided flexible wiring board.

[0016] A sixth aspect is a method for manufacturing a light control unit according to any one of claims 1 to 5, comprising: a step of fixing the light controlling sheet by sandwiching the light controlling sheet between a pair of rolls at a position a predetermined distance inside from the end of the one side; A process of opening the pair of transparent conductive films by inserting a film peeling tool with a razor-shaped tip into the light-control layer of the light-control sheet from the end of one side of the light-control sheet, and peeling the film from the end of one side of the light-control sheet fixed by a pair of rolls to a position a predetermined distance inward; removing the light-controlling layer on the transparent conductive film of the opened pair of transparent conductive films; a step of filling a sealing resin into a region behind the opened portion of the pair of transparent conductive films; A step of inserting the power supply member into sealing resin filled in a deep area of ​​a portion where the pair of transparent films of the light controlling sheet are opened while applying tension in the longitudinal direction of the power supply member; a step of laminating the inserted power supply member between a pair of the transparent films in a sandwiched form, and temporarily pressing the conductive adhesive and the sealing resin together, while further filling the sealing resin at the outer end of the light controlling sheet of the power supply member; sandwiching the power supply member and the sealing resin, laminating the transparent film with a pair of rolls so as to flatten it, curing the conductive adhesive and the sealing resin by irradiating ultraviolet light, and then cutting off unnecessary portions of the light-controlling sheet; The present invention relates to a method for manufacturing a light control unit, comprising: [Effects of the Invention]

[0017] The light control unit of the present invention includes a power supply structure formed by inserting a power supply member having a conductor layer on both sides of an insulating layer, such as a long double-sided FPC (flexible wiring board), into a portion where an end of one side of a light control sheet sandwiching a light control layer is peeled off from the light control layer, with a pair of transparent conductive films each having a transparent conductive film formed on the surface of a transparent film, with the transparent conductive film side facing inward, and embedding the power supply structure in a sealing resin. Conduction is established between the conductor layer and the transparent conductive film facing that conductor layer. Furthermore, conduction is established between the conductor layer on the other side of the power supply member and the transparent conductive film facing that conductor layer. In this way, the power supply member, which is electrically connected to the pair of transparent conductive films of the light-controlling sheet, is inserted between a pair of transparent conductive films at the end of one side of the light-controlling sheet, and the power supply member is further sealed with a sealing resin to form a fixed power supply structure. Therefore, even if an external force is applied to the power supply structure, the electrical connection between the transparent conductive film and the power supply member is not easily broken, resulting in a robust structure and a good sealing state. Furthermore, the junction area with the transparent electrode is larger than that of conventional electrode structures, and the two conductor layers that supply power to the pair of transparent conductive films are formed on the front and back surfaces of the insulating layer, thereby avoiding heat generation problems between opposing wiring areas. Furthermore, the power supply member can be manufactured using a double-sided FPC, and the process involves peeling off the end of the light-controlling sheet and inserting the power supply member, so there is no need to turn the light-controlling sheet over during the manufacturing process, and it can be manufactured with fewer steps.

[0018] Furthermore, according to the method for manufacturing a light control unit of the present invention, it is possible to provide the light control unit of the present invention. [Brief explanation of the drawings]

