Optical Laminate Structure Without Substrates or Spacers
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Solution Overview
Problem
Conventional transmittance variable optical laminates face issues such as increased manufacturing complexity and cost, thickness, retardation, and damage due to the inclusion of separate substrates and spacers, which affect surface durability and optical uniformity.
Innovation Solution
A transmittance variable optical laminate design that includes a pressure sensitive adhesive layer with excellent elastic modulus, a polymer network in the liquid crystal layer, and direct formation of conductive layers on polarizing plates, eliminating the need for separate substrates and spacers, thereby enhancing surface hardness, antifouling properties, and reducing thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate substrate is used to form the conductive layer, then the conductive layer can be properly formed, but the manufacturing process becomes complicated, the thickness increases, and retardation occurs causing transmittance changes
Solution Approach 1:
The patent merges the substrate and conductive layer into a single integrated structure where the conductive layer is formed directly on the polarizing plate without requiring a separate substrate. This eliminates the need for additional substrates while maintaining proper conductive layer formation, thereby simplifying the manufacturing process and reducing overall thickness.
Solution Approach 2:
The polarizing plate is given multiple functions: it serves as both the optical polarizing element and the substrate for the conductive layer. This multi-functionality eliminates the need for a separate substrate, reducing device complexity and thickness while maintaining reliable conductive layer formation.
2Device complexity
If the laminate thickness is reduced, then the manufacturing complexity and cost decrease, but the optical laminate becomes damaged or surface-scratched when applied
Solution Approach 1:
The patent employs composite material structures where multiple layers (polarizing plates, liquid crystal layers, adhesive layers) are combined to create a thin yet durable laminate. The composite structure provides both reduced thickness and enhanced surface durability through the synergistic properties of different materials working together.
Solution Approach 2:
The patent utilizes thin film structures for the polarizing plates and adhesive layers that maintain flexibility and durability despite reduced thickness. These thin films are engineered to provide sufficient mechanical strength and surface durability while keeping the overall laminate thin and simple to manufacture.
3Stability of the object's composition
If a column spacer is included in the liquid crystal layer, then the cell gap can be maintained, but the manufacturing process becomes more complicated and the alignment film is damaged by UV light irradiation
Solution Approach 1:
The patent extracts and removes the column spacer from the liquid crystal layer structure. Instead of using spacers to maintain cell gap, the invention relies on the inherent properties of the liquid crystal layer and adhesive layers to maintain stable cell gap, thereby eliminating the complicated spacer formation process and associated UV light damage to alignment films.
4Device complexity
If a ball spacer is used to maintain cell gap, then the structure is simpler, but uniform cell gap cannot be maintained and short circuits occur
Solution Approach 1:
The patent removes ball spacers from the structure entirely. The cell gap uniformity is achieved through precise control of layer thicknesses and material properties without requiring any spacer elements, thereby maintaining structural simplicity while achieving superior manufacturing precision and eliminating short circuit risks.
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
The laminate achieves improved surface durability, reduced thickness, and enhanced optical uniformity while maintaining consistent transmittance control, with improved flexural resistance and simplified manufacturing.
Implementation Method 1
The transmittance variable optical laminate is driven to change transmittance by driving liquid crystals in response to application of a voltage
Implementation Method 2
Still yet another object of the present disclosure is to provide a transmittance variable optical laminate which, by including a liquid crystal layer including a polymer network, may prevent damage to an alignment film
Implementation Method 3
Another object of the present disclosure is to provide a transmittance variable optical laminate which, by including a pressure sensitive adhesive layer having excellent elastic modulus, may have excellent flexural resistance, may be prevented from being damaged
Data Source
AI summary
Disclosed is a transmittance variable optical laminate including: a first polarizing plate; a surface treatment layer formed on one surface of the first polarizing plate; a first transparent conductive layer formed on the other surface of the first polarizing plate; a second polarizing plate opposite to the first polarizing plate; a second transparent conductive layer formed on one surface of the second polarizing plate; a liquid crystal layer provided between the first transparent conductive layer and the second transparent conductive layer; and a pressure sensitive adhesive layer provided on one surface of the second polarizing plate, wherein the thickness of the first polarizing plate is equal to or greater than the thickness of the second polarizing plate, and the optical laminate has a surface hardness of H or higher. Also disclosed are a smart window comprising the laminate, and an automobile or a window for a building using the same.