Light control film assembly, light control laminated glass, and method for producing light control laminated glass

Abstract

A light control film assembly (11) comprises a light control laminate (14) and a frame-like edge seal (20) which covers an edge part of the light control laminate (14) along the entire perimeter thereof. The light control laminate (14) has a light control layer (15) which includes a polymeric resin and liquid crystals, a pair of transparent base materials (16) which are disposed so as to sandwich the light control layer (15), and electroconductive films (17) which are respectively provided to the main surfaces of the transparent base materials (16) which face the light control layer (15). The edge seal (20) has a sandwiching part (22) which sandwiches the edge part of the light control laminate (14) and an outer extending part (23) which is provided so as to surround light control laminate (14) in plan view, and which extends outward from the sandwiching part (22).

Description

Dimming Film Assembly, Dimming Laminated Glass, and Method for Manufacturing Dimming Laminated Glass

[0001] The present invention relates to a dimming film assembly, a dimming laminated glass, and a method for manufacturing the dimming laminated glass.

[0002] Patent Document 1 describes a dimming film assembly (referred to as a "dimming film layer" in Patent Document 1) that can be switched between transparent and opaque by the presence or absence of voltage application. This dimming film assembly includes a dimming laminate having a dimming layer (a mixture of liquid crystal and polymer resin in Patent Document 1) and a pair of transparent substrates (referred to as "polymer film substrates" in Patent Document 1) arranged so as to sandwich the dimming layer.

[0003] Further, this dimming film assembly includes an edge seal (referred to as a "polyester tape" in Patent Document 1) that covers the edge of the dimming laminate. This edge seal has a U-shaped (horseshoe-shaped) cross-section that sandwiches the edge of the dimming laminate when viewed in a cross-section perpendicular to the main surface of the transparent substrate.

[0004] Japanese Patent Application Laid-Open No. 5-165011

[0005] In the dimming film assembly described in Patent Document 1, wrinkles are likely to occur in the edge seal. The wrinkles in the edge seal create gaps in the edge seal. Therefore, when manufacturing a dimming laminated glass sandwiching this dimming film assembly, a plasticizer contained in an intermediate layer (e.g., polyvinyl butyral resin) that adheres the glasses is likely to penetrate into the dimming layer through the gaps in the edge seal. When the plasticizer penetrates into the dimming layer, the polymer resin in the dimming layer deteriorates.

[0006] An object of the present invention is to provide a dimming film assembly, a dimming laminated glass, and a method for manufacturing the dimming laminated glass in which it is difficult for a plasticizer to penetrate into the dimming layer.

[0007] The dimmable film assembly according to the present invention is characterized by comprising a dimmable laminate and a frame-shaped edge seal that covers the entire edge of the dimmable laminate, wherein the dimmable laminate has a dimmable layer containing a polymer resin and liquid crystal, a pair of transparent substrates arranged to sandwich the dimmable layer, and a conductive film provided on the main surface of each transparent substrate facing the dimmable layer, and the edge seal has a clamping portion that clamps the edge of the dimmable laminate and an outward extension portion that surrounds the dimmable laminate in a plan view and extends outward from the clamping portion.

[0008] With this configuration, for example, an edge seal can be provided by sandwiching (heat-sealing) the light-adjustable laminate between a pair of frame-shaped resin films. Therefore, compared to a configuration in which the edges of the light-adjustable laminate are covered with a U-shaped (U-shaped) edge seal (tape) in a cross-sectional view perpendicular to the main surface of the transparent substrate, gaps that would allow plasticizers to penetrate into the light-adjustable layer are less likely to occur in the edge seal. Consequently, with this configuration, it is difficult for plasticizers to penetrate into the light-adjustable layer.

[0009] Furthermore, in the present invention, it is preferable that the extension width of the outward extension portion is smaller than the width of the clamping portion in a plan view.

[0010] This configuration results in a relatively small extension width for the outward extension portion. This makes it easier to set a larger size for the light-adjustable laminate when, for example, a light-adjustable film assembly is sandwiched between a pair of glass plates to manufacture light-adjustable laminated glass, provided that the size of the glass plates in plan view is predetermined. This allows for a larger area of ​​the portion of the light-adjustable laminated glass that has a light-adjustable function (in other words, the portion where the light-adjustable laminate exists).

[0011] Furthermore, in the present invention, it is preferable that the extension width of the outer extension portion is greater than the thickness of the dimmable laminate.

[0012] With this configuration, the extension width of the outer extension portion becomes relatively large. As a result, wrinkles are less likely to form in the outer extension portion compared to a configuration with a relatively small extension width, and the alignment of the dimming film assembly is more stable when sandwiching the dimming film assembly between a pair of glass plates to manufacture dimming laminated glass.

[0013] Furthermore, in the present invention, it is preferable that the edge seal is composed of a pair of frame-shaped resin films, the outer edges of each resin film are bonded to each other, and the outward extension is composed of the outer edges of the pair of resin films.

[0014] This configuration makes it possible to provide a frame-shaped edge seal having a clamping portion and an outward extension portion with a relatively simple structure.

[0015] Furthermore, in the present invention, it is preferable that the transparent substrate is made of polyethylene terephthalate.

[0016] This configuration tends to result in good durability and transparency of the transparent substrate. This, in turn, tends to improve the quality of the dimmable film assembly.

[0017] Furthermore, in the present invention, it is preferable that an electrode is provided which is sandwiched between a pair of conductive films and electrically connected to the pair of conductive films, and the electrode has a first portion which overlaps with the photochromic laminate in a plan view and a second portion which does not overlap with the photochromic laminate in a plan view.

[0018] This configuration makes it easier to electrically connect the electrode to the pair of conductive films compared to a configuration in which the electrode does not have a first portion. Furthermore, the electrode can be made larger compared to a configuration in which the electrode does not have a second portion. This makes it easier to ensure electrode strength compared to cases where the electrode is relatively small.

