Smart Window Film Laminate With End Gap Layers Against LC Mura
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Solution Overview
Problem
Conventional transmittance variable optical laminates face issues with uneven distribution of liquid crystals during glass bonding, leading to liquid crystal mura, especially when a polarizing plate and conductive layer are in direct contact without a substrate, and there is a need for a structure that minimizes pressure on the liquid crystal layer to prevent such defects.
Innovation Solution
Incorporating a gap layer with specific properties and structure at the ends of the optical laminate, including a polyvinyl butyral film, and a two-step bonding process to minimize pressure on the liquid crystal layer during glass bonding, thereby preventing liquid crystal mura.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If glass bonding is performed on a conventional optical laminate without a substrate, then the laminate thickness is reduced, but liquid crystal mura occurs due to uneven pressure distribution
Solution Approach 1:
A substrate is introduced as an intermediary element between the glass and the optical laminate. This substrate distributes the bonding pressure uniformly across the liquid crystal layer, preventing direct contact between glass and the thin optical laminate, thereby eliminating liquid crystal mura while enabling reduced overall thickness
Solution Approach 2:
The substrate serves as a cushioning layer that absorbs and distributes bonding pressure before it reaches the liquid crystal layer. By providing this protective intermediary structure beforehand, the system prevents pressure-induced liquid crystal distribution issues during the glass bonding process
2Ease of manufacture
If the optical laminate includes a substrate for forming a conductive layer, then manufacturing is simplified, but the overall thickness increases
Solution Approach 1:
The substrate performs multiple functions simultaneously: it provides mechanical support during bonding, distributes pressure uniformly, and serves as the base for forming the conductive layer. By merging these functions into a single element, the design eliminates the need for separate substrate and conductive layer components, reducing overall thickness while maintaining ease of manufacture
3Strength
If liquid crystal layer is pressed during glass bonding, then bonding strength is improved, but liquid crystal mura occurs due to fluidity of liquid crystals
Solution Approach 1:
The substrate acts as a mediator that transmits bonding pressure uniformly to the liquid crystal layer without causing localized stress concentration. This intermediary structure enables sufficient bonding strength while preventing the uneven pressure distribution that causes liquid crystal mura
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 solution effectively prevents liquid crystal mura by reducing pressure on the liquid crystal layer, ensuring a high-quality smart window with improved appearance and reduced thickness compared to conventional laminates.
Implementation Method 1
The transmittance variable optical laminate is driven to change transmittance by driving liquid crystals in response to application of a voltage
Data Source
AI summary
Disclosed is a film laminate including: an optical laminate; and a gap layer formed at ends of the optical laminate and including a polyvinyl butyral (PVB) film, wherein the thickness of the gap layer is larger than the thickness of the optical laminate. By providing a structure in which the gap layer thicker than the optical laminate is formed in a pillar shape at ends of the optical laminate so as to minimize the pressure applied to a liquid crystal layer during glass bonding, the uneven distribution of liquid crystals due to the fluidity thereof does not occur, and thus the occurrence of liquid crystal mura may be prevented.