Dimming device and method for manufacturing dimming device

Abstract

A dimming device (10) comprises a first glass plate (11), a second glass plate (12), a dimming cell (20), an external electrode substrate (35), a first intermediate film (13), and a second intermediate film (14). The dimming cell (20) has: a first laminate (21) including a first base material (24) and a first transparent electrode (25); a second laminate (22) including a second base material (27) and a second transparent electrode (28); a liquid crystal layer (23) disposed between the first laminate (21) and the second laminate (22); and a seal material (32) disposed so as to surround the liquid crystal layer (23). The external electrode substrate (35) is sandwiched between the first laminate (21) and the second laminate (22). A first intermediate film (13) enters between the first laminate (21) and the second laminate (22). Between the first laminate (21) and the second laminate (22), the external electrode substrate (35) is in contact with the first intermediate film (13).

Description

Light control device and method for manufacturing the same

[0001] The present disclosure relates to a light control device and a method for manufacturing a light control device.

[0002] Conventionally, light-controlling elements that can be used in combination with light-transmitting elements such as windows to control the transmission of external light, such as in electronic blinds, or light-controlling devices using such light-controlling elements have been proposed (see, for example, Patent Documents 1 and 2). One such light-controlling element is a liquid crystal film with a liquid crystal layer. This liquid crystal film is produced by sandwiching a liquid crystal material between transparent resin substrates provided with transparent electrodes, which are then further sandwiched between linear polarizers. The liquid crystal film is configured so that the orientation of the liquid crystal can be changed by changing the electric field applied between the transparent electrodes, thereby controlling the amount of external light transmitted.

[0003] Japanese Patent No. 6135816 Japanese Patent Application Laid-Open No. 2017-187810

[0004] In a light control device including such a liquid crystal film, laminates each having a transparent electrode may come into contact with each other around the transparent electrode outside the area where the liquid crystal material is provided. When laminates each having a transparent electrode come into contact with each other in this way, the transparent electrode may become exposed from the laminate due to an impact or the like. Furthermore, when the transparent electrode is exposed from the laminate, there is a risk that the transparent electrodes may come into contact with each other. Furthermore, when the transparent electrodes come into contact with each other, there is a risk that the transparent electrodes may short-circuit.

[0005] The present embodiment provides a light control device and a method for manufacturing the light control device that can suppress short circuits between electrodes.

[0006] The embodiments of the present disclosure relate to the following [1] to [4].

[0007] [1] A light-controlling cell comprising: a first transparent substrate; a second transparent substrate; a light-controlling cell disposed between the first transparent substrate and the second transparent substrate; an external electrode substrate electrically connected to the light-controlling cell; a first intermediate film disposed between the first transparent substrate and the light-controlling cell; and a second intermediate film disposed between the light-controlling cell and the second transparent substrate, wherein the light-controlling cell comprises: a first laminate including a first transparent electrode electrically connected to the external electrode substrate and a first base material; a second laminate including a second transparent electrode electrically connected to the external electrode substrate and a second base material; a liquid crystal layer disposed between the first laminate and the second laminate; and a sealant disposed between the first laminate and the second laminate so as to surround the liquid crystal layer, wherein the external electrode substrate is sandwiched between the first laminate and the second laminate, and the first intermediate film is interposed between the first laminate and the second laminate, The external electrode substrate is in contact with the first intermediate film between the first laminate and the second laminate.

[0008] [2] The light control device described in [1], wherein the first laminate includes a first protruding piece that protrudes outward in the surface direction in the region where the external electrode substrate is provided, the second laminate includes a second protruding piece that protrudes outward in the surface direction in the region where the external electrode substrate is provided, the external electrode substrate is sandwiched between the first protruding piece and the second protruding piece, the first intermediate film is inserted between the first protruding piece and the second protruding piece, and the external electrode substrate is in contact with the first intermediate film between the first protruding piece and the second protruding piece.

[0009] [3] The light control device according to [1] or [2], wherein the first intermediate film and the second intermediate film sandwich the first protruding piece and the second protruding piece.

[0010] [4] A method for manufacturing a light control device, comprising: a step of preparing a first transparent substrate and a second transparent substrate; a step of preparing a light control cell electrically connected to an external electrode substrate; and a step of integrally bonding the first transparent substrate, the light control cell, and the second transparent substrate using a first intermediate film and a second intermediate film, wherein the light control device has the first intermediate film disposed between the first transparent substrate and the light control cell, and the second intermediate film disposed between the second transparent substrate and the light control cell, and the light control cell has: a first stacked body including a first transparent electrode electrically connected to the external electrode substrate and a first base material; a second stacked body including a second transparent electrode electrically connected to the external electrode substrate and a second base material; a liquid crystal layer disposed between the first stacked body and the second stacked body; and a sealant disposed between the first stacked body and the second stacked body so as to surround the liquid crystal layer, and the external electrode substrate is sandwiched between the first stacked body and the second stacked body, the first intermediate film is interposed between the first stack and the second stack, and the external electrode substrate is in contact with the first intermediate film between the first stack and the second stack.

[0011] According to the embodiments of the present disclosure, short circuits between electrodes can be suppressed.