[0019] Furthermore, in the present invention, it is preferable that the extended end of the second portion is located outside the outer end of the edge seal.

[0020] With this configuration, for example, when an edge seal is provided by sandwiching (heat sealing) a photochromic laminate between a pair of frame-shaped resin films, the outer edges of the pair of resin films that sandwich the electrodes can be adhered to the main surface of the electrodes, which have relatively high strength. This makes it easier to achieve good (stable) adhesion of the outer edges of the resin films compared to a configuration where the outer edges of the pair of resin films are adhered to each other over the entire circumference of the edge seal.

[0021] The characteristic of the dimmable laminated glass according to the present invention is that it comprises the above-mentioned dimmable film assembly, an intermediate layer that holds the dimmable film assembly inside, and a pair of glass plates arranged so as to sandwich the intermediate layer.

[0022] With this configuration, for example, an edge seal can be provided by sandwiching (heat-sealing) the light-adjustable laminate between a pair of frame-shaped resin films. Therefore, compared to a configuration in which the edges of the light-adjustable laminate are covered with a U-shaped (U-shaped) edge seal (tape) in a cross-sectional view perpendicular to the main surface of the transparent substrate, gaps that would allow plasticizers to penetrate into the light-adjustable layer are less likely to occur in the edge seal. Consequently, with this configuration, it is difficult for plasticizers to penetrate into the light-adjustable layer.

[0023] Furthermore, in the present invention, the intermediate layer comprises a soft layer and a hard layer, and it is preferable that the soft layer is softer than the hard layer.

[0024] This configuration improves the sound insulation of the intermediate layer. As a result, it is possible to create a dimmable laminated glass with excellent sound insulation.

[0025] Furthermore, in the present invention, it is preferable that the intermediate layer contains a coloring component.

[0026] According to this configuration, by appropriately adjusting the type and amount of coloring components, it is possible to realize dimmable laminated glass with a suitable color (for example, a color that matches the user's needs).

[0027] Furthermore, in the present invention, it is preferable that the extended end of the outward extension is located on one side in the thickness direction of the dimmable film assembly, rather than at the center position in the thickness direction of the dimmable film assembly.

[0028] According to this configuration, for example, when dimmable laminated glass is installed in a vehicle window, and one main surface of the dimmable laminated glass is designated as facing the outside of the vehicle and the other main surface as facing the inside of the vehicle, each main surface can be identified based on the position of the outward extension. This improves the convenience of the dimmable laminated glass.

[0029] Furthermore, in the present invention, it is preferable that the outward extension extends outward from the clamping portion and toward one side in the thickness direction of the dimming film assembly.

[0030] With this configuration, compared to a configuration where the outward extension extends horizontally to the main surface of the dimmable film assembly, the outer end of the edge seal is positioned further inward in a plan view. This makes it easier to set a larger size for the dimmable laminate when the size of the glass plate in a plan view is fixed. As a result, the area of ​​the portion that has the dimming function (in other words, the portion where the dimmable laminate exists) in the dimmable laminated glass can be increased.

[0031] The manufacturing method for dimmable laminated glass according to the present invention is characterized by the above-described method for manufacturing dimmable laminated glass, comprising: a lamination step of obtaining a pre-adhesion laminate by sequentially laminating one of the pair of glass plates, a first partial intermediate layer, a second partial intermediate layer that is frame-shaped and holds the dimmable film assembly, a third partial intermediate layer, and the other of the pair of glass plates; and a heating and pressing step of heating and pressing the pre-adhesion laminate so that the first partial intermediate layer, the second partial intermediate layer, and the third partial intermediate layer become the intermediate layers and the pair of glass plates are bonded via the intermediate layers, wherein in the lamination step, the outward extension is sandwiched between the first partial intermediate layer and the second partial intermediate layer, or between the second partial intermediate layer and the third partial intermediate layer.

[0032] In this configuration, the outer extension is sandwiched between the first and second intermediate layers, or between the second and third intermediate layers. This makes it less likely for wrinkles to form in the outer extension.

[0033] This figure shows a light-adjustable laminated glass installed in a vehicle. This is a plan view of the light-adjustable laminated glass. This is a cross-sectional view taken from III-III in Figure 2. This is a cross-sectional view taken from IV-IV in Figure 2. This is a plan view of the light-adjustable film assembly. This is a cross-sectional view taken from VI-VI in Figure 5. This is a cross-sectional view taken from VII-VII in Figure 5. This is a perspective view showing a pair of resin films sandwiching a light-adjustable laminate. This is a cross-sectional view showing a pair of resin films sandwiching a light-adjustable laminate. This figure shows a method for manufacturing light-adjustable laminated glass. This is a cross-sectional view showing a laminate before bonding. This is a plan view of the light-adjustable film assembly in a first alternative embodiment. This is a cross-sectional view taken from XIII-XIII in Figure 12. This is a perspective view showing two pairs of first films sandwiching a light-adjustable laminate in a first alternative embodiment. This is a perspective view showing two pairs of second films sandwiching a light-adjustable laminate in a first alternative embodiment. This is a plan view of the light-adjustable film assembly in a second alternative embodiment. This is a cross-sectional view taken from XVII-XVII in Figure 16. This is a cross-sectional view showing light-adjustable laminated glass of another embodiment (1). This is a cross-sectional view showing a dimming film assembly of another embodiment (2). This is a cross-sectional view showing the configuration of a conductive film, etc., of another embodiment (3).

[0034] Embodiments for carrying out the present invention will be described with reference to the drawings.

[0035] [Overall Configuration of Dimmable Laminated Glass] As shown in Figure 1, the dimmable laminated glass 10 is used, for example, in the glass of a vehicle 1. More specifically, the dimmable laminated glass 10 may be used in the roof glass, rear glass, door glass, windshield, etc. of the vehicle 1. In this embodiment, the dimmable laminated glass 10 is used in the roof glass of the vehicle 1.