[0019] [Figure 1] FIG. 2 is an explanatory diagram illustrating a top view of a power supply structure of the light control unit of the present invention. [Figure 2] 2 is an explanatory diagram illustrating a cross-sectional view of the power supply structure taken along the line aa' in FIG. 1; [Figure 3] 2 is an explanatory diagram illustrating a cross-sectional view of the power supply structure taken along the line cc′ in FIG. 1; FIG. [Figure 4] FIG. 2 is an explanatory diagram illustrating a top view of a power supply structure of the light control unit of the present invention. [Figure 5] 5 is an explanatory diagram illustrating a cross-sectional view of the power supply structure taken along the b1-b1′ cutting line in FIG. 4; FIG. [Figure 6] 5 is an explanatory diagram illustrating a cross-sectional view of the power supply structure taken along the b2-b2′ cutting line in FIG. 4; FIG. [Figure 7]10A and 10B are cross-sectional explanatory views illustrating a manufacturing process of the power supply structure of the light control unit of the present invention, showing a state in which a liquid crystal light control sheet is set between a pair of pressing and laminating rolls. [Figure 8] This is a cross-sectional explanatory diagram illustrating the manufacturing process of the power supply structure of the dimming unit of the present invention, showing the state in which a film peeling tool is inserted into the dimming layer of the liquid crystal dimming sheet and the transparent film on which two transparent conductive films are formed is peeled off. [Figure 9] This is a cross-sectional explanatory diagram illustrating the manufacturing process of the power supply structure of the dimming unit of the present invention, showing the state in which after the film peeling tool is removed, a dimming layer wiping tool is inserted to wipe off the dimming layer on the transparent conductive film of the transparent film on which two transparent conductive films are formed. [Figure 10] FIG. 10 is a cross-sectional explanatory view illustrating the manufacturing process of the power supply structure of the dimming unit of the present invention, showing the state in which, after FIG. 9, sealing resin is filled between two transparent films on which transparent conductive films are formed using a sealing resin dispenser tool. [Figure 11] 10A to 10C are cross-sectional explanatory views illustrating a manufacturing process of the power supply structure of the light control unit of the present invention, showing a state in which the power supply structure is inserted into filled sealing resin. [Figure 12] FIG. 10 is a cross-sectional explanatory diagram illustrating the manufacturing process of the power supply structure of the dimming unit of the present invention, showing the state in which, after the power supply structure is inserted, the transparent conductive films of the transparent film on which two transparent conductive films have been formed are pressed against the conductive adhesive of the power supply structure by a pair of holding and laminating rolls, and the peeled transparent film on which the two transparent conductive films have been formed is resealed with sealing resin. [Figure 13] This is a cross-sectional explanatory diagram illustrating the manufacturing process of the power supply structure of the dimming unit of the present invention, showing the state just before the edge of the liquid crystal dimming sheet is cut using a cutter after the sealing resin has been hardened by irradiating ultraviolet light onto the part resealed with the sealing resin. [Figure 14] FIG. 10 is a top view illustrating a power supply structure of a conventional dimming unit. [Figure 15]12 is a cross-sectional explanatory view illustrating the cross-sectional structure of the light controlling sheet 110 and the connection portion 160A taken along the XII-XII′ cutting line in FIG. 14. [Figure 16] 13 is a cross-sectional explanatory diagram illustrating the cross-sectional structure of the light controlling sheet 110 and the connection portion 160B taken along the XIII-XIII′ cutting line in FIG. 14. DETAILED DESCRIPTION OF THE INVENTION

[0020] <Dimming unit> (First embodiment) 1 to 3 show a first embodiment of a light control unit 100-1 of the present invention. The dimming unit 100-1 of the present invention is a dimming unit that includes a pair of transparent conductive films (not shown) having transparent conductive films 2A and 2B formed on the surfaces of transparent films 1A and 1B, respectively, with the transparent conductive films 2A and 2B facing inward, and a dimming layer 3 whose light transmittance changes depending on the applied voltage, sandwiched between the pair of transparent conductive films. The dimming unit has a power supply structure 8-1 that supplies a driving voltage to the dimming sheet A at the end of one side of the dimming sheet A. The dimming sheet A has a dimming layer 3 whose light transmittance changes depending on the applied voltage.

[0021] The power supply structure 8-1 is configured by sandwiching and adhering a long power supply member B1, having a length of 80% or more of the length of one side, between the transparent conductive films 2A and 2B of a pair of transparent conductive films (a transparent conductive film 2A formed on the surface of a transparent film 1A, and a transparent conductive film 2B formed on the surface of a transparent film 1B) that have been peeled off parallel to one end of the dimming sheet A along that end, via conductive adhesives 7A and 7B.

[0022] The power supply member B1 is a double-sided conductive tape having a long insulating layer 5 with a first conductive layer 6A on one side and a second conductive layer 6B on the other side.

[0023] The first conductive layer 6A and the second conductive layer 6B are covered with a first insulating layer 5A and a second insulating layer 5B, respectively.