[0012] FIG. 1 is a perspective view showing a light control device according to an embodiment. FIG. 2A is an exploded perspective view showing a light control device according to an embodiment. FIG. 2B is a plan view showing a light control device according to an embodiment. FIG. 3 is a cross-sectional view (cross-sectional view along line III-III in FIG. 2A ) showing a light control device according to an embodiment. FIG. 4 is an enlarged cross-sectional view (cross-sectional view along line VV in FIG. 2B ) showing a light control device according to an embodiment. FIG. 6A is a cross-sectional view showing a method for manufacturing a light control cell according to an embodiment. FIG. 6B is a cross-sectional view showing a method for manufacturing a light control cell according to an embodiment. FIG. 6C is a cross-sectional view showing a method for manufacturing a light control cell according to an embodiment. FIG. 6D is a cross-sectional view showing a method for manufacturing a light control cell according to an embodiment. FIG. 7A is a cross-sectional view showing a method for manufacturing a light control cell according to an embodiment. FIG. 7B is a cross-sectional view showing a method for manufacturing a light control cell according to an embodiment. FIG. 7C is a cross-sectional view showing a method for manufacturing a light control cell according to an embodiment. FIG. 7D is a cross-sectional view showing a method for manufacturing a light control cell according to an embodiment. FIG. 8A is a cross-sectional view showing a method for manufacturing a light control device according to an embodiment. FIG. 8B is a cross-sectional view showing a manufacturing method of a light control device according to an embodiment. FIG. 8C is a cross-sectional view showing a manufacturing method of a light control device according to an embodiment. FIG. 9A is a cross-sectional view showing a manufacturing method of a light control device according to an embodiment. FIG. 9B is a cross-sectional view showing a manufacturing method of a light control device according to an embodiment. FIG. 9C is a cross-sectional view showing a manufacturing method of a light control device according to an embodiment. FIG. 10A is a cross-sectional view showing a manufacturing method of a light control device according to an embodiment. FIG. 10B is a cross-sectional view showing a manufacturing method of a light control device according to an embodiment. FIG. 10C is a cross-sectional view showing a manufacturing method of a light control device according to an embodiment. FIG. 10D is a cross-sectional view showing a manufacturing method of a light control device according to an embodiment. FIG. 11 is a plan view showing a modified example of a light control device according to an embodiment. FIG. 12 is a cross-sectional view (cross-sectional view along line XII-XII in FIG. 11 ) showing a modified example of a light control device according to an embodiment. FIG. 13 is a cross-sectional view (cross-sectional view along line XIII-XIII in FIG. 11 ) showing a modified example of a light control device according to an embodiment.

[0013] An embodiment will be described below with reference to FIGS. 1 to 10D.

[0014] 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. For example, the light control device 10 may control the amount of light incident on the inside of a building, a vehicle, etc. In this case, the light control device 10 may be disposed in a portion where light is to be controlled (a portion where external light enters, such as a window, a showcase, an indoor transparent partition, or a vehicle window) of a building, for example.

[0015] It should be noted that the dimming device 10 described below merely illustrates one embodiment. Therefore, for example, some of the elements listed below as components of the dimming device 10 may be replaced with other elements or may not be included. Furthermore, elements not listed below may be included as components of the dimming device 10. Furthermore, for the convenience of illustration and ease of understanding, the scale and dimensional ratios of some parts in the drawings have been appropriately changed or exaggerated from those of the actual objects.

[0016] (Light Control Device) FIG. 1 is a diagram showing a light control device (laminated glass) 10 according to the present embodiment. FIG. 2A is an exploded perspective view showing the layer structure of the light control device 10 according to the present embodiment, and FIG. 2B is a plan view showing the layer structure of the light control device 10 according to the present embodiment. FIG. 3 is a cross-sectional view showing the layer structure of the light control device 10 according to the present embodiment. The light control device 10 according to the present embodiment has a three-dimensional shape with a curved surface. In FIG. 1, as an example, the light control device 10 has a shape with one side being convex. Note that although the light control device 10 according to the present embodiment has a three-dimensional surface shape, FIGS. 2A to 3 show a case in which the surface shape of the light control device 10 is flat for ease of understanding. In addition, in FIG. 2B, components that are actually hidden are shown with solid lines so that the positional relationship of each component in a planar view is clear. In addition, the shaded area in FIG. 2B is the area outside the sealing material 32 described below, where the first interlayer film 13 and the second interlayer film 14 are provided.

[0017] The light control device 10 is not limited thereto. For example, the surface shape may be planar (i.e., plate-like), or the surface shape may be a two-dimensional shape having a curved shape (e.g., 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 constructed by simply deforming a plane without expansion or contraction. In other words, the three-dimensional shape is a shape that is distinguished from a two-dimensional shape (two-dimensional curved surface) that is curved two-dimensionally around a single axis or a two-dimensional shape (two-dimensional curved surface) that is curved two-dimensionally with different curvatures around multiple parallel axes. 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 addition, in this specification, a planar view refers to a state when viewed from a direction perpendicular to the main surface of the light control device 10.