[0036] As shown in Figures 2 to 4, the dimmable laminated glass 10 comprises a dimmable film assembly 11, an intermediate layer 12, and a pair of glass plates 13.

[0037] The dimmable film assembly 11 has a dimming function (in other words, a function to switch the light transmittance). As a result, the dimmable laminated glass 10 has a dimming function.

[0038] The intermediate layer 12 is a transparent adhesive layer, formed, for example, from a thermoplastic resin. Examples of thermoplastic resins include plasticized polyvinyl acetal resins, plasticized polyvinyl chloride resins, saturated polyester resins, plasticized saturated polyester resins, polyurethane resins, plasticized polyurethane resins, ethylene-vinyl acetate copolymer resins, ethylene-ethyl acrylate copolymer resins, cycloolefin polymer resins, and ionomer resins. Among these thermoplastic resins, plasticized polyvinyl acetal resins are preferably used for the intermediate layer 12. These thermoplastic resins may be used individually or in combination of two or more types. The material forming the intermediate layer 12 is not limited to thermoplastic resins. The intermediate layer 12 may contain functional particles such as infrared absorbers, ultraviolet absorbers, and light-emitting agents. The intermediate layer 12 may have a colored portion called a shade band. That is, the intermediate layer 12 may contain a coloring component. The coloring component may include, for example, dyes or pigments.

[0039] Examples of the above dyes include pyrene dyes, aminoketone dyes, anthraquinone dyes, and azo dyes. Examples of the above pyrene dyes include Solvent Green 5 (CAS79869-59-3), examples of the above aminoketone dyes include Solvent Yellow 98 (CAS12671-74-8), examples of the above anthraquinone dyes include Solvent Yellow 163 (CAS13676091-0), and examples of the above azo dyes include Solvent Yellow 30 (CAS3321-10-4). Examples of the above pigments include indole pigment (CAS No. 5590-18-1).

[0040] Further, the intermediate layer 12 contains a plasticizer. As the plasticizer, for example, conventionally known plasticizers can be used. Such plasticizers include, for example, organic ester plasticizers such as monobasic organic acid esters and polybasic organic acid esters, and phosphoric acid plasticizers such as organic phosphoric acid plasticizers and organic phosphorous acid plasticizers. Among them, organic ester plasticizers are preferred. For example, an ester compound of a polybasic organic acid and an alcohol having a linear or branched structure with 4 to 8 carbon atoms can be mentioned. The above organic ester plasticizer is not particularly limited, and triethylene glycol di-2-ethylbutyrate and the like can be mentioned. The above plasticizer is preferably a diester plasticizer represented by the following chemical formula 1.

[0041]

[0042] By adjusting the Young's modulus with this plasticizer, the sound insulation of the light control laminated glass 10 can be enhanced. However, there is a risk that this ester group reacts with the organic resin component constituting the light control layer 15 (described later) and causes bleed-out or the like (deterioration of the adhesiveness between the light control layer 15 and the conductive film 17 (described later), deterioration of the conductivity of the conductive film 17, and deterioration of optical quality such as deterioration of permeability due to bleeding into the liquid crystal).

[0043] The light control film assembly 11 is held inside the intermediate layer 12. The pair of glass plates 13 are arranged so as to sandwich the intermediate layer 12. The pair of glass plates 13 are adhered to each other through the intermediate layer 12. Each glass plate 13 is constituted by a known glass plate-like member.

[0044] Thus, the light control laminated glass 10 includes the light control film assembly 11, the intermediate layer 12 that holds the light control film assembly 11 inside, and a pair of glass plates 13 arranged so as to sandwich the intermediate layer 12.

[0045] [Light control film assembly] As shown in FIGS. 5 to 7, the light control film assembly 11 includes a light control laminate 14 and an edge seal 20. The edge seal 20 covers the edge portion (outer end portion or outer peripheral portion) of the light control laminate 14 over the entire circumference.

[0046] As shown in FIGS. 6 and 7, the dimming laminate 14 includes a dimming layer 15, a pair of transparent substrates 16, and a pair of conductive films 17. The dimming layer 15 contains a polymer resin and liquid crystal. Although not particularly limited, the dimming layer 15 in the present embodiment is a liquid crystal-resin composite in which liquid crystal microparticles encapsulating liquid crystal in microcapsules are dispersed in a resin binder (resin matrix).

[0047]

[0048] In the above chemical formula 2, R1 is a hydrogen atom or a methyl group, and R2 is a linear or branched chain alkyl group having 1 to 20 carbon atoms or a cyclic alkyl group having 5 to 20 carbon atoms.

[0049] The resin matrix constituting the liquid crystal-resin composite in the present embodiment is a polymer containing (meth)acrylic acid alkyl ester or (meth)acrylic acid cycloalkyl ester represented by the above chemical formula 2 as a monomer. Examples of the (meth)acrylic acid alkyl ester include methyl (meth)acrylate, ethyl (meth)acrylate, butyl (meth)acrylate, iso-butyl (meth)acrylate, and the like.

[0050] This monomer reduces the interaction between the resin matrix and the liquid crystal molecules constituting the liquid crystal microparticles in the liquid crystal-resin composite. It is considered that the reduction of this interaction contributes to the improvement of the orientation of the liquid crystal molecules in the voltage-applied state. If the amount of this monomer is too low, the glass transition temperature becomes too high and there is a problem with the adhesion to other layers (for example, the conductive film 17), and a large amount of a plasticizer to be described later is required to compensate for this. On the other hand, if the amount of this monomer is too high, there is a problem that the liquid crystal material to be described later is not well dispersed.

