Switchable Liquid Crystal Glazing Lamination Process
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Solution Overview
Problem
The challenge in producing laminated glazing with a switchable liquid crystal layer is the occurrence of optical defects due to polymeric substrate deformation during the lamination process, which affects adhesion and functional characteristics, leading to permanent deformation and color zones.
Innovation Solution
A laminated glazing design featuring two stacks of components, with a plastic bonding layer between exterior and intermediate glass layers, and a liquid crystal layer sandwiched between the intermediate and interior glass layers using an optically clear adhesive, ensuring proper alignment and adhesion without compromising optical clarity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a liquid crystal film is laminated using a standard lamination process, then adhesion to glass substrates is achieved, but optical defects occur due to polymeric substrate deformation
Solution Approach 1:
The patent divides the lamination process into two separate stages: first bonding the liquid crystal film to one glass substrate, then bonding the assembly to the second glass substrate. This segmentation prevents the polymeric substrate from deforming under the combined pressure and temperature conditions, eliminating optical defects while maintaining adhesion.
Solution Approach 2:
The liquid crystal film is pre-bonded to one glass substrate before the final lamination step. This preliminary action establishes a stable base that prevents deformation during subsequent processing, ensuring both adhesion and optical quality are maintained.
2Strength
If high pressure and temperature are applied during lamination, then adhesion to glass substrates is improved, but liquid crystal orientation is compromised causing color zones
Solution Approach 1:
The lamination process is segmented into two distinct bonding operations. The first bonding step occurs under controlled conditions that preserve liquid crystal orientation, while the second step completes the assembly without exposing the liquid crystals to damaging pressure and temperature conditions.
Solution Approach 2:
The liquid crystal film is pre-aligned and pre-bonded to one substrate before final assembly. This preliminary action secures the liquid crystal orientation in place, preventing subsequent deformation during the final lamination step.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of laminated glazing with a switchable liquid crystal layer that meets automotive safety standards while avoiding optical defects, ensuring efficient lamination and maintaining functional characteristics.
Implementation Method 1
liquid crystal (LC) films which can quickly change their light transmittance in response to an electrical field
Implementation Method 2
a first optically clear adhesive, and a liquid crystal layer. This second stack of components is disposed on and bonded to the first stack of components by said first optically clear adhesive
Data Source
AI summary
A switchable laminated glazing comprising two stacks of components with different lamination parameters, a first stack of components which provides the mechanical protection of the glazing, and a second stack of components with variable light transmission.