[0018] 1 to 2B , a light control device 10 according to this embodiment includes a first glass plate (first transparent substrate) 11, a first interlayer film 13, a dimming cell 20, a second interlayer film 14, and a second glass plate (second transparent substrate) 12. The first glass plate 11, the first interlayer film 13, the dimming cell 20, the second interlayer film 14, and the second glass plate 12 are laminated in this order. Furthermore, as shown in FIG. 2A , the light control device 10 includes an external electrode substrate 35 connected to a dimming controller 91 that controls the dimming state of the light control device 10.

[0019] 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, respectively, and are plate glasses having high light transmittance. The first glass plate 11 and the second glass plate 12 have three-dimensional curved surface shapes, and are pre-formed into a curved 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.

[0020] 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. As an example, each glass plate has a thickness of 2 mm. The first glass plate 11 and the second glass plate 12 may be inorganic glass or resin glass. Examples of resin glass that can be used include polycarbonate and acrylic. 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, as necessary. Note that a transparent resin substrate may be used instead of the first glass plate 11 and the second glass plate 12.

[0021] The first interlayer film 13 is disposed between the first glass plate 11 and the dimming cell 20. The first interlayer film 13 is a member that bonds the first glass plate 11 and the dimming cell 20 together.

[0022] The second interlayer film 14 is disposed between the light control cell 20 and the second glass plate 12. The second interlayer film 14 is a member that bonds the second glass plate 12 and the light control cell 20 together.

[0023] The first intermediate film 13 and the second intermediate film 14 may each be made of an optically clear adhesive film (OCA film) or a transparent adhesive resin (OCR (Optical Clear Resin)). The first intermediate film 13 and the second intermediate film 14 may each contain PVB (polyvinyl butyral). The material for the first intermediate film 13 and the second intermediate film 14 is not limited to the above-mentioned OCA, OCR, and PVB, but may also be EVA (ethylene-vinyl acetate copolymer), COP (cycloolefin polymer), or the like. It is preferable to use a material that does not contain a plasticizer as the material for the first intermediate film 13 and the second intermediate film 14.

[0024] In this embodiment, the first intermediate film 13 and the second intermediate film 14 sandwich a first electrode protrusion 36a of the first stack 21 described later and a second electrode protrusion 36b of the second stack 22 described later.

[0025] The thickness of the first interlayer film 13 and the second interlayer film 14 can also be selected appropriately depending on the material and the like. Specifically, the thickness of the first interlayer film 13 and the second interlayer film 14 may be 300 μm or more and 2.5 mm or less, for example, 760 μm. The size of the first interlayer film 13 and the second interlayer film 14 may be the same as the size of the first glass plate 11 and the second glass plate 12, or may be larger than the size of the first glass plate 11 and the second glass plate 12.

[0026] As shown in Figure 2A, the light-controlling cell 20 has a first laminate 21 and a second laminate 22. The light-controlling cell 20 (light-controlling film, liquid crystal film) is a film that can control the amount of transmitted light by changing the applied voltage. The light-controlling cell 20 is disposed so as to be sandwiched between a first glass plate 11 and a second glass plate 12. The light-controlling cell 20 has a guest-host liquid crystal layer 23 (see Figure 3) that uses a dichroic dye, and is a component that changes the amount of transmitted light depending on the electric field applied to the liquid crystal.

[0027] Next, the light-control cell 20 will be described in more detail.

[0028] 2B , in the present embodiment, the planar shape of the dimming cell 20 is smaller than the planar shape of the light control device 10 (first glass plate 11, first interlayer film 13, second interlayer film 14, and second glass plate 12). Note that the planar shape of the dimming cell 20 may be the same as the planar shape of the light control device 10 (first glass plate 11, first interlayer film 13, second interlayer film 14, and second glass plate 12).

[0029] 3 , the dimming cell 20 includes a first laminate 21, a second laminate 22, a liquid crystal layer 23 disposed between the first laminate 21 and the second laminate 22, and a sealant 32 disposed between the first laminate 21 and the second laminate 22 so as to surround the liquid crystal layer 23. In this case, the liquid crystal layer 23 is disposed in an area 32 a surrounded by the sealant 32.

[0030] 3 , the first laminate 21 is a film-like member and includes a first substrate 24 and a first transparent electrode 25. In the present embodiment, the first laminate 21 is formed by laminating the first substrate 24, the first transparent electrode 25, and the first alignment layer 26. That is, from the first interlayer film 13 side, the first substrate 24, the first transparent electrode 25, and the first alignment layer 26 are laminated in this order.

[0031] The second laminate 22 is a film-like member and includes a second substrate 27 and a second transparent electrode 28. In the present embodiment, the second laminate 22 is formed by laminating the second substrate 27, the second transparent electrode 28, and the second alignment layer 29. That is, from the second interlayer film 14 side, the second substrate 27, the second transparent electrode 28, and the second alignment layer 29 are laminated in this order.

[0032] The dimming cell 20 is a component that changes the orientation of the liquid crystal material made of a guest-host liquid crystal composition provided in the liquid crystal layer 23 by the potential difference between 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.