[0051] Furthermore, monomers having nonionic hydrophilic groups may also be included. The nonionic hydrophilic group is preferably at least one selected from an amide group, a hydroxyl group, and a polyoxyalkylene group, more preferably an amide group and / or a hydroxyl group. Examples of amide group-containing monomers include (meth)acrylamide, and examples of hydroxyl group-containing monomers include 2-hydroxyethyl (meth)acrylate. Including these monomers enables the liquid crystal material to disperse well and achieve so-called encapsulation. Other monomers can also be included in the resin matrix. The resin matrix is ​​formed by polymerization of these monomers. If too much plasticizer is added, bleed-out may occur and the encapsulated liquid crystal material may seep out. Therefore, it is particularly important to prevent plasticizer from entering from the intermediate layer 12 to the light-adjusting layer 15.

[0052] The liquid crystal material used in this invention does not need to be a single (one type) liquid crystalline compound; it may be a mixture containing two or more liquid crystal compounds or substances other than liquid crystal compounds, and any material that is generally recognized as a liquid crystal material in this art is acceptable, with those having positive dielectric anisotropy being preferred. The liquid crystals used are preferably nematic liquid crystals, smectic liquid crystals, and cholesteric liquid crystals, with nematic liquid crystals being particularly preferred.

[0053] The liquid crystal dispersed in the organic matrix (resin matrix) capable of forming the dimming layer 15 is not particularly limited, and can be any liquid crystal that can be used for liquid crystal display elements. Specifically, examples include azoxy compounds such as p-alkoxy-p'-alkylazobenzene and p-azoxyphenetol, nitrogen-based compounds such as p-alkoxy-p'-alkylbenzylideneaniline and p-alkoxybenzylidene-p'-alkylaniline, phenyl ester compounds such as p-alkoxy-p'-cyanophenylbenzoic acid and cholesteric benzoic acid, biphenyl compounds such as p-alkoxy-p'-cyanobiphenyl and p-alkoxy-p'-carboxylate biphenylalkyl ester, phenylcyclohexane compounds, dioxane compounds, pyrimidine compounds, etc., which can be used individually or as a mixture.

[0054] By incorporating dichroic dyes into liquid crystal materials, visibility can be improved through contrast and color display. Furthermore, by using black dyes, a light shutter function can be added, expanding the range of applications. Any dichroic dye used in liquid crystal applications can be used. Examples include anthraquinone-based, azo-based, quinophthalone-based, perylene-based, coumarin-based, thioindigo-based, merocyanine-based, styryl-based, and oxonol-based dichroic dyes. In addition, these dyes can be appropriately blended and used depending on the purpose.

[0055] Examples of commercially available dichroic dyes include "SI-497" (blue pigment), "M-137" (blue pigment), "SI-426" (red pigment), "S-416" (black pigment), and "S-344" (black pigment) from Mitsui Toatsu Dye Co., Ltd., "LCD-118" (blue pigment), "LCD-208" (red pigment), and "LCD-465" (black pigment) from Nippon Kayaku Co., Ltd., and "CLD-506" (blue pigment) from Sumitomo Chemical Co., Ltd.

[0056] The dimming layer 15 switches between a transparent state and an opaque state by changing its haze rate depending on whether or not power is applied. In other words, the light transmittance of the dimming layer 15 can be adjusted by applying a voltage. In this embodiment, the dimming layer 15 is configured to be transparent when a voltage is applied and opaque when no voltage is applied. However, the present invention is not limited to this. The dimming layer 15 may be configured to be opaque when a voltage is applied and transparent when no voltage is applied.

[0057] A pair of transparent substrates 16 are arranged facing each other and sandwiching the light-adjusting layer 15. The transparent substrates 16 are transparent resin layers. In this embodiment, the transparent substrates 16 are made of a polymer film made of polyethylene terephthalate. However, the present invention is not limited to this. Examples of the polymer film include polyester films such as polyethylene terephthalate, polyolefin films such as polypropylene, polyvinyl chloride, acrylic resin films, polyethersulfone films, polyarylate films, and polycarbonate films. Among these, polyester polymers, specifically polyethylene terephthalate films, are preferred because they have excellent transparency, moldability, adhesion, processability, and especially resistance to plasticizers, i.e., the function of preventing plasticizers from eroding to the inside. However, any material with high resistance to plasticizers can be used, not limited to the above material. The thickness of the transparent substrate 16 is preferably 5 μm or more and 150 μm or less. If the thickness is less than 5 μm, it is too thin and the edge seal 20 is prone to tearing, and there is a risk that plasticizers contained in the intermediate layer 12 may penetrate through the torn gap. Furthermore, there is a risk of problems such as the material being too thin and difficult to handle in the manufacturing process. Also, if the thickness exceeds 150 μm, there is a risk of bubble defects occurring around the steps caused by the thickness of the transparent substrate 16. The thickness of the transparent substrate 16 is more preferably 7 μm to 100 μm, and even more preferably 10 μm to 50 μm. An example of a transparent substrate 16 thickness is 15 μm.

[0058] The conductive film 17 is provided on the main surface of each transparent substrate 16 facing the light-adjusting layer 15. The conductive film 17 is provided so as to cover the entire main surface. The pair of conductive films 17 are arranged so as to face each other and sandwich the light-adjusting layer 15.

[0059] Each conductive film 17 is in contact with the dimming layer 15, and a voltage is applied to the dimming layer 15 when power is supplied. For example, transparent conductive oxide (TCO) can be used as the conductive film 17. Examples of TCO include tin-doped indium oxide (ITO), aluminum-doped zinc oxide (AZO), and indium-doped cadmium oxide. Furthermore, transparent conductive polymers such as poly(3,4-ethylenedioxythiophene) (PEDOT), poly(4,4-dioctylcyclopentadithiophene), a laminated film of a metal layer and a dielectric layer, silver nanowires, and silver or copper metal meshes can be used as the conductive film 17. The conductive film 17 is not limited to these and may be composed of other materials.