[0024] The first conductive layer 6A and one of the transparent conductive films 2A are bonded together via a conductive adhesive 7A provided in an opening formed in the first insulating layer 5A (not shown, but this is the portion where the first insulating layer 5A has been removed and where the conductive adhesive 7A is formed).

[0025] Similarly, the second conductive layer 6B and the other transparent conductive film 2B are bonded via the conductive adhesive 7B provided in an opening (not shown) formed in the second insulating layer 5B, where the second insulating layer 5B has been removed and where the conductive adhesive 7B has been formed. These two openings are formed at positions that overlap in plan view.

[0026] In addition, in the power supply structure 8-1, the power supply member B1 is embedded with sealing resin 4 filled in the space surrounded by one transparent conductive film 2A, the other transparent conductive film 2B, and the surface of the dimming layer 3 that is not in contact with the transparent conductive films 2A and 2B, and the surface of the dimming layer 3 that is not in contact with the transparent conductive films 2A and 2B is sealed.

[0027] The dimming unit 100-1 of the present invention will now be described in more detail. As shown in Figure 1, a power supply structure 8-1 is sandwiched at the end of one side of the light controlling sheet A between a transparent film 1A having a transparent conductive film 2A and a transparent film 1B having a transparent conductive film 2B facing each other, and at least one end of the power supply structure 8-1 protrudes from the liquid crystal light controlling sheet A as a wiring region C1. The wiring region C1 functions as a lead wire that supplies a driving voltage to drive the light controlling sheet A.

[0028] FIG. 2 shows the cross-sectional structure of the power supply structure 8-1 taken along the aa' cutting line in FIG. 1. The power supply structure 8-1 is a structure in which a power supply member B1 is connected to transparent conductive films 2A and 2B. The power supply member B1 has an insulating layer 5 as a base material, on the front and back of which a first conductive layer 6A and a second conductive layer 6B are formed, and on top of these, a first insulating layer 5A and a second insulating layer 5B are formed, respectively. The first insulating layer 5A and the second insulating layer 5B are connected to the transparent conductive film 2A, the first conductive layer 6A, and the transparent conductive film 2B. An opening is provided for connecting the conductive film 2B and the second conductive layer 6B.

[0029] 1 and 2 show the case where openings are formed in the first insulating layer 5A and the second insulating layer 5B to bond the opposing transparent conductive films 2A and 2B in a back-to-back position facing each other. Conductive adhesives 7A and 7B are formed in these openings, electrically connecting the transparent conductive film 2A to the first conductive layer 6A and the transparent conductive film 2B to the second conductive layer 6B via these adhesives. The first conductive layer 6A and the second conductive layer 6B are formed continuously as far as the wiring region C1, where they are connected by soldering or a socket to wiring to the power supply, which supplies the driving voltage.

[0030] 1, a plurality of openings and connecting portions each having a conductive adhesive are provided in an island shape, but it is sufficient that the connecting portion is provided in at least one location on each of the front and back of the power supply member B1. The length of the connecting portion (the length in the longitudinal direction of the power supply member B1) is not limited, but it is preferable that it is close to the length of one side of the light-controlling sheet A on which the power supply structure 8-1 is provided, and that it is 80% or more in order to prevent current concentration and ensure efficient power supply.

[0031] Fig. 3 shows a cross-sectional structure of the power supply structure 8-1 taken along the line cc' in Fig. 1. In the wiring region C1, the portion where the power supply member B1 protrudes is configured such that the opening in the second insulating layer 5B and the conductive adhesives 7A and 7B are not provided.

[0032] An insulating encapsulating resin 4 is provided around the power supply structure 8-1, filling the area up to the edge of the light-controlling sheet A, including the protruding portion of the power supply member B1 in the wiring region C1, sandwiching it between the transparent conductive films 2A and 2B. The light-controlling layer 3 around the power supply member B1 has been removed, and the space between the power supply member B1 and the light-controlling layer 3 is similarly filled with encapsulating resin 4. As mentioned above, at least one opening on each side is required for connecting the first conductive layer 6A and the second conductive layer 6B to the transparent conductive films 2A and 2B. However, if there are only one or a few electrodes on each side, it becomes necessary to individually design the power supply member B1 to fit the size of the light-controlling sheet A. Figure 1 avoids this problem by providing multiple island-shaped openings in the first insulating layer 5A and the second insulating layer 5B and conductive adhesives 7A and 7B. The area between the openings has a structure similar to the cross section at the cc' cutting line of the wiring area C1 described above (see Figure 1), and can be cut between any openings, so a power supply structure can be supplied that can flexibly accommodate various sizes of dimming panels using one or a small number of power supply components.