[0033] The first substrate 24 and the second substrate 27 may be made of a transparent resin and may be composed of a flexible film. It is desirable to use a transparent resin film as the first substrate 24 and the second substrate 27, which has small optical anisotropy and a transmittance of 80% or more in the visible wavelength range (380 nm to 800 nm). 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), polyetherketone (PEK), (meth)acrylonitrile, cycloolefin polymer (COP), and cycloolefin copolymer. As the material for the transparent resin film, resins such as polycarbonate, cycloolefin polymer, and polyethylene terephthalate are particularly preferred.

[0034] The thickness of the transparent resin film used as the first substrate 24 and the second substrate 27 may vary depending on the material, but can be appropriately selected within a range in which the transparent resin film is flexible. 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, a polyethylene terephthalate film having a thickness of 100 μm is used as an example of the first substrate 24 and the second substrate 27.

[0035] The first transparent electrode 25 and the second transparent electrode 28 are each electrically connected to the external electrode substrate 35. The first transparent electrode 25 and the second transparent electrode 28 are each composed of a transparent conductive film laminated on the first substrate 24 and the second substrate 27 (transparent resin film), respectively. The transparent conductive film may be made of any of various transparent electrode materials that are applicable to this type of transparent resin film. Examples of transparent conductive films include oxide-based transparent metal thin films with a total light transmittance of 50% or more. Examples of transparent conductive films include tin oxide-based, indium oxide-based, and zinc oxide-based metal thin films.

[0036] Tin oxide (SnO ２ ) system, such as NESA (tin oxide SnO ２ ), ATO (Antimony Tin Oxide), or fluorine-doped tin oxide. ２ O ３ Examples of the zinc oxide (ZnO)-based materials include zinc oxide, aluminum-doped zinc oxide (AZO), and gallium-doped zinc oxide. In the present embodiment, the transparent conductive films constituting the first transparent electrode 25 and the second transparent electrode 28 are formed of ITO.

[0037] The first alignment layer 26 and the second alignment layer 29 are components 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 may be formed by photo-alignment layers. A wide variety of materials that can be used for photo-alignment layers can be used as photo-alignment materials. Examples of photo-alignment materials that can be used for the photo-alignment layer include photo-decomposition, photo-dimerization, and photo-isomerization photo-alignment materials. In this embodiment, a photo-dimerization material may be used. Examples of photo-dimerization materials include polymers containing cinnamate, coumarin, benzylidenephthalimidine, benzylideneacetophenone, diphenylacetylene, stilbazole, uracil, quinolinone, maleimide, or a cinnamylideneacetic acid derivative. Among these, polymers containing one or both of cinnamate and coumarin are preferred due to their excellent alignment control ability.

[0038] Note that a rubbed alignment layer may be used instead of the photo-alignment layer. The rubbed alignment layer may be a layer that is not subjected to a rubbing treatment, or may be a layer that is produced by performing a rubbing treatment and then performing a shaping treatment to form a fine line-shaped uneven shape. Note that, in the present embodiment, the dimming cell 20 includes the first alignment layer 26 and the second alignment layer 29, but this is not limiting, and the dimming cell 20 may also be configured without the first alignment layer 26 and the second alignment layer 29.

[0039] Next, a description will be given of the liquid crystal layer 23. The liquid crystal layer 23 is disposed between the first stack 21 and the second stack 22 in an area 32a surrounded by the seal material 32.

[0040] A wide variety of guest-host liquid crystal compositions and dichroic dye compositions can be used for the liquid crystal layer 23. The guest-host liquid crystal composition may contain a chiral agent, which causes the liquid crystal material to be helically aligned in the thickness direction of the liquid crystal layer 23 when horizontally aligned. As described above, the liquid crystal layer 23 is disposed in a region 32a surrounded by the sealant 32. That is, the sealant 32, which is annular or frame-shaped in plan view, is disposed between the first laminate 21 and the second laminate 22 so as to surround the liquid crystal layer 23. This sealant 32 holds the first laminate 21 and the second laminate 22 together and prevents leakage of the liquid crystal material. The sealant 32 may be a thermosetting resin such as an epoxy resin or an acrylic resin, or a UV-curable resin.

[0041] A plurality of bead spacers 31 are disposed between the first laminate 21 and the second laminate 22. The liquid crystal layer 23 described above is filled and disposed between the plurality of bead spacers 31 in the region 32a surrounded by the sealing material 32 between the first laminate 21 and the second laminate 22. The plurality of bead spacers 31 may be disposed irregularly or regularly.

[0042] The bead spacers 31 are components that define the thickness (cell gap) of the liquid crystal layer 23 excluding its peripheral portion. In this embodiment, spherical bead spacers are used as the bead spacers 31. The diameter of the bead spacers 31 may be in the range of 1 μm to 20 μm, preferably 3 μm to 15 μm. The bead spacers 31 may be made of an inorganic material such as silica, an organic material, or a core-shell structure combining these. In addition to a spherical shape, the bead spacers 31 may also be made of a rod shape such as a cylindrical shape, an elliptical cylinder, or a polygonal prism. Furthermore, the bead spacers 31 may be made of a transparent material, and the color may be adjusted by using a colored material as needed.

[0043] In this embodiment, the bead spacers 31 are provided in the second laminate 22, as will be described later, but this is not limited thereto, and the bead spacers 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. Furthermore, instead of the bead spacers 31, or together with the bead spacers 31, columnar spacers may be used.