[0060] Thus, the dimmable laminate 14 includes a dimmable layer 15 containing a polymer resin and liquid crystal, a pair of transparent substrates 16 arranged so as to sandwich the dimmable layer 15, and a conductive film 17 provided on the main surface of each transparent substrate 16 facing the dimmable layer 15.

[0061] As shown in Figure 6, the edge seal 20 is composed of a pair of resin films 21. The pair of resin films 21 are arranged facing each other. As shown in Figures 8 and 9, the pair of resin films 21 have the same shape. As shown in Figure 5, each resin film 21 has a frame-like shape in plan view. That is, the edge seal 20 is composed of a pair of frame-shaped resin films 21.

[0062] As shown in Figure 5, in a plan view, the outer dimensions of the resin film 21 are larger than the outer dimensions of the light-adjustable laminate 14. In a plan view, the inner (inner circumference) portion of the resin film 21 overlaps with the light-adjustable laminate 14, while the outer (outer circumference) portion does not overlap with the light-adjustable laminate 14.

[0063] As shown in Figures 8 and 9, the dimmable laminate 14 is sandwiched between a pair of resin films 21. The outer edges of each resin film 21 are then bonded together, for example, by heat sealing, to form an edge seal 20. As a result, the edge seal 20 has a frame-like shape in plan view, as shown in Figure 5.

[0064] In other words, the outer edges of each resin film 21 are bonded to each other. The dimming film assembly 11 also includes a frame-shaped edge seal 20 that covers the entire circumference of the edge of the dimming laminate 14. In this embodiment, the edge seal 20 and the resin film 21 are rectangular in shape when viewed from above, but the present invention is not limited to this. For example, the edge seal 20 and the resin film 21 may be circular or elliptical in shape when viewed from above.

[0065] The material of the edge seal 20 (each resin film 21) is preferably one that has excellent resistance to plasticizers, that is, a function that prevents plasticizers from eroding to the inside, similar to the transparent substrate 16. Therefore, the material of the edge seal 20 (each resin film 21) may be the same as that of the transparent substrate 16 (as given as a specific example of the material of the transparent substrate 16), or any material with high resistance to plasticizers may be used.

[0066] As shown in Figures 5 to 7, the edge seal 20 has a clamping portion 22 and an outward extension portion 23. In the portion of the dimming film assembly 11 where the electrode 18 (described later) is absent, the clamping portion 22 has a U-shape (U-shaped) in a cross-sectional view perpendicular to the main surface of the transparent substrate 16 (the dimming laminate 14 or the main surface of the dimming film assembly 11), as shown in Figure 6. The clamping portion 22 clamps the edge of the dimming laminate 14.

[0067] As shown in Figure 6, the outer extension portion 23 extends outward from the central part of the clamping portion 22 in the thickness direction of the dimming film assembly 11. As shown in Figure 5, the outer extension portion 23 is frame-shaped in plan view and is provided to surround the dimming laminate 14.

[0068] In other words, the edge seal 20 has a clamping portion 22 that clamps the edge of the dimmable laminate 14, and an outward extension portion 23 that surrounds the dimmable laminate 14 in a plan view and extends outward from the clamping portion 22.

[0069] As shown in Figures 5 and 6, the outward extension portion 23 is composed of the outer edges of a pair of resin films 21.

[0070] Figure 5 shows the first width D1 and the second width D2. The first width D1 is the extension width of the outer extension portion 23. The second width D2 is the width of the clamping portion 22 in a plan view. The first width D1 is smaller than the second width D2. That is, the extension width of the outer extension portion 23 is smaller than the width of the clamping portion 22 in a plan view.

[0071] Figure 6 shows the first width D1 and the third width D3. The third width D3 is the thickness of the dimmable laminate 14. The first width D1 is greater than the third width D3. That is, the extension width of the outer extension portion 23 is greater than the thickness of the dimmable laminate 14.

[0072] As shown in Figures 5 and 7, the dimming film assembly 11 comprises two electrodes 18. The thickness of each electrode 18 is equivalent to that of the dimming layer 15. Each electrode 18 is sandwiched between a pair of conductive films 17 and is electrically connected to the pair of conductive films 17. That is, the dimming film assembly 11 comprises electrodes 18 that are sandwiched between a pair of conductive films 17 and electrically connected to the pair of conductive films 17. The dimming film assembly 11 is configured to allow a voltage to be applied to the dimming layer 15 via the electrodes 18 and the conductive films 17.

[0073] Furthermore, the number of electrodes 18 is not limited to two; it may be one or three or more.

[0074] As shown in Figure 5, the electrode 18 has a first portion 31 and a second portion 32. The first portion 31 overlaps with the photochromic laminate 14 in a plan view. The second portion 32 extends outward from the first portion 31. The second portion 32 does not overlap with the photochromic laminate 14 in a plan view. That is, the electrode 18 has a first portion 31 that overlaps with the photochromic laminate 14 in a plan view, and a second portion 32 that does not overlap with the photochromic laminate 14 in a plan view. Note that in a plan view, the entire first portion 31 overlaps with the photochromic laminate 14.

[0075] As shown in Figure 5, the extended end 32a of the second portion 32 (the end portion in the direction toward the outside of the dimming film assembly 11) protrudes outward from the outer end of the outer extension portion 23. That is, the extended end 32a of the second portion 32 is located outward from the outer end of the edge seal 20.

[0076] As shown in Figures 5 to 7, the edge seal 20 covers only the edges of the dimmable laminate 14. The portion of the dimmable laminate 14 not covered by the edge seal 20 (the portion inside the edges in a plan view) is exposed.