[0033] The material used for the power supply member B1 used here is not particularly limited and may be a general FPC (Flexible Printed Circuit) material.

[0034] Materials such as PET (polyethylene terephthalate), polyimide, PES (polyethersulfone), and liquid crystal polymers can be used for the insulating layer 5. Polyimide, which has solder heat resistance, is common and can be used preferably. The thickness is preferably 5 to 50 μm, and more preferably 7 to 12 μm.

[0035] The first conductive layer 6A and the second conductive layer 6B can be made of copper, silver, gold, nickel, tungsten, titanium, carbon, or laminates or composite materials thereof, but copper is preferred, and the thickness is preferably 2 to 40 μm, and more preferably 5 to 12 μm.

[0036] The first insulating layer 5A and the second insulating layer 5B can be made of a material generally known as a film-type solder resist, such as an epoxy-based, acrylic-based, or polyimide-based material, and the thickness is preferably 5 to 12 μm.

[0037] The conductive adhesives 7A and 7B can be general anisotropic conductive films, anisotropic conductive pastes, isotropic conductive films, isotropic conductive pastes, etc., but they do not necessarily have to be anisotropic. They can be heat-cured or UV-cured, but considering thermal history and stress, UV-cured silver pastes are preferable.

[0038] The sealing resin 4 need not be limited to any material as long as it prevents moisture and contaminants from entering the dimming layer 3 of the dimming unit from the external environment, but it can be a thermosetting epoxy resin, a UV radical curing sealing material, etc. A UV curing material is suitable for simultaneous formation and curing with the conductive adhesive, but it can also be used in combination with heat.

[0039] The width of the power supply member B1 can be determined as needed and is not particularly limited, but since a narrow width is often required for use in windows or partitions, it is preferably 10 mm or less, and more preferably 5 to 3 mm. Preferably, the width including the sealing region is 5 mm or less.

[0040] The width of the openings in the first insulating layer 5A and the second insulating layer 5B may also be determined as needed and is not particularly limited, but is preferably 5 to 100 mm, more preferably 25 to 50 mm.

[0041] The spacing between the openings may be parallel to one side of the light controlling sheet A, and may be equally spaced, and may be of the same shape and size, or may not be so. This may be determined depending on the positioning accuracy of the power supply member, cutting accuracy, and the need for a sealing area. For example, but not limited to, a spacing of 5 to 10 mm is suitable.

[0042] (Second embodiment) 4 to 6 show a second embodiment of the light control unit of the present invention. A dimming unit 100-2 according to the second embodiment differs from the dimming unit 100-1 according to the first embodiment in the positions of the openings formed in the first insulating layer 5A and the second insulating layer 5B of the dimming member B2. In the second embodiment, the openings formed in the first insulating layer 5A and the second insulating layer 5B are positioned so as not to overlap in a plan view.

[0043] 4 illustrates a top view of a light-adjusting unit 100-2 according to the present invention. The light-adjusting unit 100-2 according to the present invention includes a power supply structure 8-2 at the end of one side of the light-adjusting sheet A, parallel to that side. The unit also includes a wiring area C2, where a power supply member B2 protrudes from the end of at least one of the two sides adjacent to the first side. This wiring area C2 allows the power supply member B2 to be connected to a power source that generates a drive voltage, enabling the drive voltage to be supplied to the light-adjusting sheet A. FIG. 5 is a cross-sectional view taken along the line b1-b1' in FIG. FIG. 6 is a cross-sectional view taken along the line b2-b2' in FIG.