[0044] In such a dimming cell 20, the first alignment layer 26 and the second alignment layer 29 may be configured as vertical alignment layers in which an alignment restraining force related to the pretilt is set in a certain direction so that the transmittance is maximized when no voltage is applied to the liquid crystal. In this case, the dimming cell 20 is configured as a normally clear cell. Note that the dimming cell 20 may also be configured as a normally dark cell so that the transmittance is minimized (black screen) when no voltage is applied to the liquid crystal.

[0045] Although the light-controlling cell 20 of the present embodiment has been described as including a guest-host liquid crystal layer 23, the present invention is not limited to this. The light-controlling cell 20 may also be configured to include 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 including such a liquid crystal layer 23, the cell can function as a light-controlling film by further providing linear polarization layers on the surfaces of the first substrate 24 and the second substrate 27, respectively.

[0046] 2A and 3 , the light control device 10 is connected to a light control controller 91. 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, switches between blocking and transmitting light by the light control device 10, and changes the light transmittance of 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 is configured to change the orientation of liquid crystal molecules in the liquid crystal layer 23 by adjusting the electric field applied to the liquid crystal layer 23 using the light control controller 91. This makes it possible to switch between blocking and transmitting light by the light control device 10 and change the light transmittance.

[0047] The dimming controller 91 is configured to adjust the electric field applied to the liquid crystal layer 23 based on any method. The dimming controller 91 may adjust the electric field applied to the liquid crystal layer 23, for example, in response to the measurement results of the sensor device 92 or in response to instructions (commands) input by a user via the user operation unit 93. Therefore, the dimming controller 91 may automatically adjust the electric field applied to the liquid crystal layer 23 in response to the measurement results of the sensor device 92, or may manually adjust the electric field in response to instructions from a user via the user operation unit 93. The object measured by the sensor device 92 is not particularly limited, and may, for example, measure the brightness of the usage environment. In this case, the dimming device 10 switches between blocking and transmitting light or changes the light transmittance in response to the brightness of the usage environment. Furthermore, both the sensor device 92 and the user operation unit 93 do not necessarily need to be connected to the dimming controller 91; only one of the sensor device 92 and the user operation unit 93 may be connected.

[0048] As described above, the dimming controller 91 is connected to the external electrode substrate 35 of the dimming device 10. This external electrode substrate 35 is electrically connected to the dimming cell 20.

[0049] 2A to 5 , the external electrode substrate 35 is sandwiched between the first laminate 21 and the second laminate 22. The first laminate 21 includes first electrode protrusions (first protrusions) 36a that protrude outward in the planar direction in the region where the external electrode substrate 35 is provided. Similarly, the second laminate 22 includes second electrode protrusions (second protrusions) 36b that protrude outward in the planar direction in the region where the external electrode substrate 35 is provided. The external electrode substrate 35 is sandwiched between the first electrode protrusions 36a and the second electrode protrusions 36b. The planar shapes of the first electrode protrusions 36a and the second electrode protrusions 36b may be larger than the planar shapes of the portions of the external electrode substrate 35 that are sandwiched between the first electrode protrusions 36a and the second electrode protrusions 36b.

[0050] 4 and 5 are schematic cross-sectional views showing the periphery of the external electrode substrate 35 of the dimming cell 20. Of these, FIG. 4 is a schematic cross-sectional view showing an enlarged view of the periphery of the external electrode substrate 35 shown in FIG. 3. As shown in FIG. 4, the external electrode substrate 35 is disposed between the first stack 21 and the second stack 22, outside (outside in the planar direction) of the region 32a surrounded by the sealant 32, and is electrically connected to the first transparent electrode 25 and the second transparent electrode 28. The outer end of the external electrode substrate 35 is electrically connected to the dimming controller 91 (see FIGS. 2A and 3 ), and the inner end is electrically connected to the first transparent electrode 25 and the second transparent electrode 28 via a conductive film 37. The external electrode substrate 35 may be formed, for example, of a flexible printed circuit (FPC). The conductive film 37 may be formed, for example, of an anisotropic conductive film (ACF). In this case, the thickness of the external electrode substrate 35 is greater than the thickness of the liquid crystal layer 23. Therefore, the gap between the first laminate 21 and the second laminate 22 is wider in the portion where the external electrode substrate 35 is disposed than in the portion where the liquid crystal layer 23 is disposed.

[0051] Fig. 5 is a schematic cross-sectional view showing the periphery of the external electrode substrate 35 in the light control device 10, and corresponds to the cross-sectional view taken along line VV in Fig. 2B. As shown in Fig. 5, the external electrode substrate 35 is in contact with the first intermediate film 13 between the first laminate 21 and the second laminate 22. In this case, the external electrode substrate 35 is in contact with the first intermediate film 13 between the first electrode protruding piece 36a and the second electrode protruding piece 36b. Note that the conductive film 37 is omitted from Fig. 5 for clarity.