[0077] [Arrangement of Outer Extensions in Dimmable Laminated Glass] Figures 3 and 4 show the central position CE of the film. The central position CE of the film is the central position in the thickness direction of the dimmable film assembly 11. As shown in Figures 3 and 4, in the dimmable laminated glass 10, the extended end 23a of the outer extension 23 is located on one side (upper side in Figures 3 and 4) in the thickness direction of the dimmable film assembly 11, relative to the central position CE of the film. That is, the extended end 23a of the outer extension 23 is located on one side in the thickness direction of the dimmable film assembly 11, relative to the central position in the thickness direction of the dimmable film assembly 11.

[0078] As shown in Figures 3 and 4, in the dimmable laminated glass 10, the outward extension portion 23 extends outward from the clamping portion 22 and to one side in the thickness direction of the dimmable film assembly 11 (the upper side in Figures 3 and 4).

[0079] [Method for manufacturing dimmable laminated glass] Figure 10 shows the method for manufacturing the dimmable laminated glass 10 described above. In this manufacturing method, a lamination step is performed first, followed by a heating and pressing step.

[0080] In the lamination step, as shown in Figure 11, a pre-bonded laminate 50 is obtained by laminating the glass plate 13, the first partial intermediate layer 41, the second partial intermediate layer 42 holding the dimming film assembly 11, the third partial intermediate layer 43, and the glass plate 13 in that order from the bottom.

[0081] The two glass plates 13 contained in the pre-bonded laminate 50 constitute a pair of glass plates 13 in the dimmable laminated glass 10.

[0082] The first and third intermediate layers are plate-shaped members. The second intermediate layer is a frame-shaped member capable of holding the dimming film assembly 11. The dimming film assembly 11 is held in the second intermediate layer 42 by fitting the clamping portion 22 of the dimming film assembly 11 into the second intermediate layer 42. Then, in the lamination step, the outward extension portion 23 is sandwiched between the first intermediate layer 41 and the second intermediate layer 42, or between the second intermediate layer 42 and the third intermediate layer 43. In this embodiment, as shown in Figure 11, the outward extension portion 23 is sandwiched between the second intermediate layer 42 and the third intermediate layer 43.

[0083] Thus, the manufacturing method of the dimmable laminated glass 10 includes a lamination step in which one of a pair of glass plates 13, a first partial intermediate layer 41, a second partial intermediate layer 42 which is frame-shaped and holds the dimmable film assembly 11, a third partial intermediate layer 43, and the other glass plate 13 of the pair of glass plates 13 are sequentially laminated to obtain a pre-bonded laminate 50.

[0084] In the heating and pressing step, the pre-bonded laminate 50 is heated and pressurized. Although not particularly limited, in the heating and pressing step, for example, the pre-bonded laminate 50 is placed in a rubber bag (not shown) and bonded in a vacuum with a gauge pressure of -65 kPa to -100 kPa at a temperature of approximately 70°C to 110°C. The pressure and temperature conditions can be appropriately changed considering the properties of the dimmable film assembly 11. Furthermore, by performing a compression treatment in which the laminate is heated and pressurized under conditions of, for example, 100°C to 150°C and an absolute pressure of 0.6 MPa to 1.3 MPa, a dimmable laminated glass 10 with superior durability can be obtained.

[0085] By heating and pressurizing the pre-bonding laminate 50, the first partial intermediate layer 41, the second partial intermediate layer 42, and the third partial intermediate layer 43 become one, thereby forming an intermediate layer 12 (see Figure 3). Furthermore, the pair of glass plates 13 are bonded together via the intermediate layer 12. In other words, the manufacturing method of the dimmable laminated glass 10 includes a heating and pressurizing step in which the pre-bonding laminate 50 is heated and pressurized so that the first partial intermediate layer 41, the second partial intermediate layer 42, and the third partial intermediate layer 43 become an intermediate layer 12, and the pair of glass plates 13 are bonded together via the intermediate layer 12.

[0086] As described above, with the manufacturing method of the dimmable laminated glass 10, the extended end 23a of the outer extension 23 is located on one side in the thickness direction of the dimmable film assembly 11 (upper side in Figures 3 and 4) relative to the film center position CE. Furthermore, as described above, the outer extension 23 extends outward from the clamping portion 22 and to one side in the thickness direction of the dimmable film assembly 11 (upper side in Figures 3 and 4).

[0087] As described above, an edge seal 20 can be provided by, for example, sandwiching (heat-sealing) the light-adjusting laminate 14 between a pair of frame-shaped resin films 21. Therefore, compared to a configuration in which the edges of the light-adjusting laminate 14 are covered with a U-shaped (U-shaped) edge seal 20 (tape) in a cross-sectional view perpendicular to the main surface of the transparent substrate 16, gaps that would serve as passages for plasticizer to penetrate into the light-adjusting layer 15 are less likely to occur in the edge seal 20. Consequently, with this configuration, it is difficult for plasticizer to penetrate into the light-adjusting layer 15.

[0088] [First Alternative Embodiment] In the above embodiment, as shown in Figures 5 and 8, each resin film 21 is composed of a single component (film). With this configuration, the thickness of the edge seal 20 (each resin film 21) becomes uniform, resulting in a high aesthetic appearance and a reduction in the number of manufacturing steps.

[0089] However, the present invention is not limited thereto. Below, a first alternative embodiment of the present invention will be described, focusing on the differences from the above embodiment. The configuration other than the parts described below is the same as in the above embodiment. Also, the same reference numerals are used for the same components as in the above embodiment.

[0090] As shown in Figures 12 and 13, in the first alternative embodiment, each resin film 21 is composed of two first films 61 and two second films 62. Both the first film 61 and the second film 62 are strip-shaped films. The materials of the first film 61 and the second film 62 are the same as those of the edge seal 20 (each resin film 21) in the above embodiment.

[0091] The direction in which each first film 61 extends is the same as that of the other. Also, the direction in which each second film 62 extends is the same as that of the other. The direction in which each first film 61 extends is perpendicular to the direction in which each second film 62 extends.