[0044] In the first embodiment, the power supply member B1 of the power supply structure 8-1 of the dimming unit 100-1 has the opening of the first conductive layer 6A connected to the transparent conductive film 2A and the opening of the second conductive layer 6B connected to the transparent conductive film 2B positioned back to back. However, in the power supply member B2 of the power supply structure 8-2 of the dimming unit 100-2 of the second embodiment, the opening of the first conductive layer 6A and the opening of the second conductive layer 6B are shifted so that they do not overlap in a planar view.

[0045] The arrangement of the openings in the first embodiment is advantageous for increasing the connection area between the transparent conductive films 2A, 2B and the conductive layers 6A, 6B. However, depending on the design of the light-controlling unit, such as the size of the light-controlling sheet, if the openings are arranged back to back and a power supply part filled with a conductive adhesive is present in the opening, current concentration may occur around the power supply part, which may affect the uniformity of the supplied voltage. By arranging them in a position where they are not too close together, the current distribution can be made uniform and the voltage uniformity problem can be solved.

[0046] The materials and dimensions in the second embodiment are the same as those in the first embodiment.

[0047] <Manufacturing method of dimming unit> A method for manufacturing the dimming unit 100-1 will be described with reference to FIGS. 1 to 3 and 7 to 13. FIG. The method for manufacturing the light control unit of the present invention includes the steps of: fixing the light control sheet A of the light control unit 100-1 of the present invention by sandwiching it between a pair of rolls at a position a predetermined distance inward from the end of one side; inserting a film peeling tool F with a razor-shaped tip into the light control layer 3 of the light control sheet A from the end of the one side of the light control sheet A, thereby peeling the light control sheet A fixed by the pair of rolls (holding and laminating rolls D) from the end of the one side to a position a predetermined distance inward from the end of the one side, thereby opening the pair of transparent conductive films (a film in which a transparent conductive film 2 is formed on a transparent film 1); removing the light control layer 3 on the transparent conductive film 2 of the opened pair of transparent conductive films; and removing the opened portion of the pair of transparent conductive films. the step of filling the innermost region of the light-control sheet A with sealing resin 4; the step of inserting the power supply member B into the sealing resin 4 filled in the innermost region of the open portion of the pair of transparent films 1 (or transparent conductive films) of the light-control sheet A while applying tension in the longitudinal direction of the power supply member B; the step of laminating the inserted power supply member B so that it is sandwiched between the pair of transparent films 1, and temporarily pressing the conductive adhesive 7 and the sealing resin 4 together, while also filling the sealing resin 4 at the outer end of the light-control sheet A of the power supply member B; the step of sandwiching the power supply member B and the sealing resin 4 and laminating them with a pair of rolls D so that the transparent film 1 is flattened, irradiating with ultraviolet light to harden the conductive adhesive 7 and the sealing resin 4, and then cutting off the unnecessary portion of the light-control sheet A.

[0048] Next, a more detailed explanation will be given with reference to FIGS.

[0049] FIG. 7 shows a state in which the required amount of light controlling sheet A has been unwound by a pressing and laminating roll D.

[0050] As shown in Fig. 8, the light-controlling layer 3 sandwiched between a pair of transparent conductive films 2 is peeled off with a film peeling tool F in a uniform width across the entire side of the light-controlling sheet A, up to the part held down by the pressing and laminating roll D. At this time, the transparent film 1 may be adsorbed to the pressing and laminating roll D by a method such as adhesion or suction.

[0051] In Figure 9, the photochromic layer 3 is removed using a photochromic layer wiping tool G. Generally, thorough wiping with an organic solvent such as acetone, ethanol, or isopropyl alcohol is suitable, but cleaning the transparent conductive film 2 is important to ensure good electrical connection with the conductive adhesive. Therefore, UV cleaning or plasma cleaning may be performed as necessary.

[0052] In FIG. 10, a sealing resin 4 is filled into the back region of the opening between the pair of transparent films 1 (or the pair of transparent conductive films) having the transparent conductive film 2 using a sealing resin dispenser tool H or the like. Filling with the sealing resin 4 makes it possible to insert the power supply member B into the sealing resin 4 in the next step. Thereafter, an amount of sealing resin 4 is filled that is sufficient to bury at least a portion of the power supply member B when the pair of transparent films 1 are bonded together.