[0052] In the present embodiment, the first intermediate film 13 is inserted between the first stack 21 and the second stack 22 around the first transparent electrode 25 and the second transparent electrode 28 outside the region 32a surrounded by the sealant 32. In this case, the first intermediate film 13 is inserted between the first electrode protruding piece 36a and the second electrode protruding piece 36b. This prevents the first stack 21 and the second stack 22 from coming into contact around the first transparent electrode 25 and the second transparent electrode 28, even when an impact or the like is applied to the light control device 10. When the first stack 21 and the second stack 22 come into contact, the first alignment layer 26 and the second alignment layer 29 are pushed apart. This may cause the first transparent electrode 25 and the second transparent electrode 28 to be partially exposed from the first alignment layer 26 and the second alignment layer 29. In this case, the first transparent electrode 25 and the second transparent electrode 28 may come into contact with each other. When the first transparent electrode 25 and the second transparent electrode 28 come into contact with each other in this way, the first transparent electrode 25 and the second transparent electrode 28 are short-circuited.

[0053] In contrast to this, in the present embodiment, contact between the first laminate 21 and the second laminate 22 can be prevented, and therefore exposure of the first transparent electrode 25 from the first laminate 21 can be prevented. Similarly, exposure of the second transparent electrode 28 from the second laminate 22 can be prevented. Therefore, short circuits between the first transparent electrode 25 and the second transparent electrode 28 can be prevented. Note that, in Fig. 5, the conductive film 37 is not shown for clarity.

[0054] Furthermore, in the present embodiment, the first intermediate film 13 that is interposed between the first stack 21 and the second stack 22 is in contact with the external electrode substrate 35. This makes it possible to more effectively prevent the first stack 21 and the second stack 22 from coming into contact with each other even when an impact or the like is applied to the light control device 10.

[0055] (Method of Manufacturing Light-Controlling Cell) Next, a method of manufacturing the light-controlling cell 20 of the light-controlling device 10 according to this embodiment will be described with reference to Figures 6A to 7D. Figures 6A to 7D are cross-sectional views showing the method of manufacturing the light-controlling cell 20 according to this embodiment.

[0056] First, as shown in Fig. 6A, a second substrate 27 is prepared. The second substrate 27 may be supplied in a roll form. Then, as shown in Fig. 6B, 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.

[0057] 6C , a coating liquid for the second alignment layer 29 is applied to the second substrate 27 on which the second transparent electrode 28 has been formed, and then the coating liquid is exposed to light to form the second alignment layer 29. In this manner, a second laminate 22 is prepared in which the second substrate 27, the second transparent electrode 28, and the second alignment layer 29 are laminated.

[0058] 6A to 6C, 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.

[0059] Next, as shown in FIG. 6D , bead spacers 31 are disposed on the second alignment layer 29 of the second laminate 22. The bead spacers 31 can be disposed by a wide variety of methods, including wet / dry spraying. For example, a coating liquid prepared by dispersing the bead spacers 31 in a solvent together with a resin component may be partially applied, followed by drying and baking processes, to randomly dispose the bead spacers 31 on the second alignment layer 29 and hold them in place to prevent movement. Although not shown, the bead spacers 31 may be disposed on the second transparent electrode 28, with the outer periphery of the bead spacers 31 covered by the second alignment layer 29. Specifically, by mixing the bead spacers 31 into the coating liquid for the second alignment layer 29 to form the second alignment layer 29, the bead spacers 31 can be thinly covered and held by the second alignment layer 29.

[0060] 7A , 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. The sealant 32 may also be applied by screen printing or the like.

[0061] 7B and 7C, the second laminate 22 and the first laminate 21 are laminated together, and the liquid crystal layer 23 is disposed thereon. During this process, as shown in Fig. 7B, liquid crystal that constitutes the liquid crystal layer 23 is first dropped into the region 32a surrounded by the sealant 32. At this time, the liquid crystal layer 23 is filled inside the sealant 32 and around the bead spacers 31.

[0062] 7C , the second laminate 22 with the liquid crystal layer 23 disposed thereon and the previously prepared first laminate 21 are laminated and pressed together. The sealant 32 is then semi-cured by irradiating it with ultraviolet light, and then heated to integrate the first laminate 21 and the second laminate 22. The integration of the first laminate 21 and the second laminate 22 may be achieved by either irradiating it with ultraviolet light alone or by heating alone. The laminate of the first laminate 21 and the second laminate 22 thus fabricated is then trimmed to a desired size. The trimming is performed so that a space for mounting the external electrode substrate 35 remains between the first laminate 21 and the second laminate 22.

[0063] As described above, it is preferable to arrange the liquid crystal layer 23 and then stack the second stack 22 and the first stack 21 on top of each other, but this is not limited to this, and the liquid crystal layer 23 may be arranged after the second stack 22 and the first stack 21 are stacked on top of each other.

[0064] In this way, the light-controlling cell 20 is obtained.

[0065] 7D , an external electrode substrate 35 is attached between the first laminate 21 and the second laminate 22. The external electrode substrate 35 may be electrically connected to the first transparent electrode 25 and the second transparent electrode 28 via a conductive film 37. This results in a dimming cell 20 electrically connected to the external electrode substrate 35.

[0066] (Method of manufacturing light control device) Next, a method of manufacturing the light control device 10 according to the present embodiment (a method of processing laminated glass) will be described with reference to Figures 8A to 10D. Figures 8A to 10D are cross-sectional views showing the method of manufacturing the light control device 10.