[0092] In the first alternative embodiment, as shown in Figure 12, each first film 61 is arranged to cover the edge (side) of the light-adjusting laminate 14 to which the electrodes 18 are attached. Each second film 62 is arranged to cover the edge (side) of the light-adjusting laminate 14 to which the electrodes 18 are not attached.

[0093] Furthermore, as shown in Figures 12 and 13, the longitudinal end of the first film 61 and the longitudinal end of the second film 62 overlap. As a result, the portion of the edge seal 20 (each resin film 21) where the first film 61 and the second film 62 overlap is thicker than the portion where the first film 61 and the second film 62 do not overlap.

[0094] The dimming film assembly 11 in the first alternative embodiment is manufactured, for example, as follows.

[0095] First, as shown in Figure 14, the light-adjustable laminate 14 is sandwiched between two sets of first films 61. At this time, the first edge of the light-adjustable laminate 14 (the right edge in Figure 12) is sandwiched between a pair of opposing first films 61, and the second edge of the light-adjustable laminate 14 (the left edge in Figure 12) is sandwiched between another pair of opposing first films 61.

[0096] The process shown in Figure 14 may consist of two steps: a first step and a second step. The first step is to sandwich the first edge of the light-adjustable laminate 14 between a pair of first films 61. The second step is to sandwich the second edge of the light-adjustable laminate 14 between another pair of first films 61. Either the first or second step may be performed first. Alternatively, the first and second steps may be performed simultaneously.

[0097] Next, as shown in Figure 15, the light-adjustable laminate 14 is sandwiched between two pairs of second films 62. At this time, the third edge of the light-adjustable laminate 14 (the upper edge in Figure 12) is sandwiched between a pair of opposing second films 62, and the fourth edge of the light-adjustable laminate 14 (the lower edge in Figure 12) is sandwiched between another pair of opposing second films 62.

[0098] The process shown in Figure 15 may also consist of two steps: a third step and a fourth step. The third step is the process of sandwiching the third edge of the light-adjustable laminate 14 with a pair of second films 62. The fourth step is the process of sandwiching the fourth edge of the light-adjustable laminate 14 with another pair of second films 62. Either the third step or the fourth step may be performed first. Alternatively, the third step and the fourth step may be performed simultaneously.

[0099] As described above, the manufacturing method results in the longitudinal end of the first film 61 being covered by the longitudinal end of the second film 62, as shown in Figure 13. However, the present invention is not limited thereto. The first and second steps may be performed after the third and fourth steps described above. In that case, the longitudinal end of the second film 62 will be covered by the longitudinal end of the first film 61.

[0100] Furthermore, the order of the first to fourth steps described above can be changed at will.

[0101] According to the configuration shown in Figures 12 and 13, the resin film 21 can be easily attached, and wrinkles are less likely to form in the edge seal 20. In addition, the edge seal 20 can reliably seal the edges of the dimmable laminate 14 around its entire circumference.

[0102] [Second Alternative Embodiment] In the first alternative embodiment, as shown in Figure 12, each first film 61 extends from the outer edge in the short direction of the second film 62 that sandwiches the third edge to the outer edge in the short direction of the second film 62 that sandwiches the fourth edge. Also, each second film 62 extends from the outer edge in the short direction of the first film 61 that sandwiches the first edge to the outer edge in the short direction of the first film 61 that sandwiches the second edge.

[0103] However, the present invention is not limited thereto. Below, a second alternative embodiment of the present invention will be described, focusing on the differences from the first alternative embodiment. The configuration other than the parts described below is the same as in the first alternative embodiment. Also, the same reference numerals are used for the same components as in the first alternative embodiment.

[0104] As shown in Figure 16, the longitudinal lengths of the first film 61 and the second film 62 in the second alternate embodiment are each shorter than the longitudinal lengths of the first film 61 and the second film 62 in the first alternate embodiment.

[0105] As shown in Figure 16, each first film 61 has a length such that it does not overlap with the outwardly extending portion 23 of each second film 62 in a plan view. Similarly, each second film 62 has a length such that it does not overlap with the outwardly extending portion 23 of each first film 61 in a plan view.

[0106] As a result, as shown in Figures 16 and 17, in the outer extension portion 23 of the edge seal 20 (each resin film 21), the first film 61 and the second film 62 do not overlap. Therefore, as shown in Figure 17, the thickness of the outer extension portion 23 in the second alternative embodiment is smaller than the thickness of the outer extension portion 23 in the first alternative embodiment (see Figure 13).

[0107] According to the configuration shown in Figures 16 and 17, the application of the resin film 21 becomes easier, and wrinkles are less likely to occur in the edge seal 20. In addition, the amount (area or weight) of resin film 21 required is reduced.

[0108] [Other Embodiments] (1) As shown in Figure 18, the intermediate layer 12 may have a soft layer 12a and a hard layer 12b. The soft layer 12a contains more plasticizer than the hard layer 12b. As a result, the soft layer 12a is softer than the hard layer 12b. In the example shown in Figure 18, the soft layer 12a is provided on one side in the thickness direction (upper side in Figure 18) of the dimming film assembly 11. Also, in the example shown in Figure 18, two hard layers 12b are provided. The soft layer 12a is sandwiched between the hard layer 12b on one side in the thickness direction (upper side in Figure 18) and the hard layer 12b on the other side (lower side in Figure 18). The hard layer 12b on the other side (lower side in Figure 18) is thicker than the hard layer 12b on the one side (upper side in Figure 18) and holds the dimming film assembly 11.

[0109] (2) As shown in Figure 19, the extended end of the electrode 18 may be enclosed by the edge seal 20. In this case, the extended end 32a of the second portion 32 (see Figure 5) will be located inside the outer end of the edge seal 20, unlike in the above embodiment.