[0053] 11, the power supply member B wound around the take-up reel is pulled out from the take-up reel, and with tension applied to both ends, the pair of transparent films 1 of the light controlling sheet A is inserted into the sealing resin 4 filled in the area at the back of the open part. At this time, the conductive adhesive 7 may be formed in advance, or may be formed in advance from the reel onto the power supply member B by a dispenser, inkjet, printing, or other method.

[0054] In Figure 12, the inserted power supply member B is laminated in a manner that it is sandwiched between a pair of transparent films 1, and the conductive adhesive 7 and sealing resin 4 are temporarily pressed together, and sealing resin 4 is also applied to the opposite end of the power supply member B (the outer end of the light-controlling sheet A).

[0055] In Figure 13, the power supply member B and the sealing resin 4 are sandwiched together, and the transparent film 1 is pressed down and laminated with a laminating roll D to flatten it. Finally, the conductive adhesive 7 and the sealing resin 4 are cured with an ultraviolet lamp I, and then the unnecessary ends of the light-controlling sheet A are cut off using a cutting means such as a cutter J, leaving only the necessary remaining portion, thereby obtaining a light-controlling unit with a power-supply structure of minimum width. [Explanation of symbols]

[0056] 1A, 1B: Transparent film 2A, 2B...Transparent conductive film 3. Photochromic layer 4...Sealing resin 5, 5A, 5B...insulating layer 6A, 6B...conductive layer 7A, 7B: Conductive adhesive 8-1, 8-2 Power supply structure 100-1, 100-2, 100´··· dimming unit 110···Light-adjusting sheet 120···Photochromic layer 130A, 130B... Electrode sheet 140A, 140B...Transparent electrode layer 150A, 150B...Transparent support layer 160A, 160B... Connection 161 Conductive adhesive 162 Conductive tape 163 Solder 164... Lead wire 200...Transparent plate 210...adhesive layer A. Light-adjusting sheet B, B1, B2... Power supply members C1, C2...Wiring area D···Retainer and laminating roll F···Film removal tool G···Photochromic layer wiping tool H···Encapsulating resin dispensing tool I. Ultraviolet lamp J···Cutter

Claims

1. A method for manufacturing a light-controlling unit, comprising: a pair of transparent conductive films each having a transparent conductive film formed on a surface of a transparent film, the transparent conductive film sides of the pair of transparent conductive films being arranged inward, and a light-controlling layer whose light transmittance changes depending on an applied voltage being sandwiched between the pair of transparent conductive films; and a power supply structure for supplying a driving voltage to the end of one side of the light-controlling sheet; the power supply structure is formed by sandwiching and bonding, at an end of the one side, a long power supply member having a length of 80% or more of the length of the one side to each transparent conductive film of a pair of transparent conductive films peeled off in parallel along the end, between the pair of transparent conductive films via a conductive adhesive, the power supply member is a double-sided conductive tape having a long insulating layer, the double-sided conductive tape including a first conductive layer on one side and a second conductive layer on the other side; the first conductive layer and the second conductive layer are covered with a first insulating layer and a second insulating layer, respectively; the first conductive layer and one of the transparent conductive films are bonded to each other via a conductive adhesive provided in an opening formed in the first insulating layer; the second conductive layer and the other transparent conductive film are bonded to each other via a conductive adhesive provided in an opening formed in the second insulating layer at a position overlapping the opening in a plan view, In the power supply structure, a sealing resin is filled in a space surrounded by one of the transparent conductive films, the other transparent conductive film, and a surface of the light-controlling layer that is not in contact with the transparent conductive film, and the power supply member is embedded with the sealing resin, and the surface of the light-controlling layer that is not in contact with the transparent conductive film is sealed; The method for manufacturing the dimming unit includes: a step of fixing the light controlling sheet by sandwiching the light controlling sheet between a pair of rolls at a position a predetermined distance inside from the end of the one side; A process of opening the pair of transparent conductive films by inserting a film peeling tool with a razor-shaped tip into the light-control layer of the light-control sheet from the end of one side of the light-control sheet, and peeling the film from the end of one side of the light-control sheet fixed by a pair of rolls to a position a predetermined distance inward; removing the light-controlling layer on the transparent conductive film of the opened pair of transparent conductive films; a step of filling a sealing resin into a region behind the opened portion of the pair of transparent conductive films; A step of inserting the power supply member into sealing resin filled in a deep area of ​​a portion where the pair of transparent films of the light controlling sheet are opened while applying tension in the longitudinal direction of the power supply member; a step of laminating the inserted power supply member between a pair of the transparent films in a sandwiched form, and temporarily pressing the conductive adhesive and the sealing resin together, while further filling the sealing resin at the outer end of the light controlling sheet of the power supply member; a step of sandwiching the power supply member and the sealing resin, laminating them with a pair of rolls so that the transparent film is flat, curing the conductive adhesive and the sealing resin by irradiating them with ultraviolet light, and then cutting off unnecessary portions of the light-controlling sheet.