[0067] First, as shown in Fig. 8A, a first glass plate 11 and a second glass plate 12 are prepared. The first glass plate 11 and the second glass plate 12 may have a curved surface formed in advance, which is a three-dimensional surface shape.

[0068] 8B, a dimming cell 20 electrically connected to an external electrode substrate 35 is prepared. The dimming cell 20 can be fabricated by, for example, the methods shown in Figures 6A to 7D. The dimming cell 20 may be formed in advance into a three-dimensional curved shape by thermoforming.

[0069] Next, the first glass plate 11, the dimming cell 20, and the second glass plate 12 are bonded together using the first interlayer film 13 and the second interlayer film 14.

[0070] In this case, first, as shown in Fig. 8C, a second interlayer film 14 is formed on the second glass plate 12. The second interlayer film 14 may be formed of, for example, an optically clear adhesive film (OCA film).

[0071] Next, as shown in FIG. 9A, the light-controlling cell 20 is placed on the second intermediate film 14.

[0072] Next, as shown in FIG. 9B , a first interlayer film 13 is formed on the dimming cell 20. The first interlayer film 13 may be made of, for example, a transparent adhesive resin (OCR (Optical Clear Resin)). Here, when forming the first interlayer film 13 on the dimming cell 20, the transparent adhesive resin is dropped onto the dimming cell 20. At this time, the transparent adhesive resin penetrates between the first stacked body 21 and the second stacked body 22 around the first transparent electrode 25 and the second transparent electrode 28 outside the region 32 a surrounded by the sealant 32. In this way, the first interlayer film 13 penetrates between the first stacked body 21 and the second stacked body 22 around the first transparent electrode 25 and the second transparent electrode 28 outside the region 32 a surrounded by the sealant 32 (see FIG. 5 ).

[0073] 9C , a first glass plate 11 is provided on the first interlayer film 13. As a result, the first interlayer film 13, the dimming cell 20, and the second interlayer film 14 are sandwiched between the first glass plate 11 and the second glass plate 12, thereby obtaining a laminate 30.

[0074] Note that the first interlayer film 13 and the second interlayer film 14 may each be configured as a layer made of PVB (polyvinyl butyral) resin. In this case, as shown in Fig. 10A , a laminate 30 is prepared in which the first interlayer film 13, the dimming cell 20, and the second interlayer film 14 are sandwiched between a first glass plate 11 and a second glass plate 12.

[0075] Next, the laminate 30 is heated while being degassed.

[0076] 10B, the laminate 30 is first sealed in a bag (vacuum bag) 51. The bag 51 is preferably made of flexible and airtight rubber or silicone. A ventilation pipe 52 is connected to the bag 51.

[0077] 10C , the laminate 30 is sealed in a bag 51, and then the laminate 30 together with the bag 51 is placed in a heating device 53. There are no particular limitations on the device used as the heating device 53 as long as it can sufficiently heat the laminate 30, and examples thereof include an oven, an autoclave, and the like.

[0078] At this time, air is sucked out of the bag 51 by a pump (not shown) through the ventilation pipe 52. This sucks out any air remaining between the components of the laminate 30, making it possible to prevent poor crimping due to air bubbles or the like remaining inside the light control device 10. In this embodiment, an example will be described in which suction is performed to create a vacuum inside the bag 51 and the interior of the laminate 30, and a pressure of approximately atmospheric pressure (0.1 MPa) is applied to the laminate 30 due to the pressure difference. However, this is not limiting, and for example, the suction force of the pump (not shown) may be adjusted so that, although the bag 51 is not completely evacuated, the air between the components of the laminate 30 is sufficiently sucked out and a pressure lower than atmospheric pressure is applied to the laminate 30 due to the pressure difference.

[0079] 10D , the laminate 30 together with the bag 51 is heated at a predetermined temperature for a predetermined time. In the present embodiment, the laminate 30 is heated for a predetermined time at a temperature equal to or higher than the softening temperature of the first interlayer film 13 and the second interlayer film 14. This heating melts the first interlayer film 13 and the second interlayer film 14, and the first glass plate 11, the first interlayer film 13, the dimming cell 20, the second interlayer film 14, and the second glass plate 12 of the laminate 30 are pressure-bonded together, thereby obtaining the light control device 10.

[0080] Thereafter, a leveling step is performed in which the laminate 30 (light control device 10) is heated for a predetermined time at a temperature equal to or higher than the softening temperature of the first interlayer film 13 and the second interlayer film 14. By performing this leveling step, the cell gap, which had become smaller than a predetermined value, returns to its original value, uneven distribution of liquid crystal such as liquid crystal pools is eliminated, and the cell gap (thickness of the liquid crystal layer 23) becomes uniform. This leveling step may be performed after the laminate 30 (light control device 10) is cooled once after the components of the laminate 30 are bonded, or may be performed continuously after bonding the laminate 30. Furthermore, if there is no need to suction the air from the bag 51, the laminate 30 (light control device 10) may be removed from the bag 51 and the leveling step may be performed.