[0110] (3) In the above embodiment, as shown in Figure 7, each conductive film 17 is provided so as to cover the entire main surface of the corresponding transparent substrate 16 facing the light-adjusting layer 15. Therefore, each electrode 18 is electrically connected to (in other words, in contact with) the two conductive films 17. However, the present invention is not limited thereto.

[0111] As shown in Figure 20, it is not necessary for a portion of the main surface to be covered by the conductive film 17. In that case, as shown in Figure 20, it is preferable that one of the two conductive films 17 (for example, the upper conductive film 17 in Figure 20) is electrically connected (in contact) only with one of the two electrodes 18 (for example, the left electrode 18 in Figure 20), and the other of the two conductive films 17 (for example, the lower conductive film 17 in Figure 20) is electrically connected (in contact) only with the other of the two electrodes 18 (for example, the right electrode 18 in Figure 20).

[0112] (4) The first width D1 may be greater than the second width D2. That is, the extension width of the outer extension 23 may be greater than the width of the clamping portion 22 in a plan view.

[0113] (5) The first width D1 may be smaller than the third width D3. That is, the extension width of the outer extension portion 23 may be smaller than the thickness of the dimmable laminate 14.

[0114] (6) The edge seal 20 may be made of a single resin film 21, or it may be made of three or more resin films 21.

[0115] (7) The entire electrode 18 may overlap with the photochromic laminate 14 in a plan view. That is, the electrode 18 does not have to have the second portion 32.

[0116] (8) In the first or second alternative embodiment described above, a film in the shape of a combination of one first film 61 and one second film 62 (L-shaped in plan view) may be formed as a single component. In that case, a frame-shaped resin film 21 is formed by combining the two films.

[0117] Furthermore, the configurations disclosed in the above-described embodiments (including other embodiments, the same applies hereinafter) can be applied in combination with configurations disclosed in other embodiments, as long as no inconsistencies arise. In addition, the embodiments disclosed herein are illustrative, and the embodiments of the present invention are not limited thereto, and can be modified as appropriate without departing from the object of the present invention.

[0118] This invention can be used not only for vehicle glass, but also for architectural glass, screens, and the like.

[0119] 10: Dimmable laminated glass 11: Dimmable film assembly 12: Interlayer 12a: Soft layer 12b: Hard layer 13: Glass plate 14: Dimmable laminate 15: Dimmable layer 16: Transparent substrate 17: Conductive film 18: Electrode 20: Edge seal 21: Resin film 22: Clamping part 23: Outer extension part 23a: Extension end 31: First part 32: Second part 32a: Extension end 41: First partial intermediate layer 42: Second partial intermediate layer 43: Third partial intermediate layer 50: Laminate before bonding

Claims

1. A dimmable film assembly comprising: a dimmable laminate; and a frame-shaped edge seal that covers the entire edge of the dimmable laminate, wherein the dimmable laminate has a dimmable layer containing a polymer resin and liquid crystal; a pair of transparent substrates arranged to sandwich the dimmable layer; and a conductive film provided on the main surface of each transparent substrate facing the dimmable layer, and the edge seal has a clamping portion that clamps the edge of the dimmable laminate and an outward extension portion that surrounds the dimmable laminate in a plan view and extends outward from the clamping portion.

2. The dimmable film assembly according to claim 1, wherein the width of the outward extension portion is smaller than the width of the clamping portion in a plan view.

3. The dimming film assembly according to claim 1, wherein the width of the outer extension portion is greater than the thickness of the dimming laminate.

4. The dimming film assembly according to claim 1, wherein the edge seal is composed of a pair of frame-shaped resin films, the outer edges of each resin film are bonded to each other, and the outward extension is composed of the outer edges of the pair of resin films.

5. The light-adjusting film assembly according to claim 1, wherein the transparent substrate is made of polyethylene terephthalate.

6. The dimming film assembly according to claim 1, comprising an electrode sandwiched between a pair of conductive films and electrically connected to the pair of conductive films, wherein the electrode has a first portion that overlaps with the dimming laminate in a plan view and a second portion that does not overlap with the dimming laminate in a plan view.

7. The dimmable film assembly according to claim 6, wherein the extended end of the second portion is located outside the outer end of the edge seal.

8. A dimmable laminated glass comprising: a dimmable film assembly according to any one of claims 1 to 7; an intermediate layer for holding the dimmable film assembly internally; and a pair of glass plates arranged to sandwich the intermediate layer.

9. The dimmable laminated glass according to claim 8, wherein the intermediate layer comprises a soft layer and a hard layer, and the soft layer is softer than the hard layer.

10. The dimmable laminated glass according to claim 8, wherein the intermediate layer contains a coloring component.

11. The light-adjustable laminated glass according to claim 8, wherein the extended end of the outer extension is located on one side in the thickness direction of the light-adjustable film assembly, rather than at the center position in the thickness direction of the light-adjustable film assembly.

12. The dimmable laminated glass according to claim 8, wherein the outward extension extends outward from the clamping portion and toward one side in the thickness direction of the dimmable film assembly.

13. A method for manufacturing dimmable laminated glass according to claim 8, comprising: a lamination step of obtaining a pre-adhesion laminate by sequentially laminating one of the pair of glass plates, a first partial intermediate layer, a second partial intermediate layer that is frame-shaped and holds the dimmable film assembly, a third partial intermediate layer, and the other of the pair of glass plates; and a heating and pressing step of heating and pressing the pre-adhesion laminate so that the first partial intermediate layer, the second partial intermediate layer, and the third partial intermediate layer become the intermediate layers and the pair of glass plates are bonded via the intermediate layers, wherein in the lamination step, the outward extension is sandwiched between the first partial intermediate layer and the second partial intermediate layer, or between the second partial intermediate layer and the third partial intermediate layer.

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