2. A method for manufacturing a light-controlling unit, comprising: a pair of transparent conductive films each having a transparent conductive film formed on a surface of a transparent film, the transparent conductive film sides of the pair of transparent conductive films being arranged inward, and a light-controlling layer whose light transmittance changes depending on an applied voltage being sandwiched between the pair of transparent conductive films; and a power supply structure for supplying a driving voltage to the end of one side of the light-controlling sheet; the power supply structure is formed by bonding, via a conductive adhesive, an elongated power supply member having a length of 80% or more of the length of the one side to each transparent conductive film of a pair of transparent conductive films that have been peeled off in parallel along the one side, at an end of the one side; the power supply member is a double-sided conductive tape having a long insulating layer, the double-sided conductive tape including a first conductive layer on one side and a second conductive layer on the other side; the first conductive layer and the second conductive layer are covered with a first insulating layer and a second insulating layer, respectively; the first conductive layer and one of the transparent conductive films are bonded to each other via a conductive adhesive provided in an opening formed in the first insulating layer; the second conductive layer and the other transparent conductive film are bonded to each other via a conductive adhesive provided in an opening formed in the second insulating layer at a position that does not overlap with the opening in a plan view, In the power supply structure, a sealing resin is filled in a space surrounded by one of the transparent conductive films, the other transparent conductive film, and a surface of the light-controlling layer that is not in contact with the transparent conductive film, and the power supply member is embedded with the sealing resin, and the surface of the light-controlling layer that is not in contact with the transparent conductive film is sealed; The method for manufacturing the dimming unit includes: a step of fixing the light controlling sheet by sandwiching the light controlling sheet between a pair of rolls at a position a predetermined distance inside from the end of the one side; A process of opening the pair of transparent conductive films by inserting a film peeling tool with a razor-shaped tip into the light-control layer of the light-control sheet from the end of one side of the light-control sheet, and peeling the film from the end of one side of the light-control sheet fixed by a pair of rolls to a position a predetermined distance inward; removing the light-controlling layer on the transparent conductive film of the opened pair of transparent conductive films; a step of filling a sealing resin into a region behind the opened portion of the pair of transparent conductive films; A step of inserting the power supply member into sealing resin filled in a deep area of ​​a portion where the pair of transparent films of the light controlling sheet are opened while applying tension in the longitudinal direction of the power supply member; a step of laminating the inserted power supply member between a pair of the transparent films in a sandwiched form, and temporarily pressing the conductive adhesive and the sealing resin together, while further filling the sealing resin at the outer end of the light controlling sheet of the power supply member; a step of sandwiching the power supply member and the sealing resin, laminating them with a pair of rolls so that the transparent film is flat, curing the conductive adhesive and the sealing resin by irradiating them with ultraviolet light, and then cutting off unnecessary portions of the light-controlling sheet.

3. 3. The method for manufacturing a dimming unit according to claim 1, wherein in the power supply structure, at least one end of the power supply member has a wiring area that protrudes from the end of the side adjacent to the one side and can be connected to a power source that supplies the driving voltage.

4. 4. The method for manufacturing a dimming unit according to claim 1, wherein the openings formed in the first insulating layer are openings of the same shape and size that are arranged parallel to and at equal intervals along the one side.

5. 5. The method for manufacturing a light control unit according to claim 1, wherein the double-sided conductive tape is made of a double-sided flexible wiring board.

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