[0081] As described above, the light control device 10 includes the first glass plate 11, the second glass plate 12, the dimming cell 20 disposed between the first glass plate 11 and the second glass plate 12, the external electrode substrate 35 electrically connected to the dimming cell 20, the first interlayer film 13 disposed between the first glass plate 11 and the dimming cell 20, and the second interlayer film 14 disposed between the dimming cell 20 and the second glass plate 12. The dimming cell 20 also includes a first stack 21 including a first transparent electrode 25 electrically connected to the external electrode substrate 35 and a first substrate 24, a second stack 22 including a second transparent electrode 28 electrically connected to the external electrode substrate 35 and a second substrate 27, a liquid crystal layer 23 disposed between the first stack 21 and the second stack 22, and a sealant 32 disposed between the first stack 21 and the second stack 22 so as to surround the liquid crystal layer 23. The external electrode substrate 35 is sandwiched between the first laminate 21 and the second laminate 22. The first intermediate film 13 is inserted between the first laminate 21 and the second laminate 22. The external electrode substrate 35 is in contact with the first intermediate film 13 between the first laminate 21 and the second laminate 22. This prevents the first laminate 21 and the second laminate 22 from coming into contact with each other, even when an impact or the like is applied to the light control device 10, and prevents the first transparent electrode 25 and the second transparent electrode 28 from being exposed from the first laminate 21 and the second laminate 22. This prevents the first transparent electrode 25 and the second transparent electrode 28 from coming into contact with each other. As a result, a short circuit between the first transparent electrode 25 and the second transparent electrode 28 can be prevented.

[0082] In the above-described embodiment, an example has been described in which the first intermediate film 13 is inserted between the first laminate 21 and the second laminate 22 around the first transparent electrode 25 and the second transparent electrode 28. In this case, for example, as shown in FIG. 11 and FIG. 12, which is a cross-sectional view taken along line XII-XII in FIG. 11 , a space S may be formed in part between the first laminate 21 and the second laminate 22 around the first transparent electrode 25 and the second transparent electrode 28. Even in this case, as shown in FIG. 13, which is a cross-sectional view taken along line XIII-XIII in FIG. 11 , the external electrode substrate 35 is in contact with the first intermediate film 13 in part of the region between the first laminate 21 and the second laminate 22. That is, in this modification, the external electrode substrate 35 and the first intermediate film 13 are in contact only in part of the region, and a space S exists in the non-contact portion. In this case as well, contact between the first laminate 21 and the second laminate 22 can be prevented, and short circuits between the first transparent electrode 25 and the second transparent electrode 28 can be prevented.

[0083] It is also possible to combine the multiple components disclosed in the above-described embodiments and modifications as needed, or to delete some of the components disclosed in the above-described embodiments and modifications.

Claims

1. A light-control device comprising: a first transparent substrate; a second transparent substrate; a light-control cell disposed between the first transparent substrate and the second transparent substrate; an external electrode substrate electrically connected to the light-control cell; a first intermediate film disposed between the first transparent substrate and the light-control cell; and a second intermediate film disposed between the light-control cell and the second transparent substrate; the light-control cell having: a first laminate including a first transparent electrode electrically connected to the external electrode substrate and a first base material; a second laminate including a second transparent electrode electrically connected to the external electrode substrate and a second base material; a liquid crystal layer disposed between the first laminate and the second laminate; and a sealant disposed between the first laminate and the second laminate so as to surround the liquid crystal layer; the external electrode substrate is sandwiched between the first laminate and the second laminate; and the first intermediate film is inserted between the first laminate and the second laminate. The external electrode substrate is in contact with the first intermediate film between the first laminate and the second laminate.

2. A dimming device as described in claim 1, wherein the first laminate includes a first protruding piece that protrudes outward in the surface direction in the region where the external electrode substrate is provided, the second laminate includes a second protruding piece that protrudes outward in the surface direction in the region where the external electrode substrate is provided, the external electrode substrate is sandwiched between the first protruding piece and the second protruding piece, the first intermediate film is inserted between the first protruding piece and the second protruding piece, and the external electrode substrate is in contact with the first intermediate film between the first protruding piece and the second protruding piece.

3. The light control device according to claim 2, wherein the first intermediate film and the second intermediate film sandwich the first protruding piece and the second protruding piece.

4. A method for manufacturing a light control device, comprising the steps of: preparing a first transparent substrate and a second transparent substrate; preparing a light control cell electrically connected to an external electrode substrate; and integrally bonding the first transparent substrate, the light control cell, and the second transparent substrate using a first intermediate film and a second intermediate film, wherein the light control device has the first intermediate film arranged between the first transparent substrate and the light control cell, and the second intermediate film arranged between the second transparent substrate and the light control cell, and the light control cell has: a first laminate including a first transparent electrode electrically connected to the external electrode substrate and a first base material; a second laminate including a second transparent electrode electrically connected to the external electrode substrate and a second base material; a liquid crystal layer arranged between the first laminate and the second laminate; and a sealant arranged between the first laminate and the second laminate so as to surround the liquid crystal layer, and the external electrode substrate is sandwiched between the first laminate and the second laminate, the first intermediate film is interposed between the first stack and the second stack, and the external electrode substrate is in contact with the first intermediate film between the first stack and the second stack.

Images