Smart Window Laminate Structure for Defect-Free Bonding
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Solution Overview
Problem
Conventional smart windows face issues during transport due to bending and damage of polarizing plates, generation of defects like lifting and pressing during bonding, and visibility problems due to wave-like patterns, which affect their handling and performance.
Innovation Solution
A smart window design with a specific thickness ratio of adhesive layers to optical laminate, using substrates like silicon or glass, and direct formation of transparent conductive layers on polarizing plates, along with a liquid crystal layer, to enhance handling, prevent defects, and maintain visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a polarizing plate is used in the optical laminate without supporting substrates, then the smart window can achieve light transmittance control, but the polarizing plate is easily bent and damaged during transport
Solution Approach 1:
The polarizing plate is embedded between adhesive layers that are bonded to glass substrates, creating a nested structure where the fragile polarizing plate is protected within the robust substrate-adhesive assembly, preventing bending and damage during transport while maintaining optical functionality
Solution Approach 2:
Adhesive layers are applied beforehand to the glass substrates to provide cushioning and protection to the polarizing plate before it is installed in the final assembly, preventing mechanical damage during handling and transport
2Strength
If bonding pressure is applied during bonding of the optical laminate to the substrate, then the optical laminate is securely attached, but defects such as lifting and pressing defects are generated
Solution Approach 1:
The adhesive layers are designed with specific thickness ratios (1:3 to 1:7) relative to the optical laminate thickness, creating localized variations in adhesive distribution that provide sufficient bonding strength in critical areas while preventing excessive pressure that causes defects in other areas
Solution Approach 2:
The invention optimizes the thickness parameters of the adhesive layers relative to the optical laminate, changing the physical dimensions to achieve the optimal balance between bonding strength and defect prevention, specifically setting adhesive layer thickness to 1/3 to 1/7 of the optical laminate thickness
3Ease of manufacture
If bonding is performed on the optical laminate, then the smart window structure is completed, but wave-like patterns are visible in the bonded portion reducing visibility
Solution Approach 1:
The adhesive layers are applied with controlled thickness ratios to create uniform local properties across the bonding interface, preventing the formation of wave-like patterns that would compromise visual quality while ensuring complete structural bonding
4Device complexity
If the adhesive layer thickness is not optimized, then the bonding process is simple, but the optical laminate may be damaged or defects may occur
Solution Approach 1:
The invention establishes specific parameter ranges for adhesive layer thickness (1:3 to 1:7 ratio with optical laminate thickness) that optimize protection and bonding performance while maintaining manufacturing simplicity, avoiding the need for complex adaptive bonding processes
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 design ensures easy handling during transport, prevents defect generation, and maintains excellent visibility by eliminating wave-like patterns, thus improving the overall performance of the smart window.
Implementation Method 1
an optical laminate that changes transmittance by driving liquid crystals in response to voltage application
Data Source
Figure 1~3b
Figure 3c~3e
AI summary
Disclosed is a smart window including: a first substrate; a first adhesive layer; a second substrate; a second adhesive layer; and an optical laminate embedded between the first adhesive layer and the second adhesive layer, wherein the optical laminate includes: a first polarizing plate; a first transparent conductive layer; a second polarizing plate; a second transparent conductive layer; and a liquid crystal layer provided between the first transparent conductive layer and the second transparent conductive layer, wherein the ratio of the thickness of each of the first adhesive layer and the second adhesive layer to the thickness of the optical laminate is 1.5 to 3.5. The smart window is easy to handle, prevents defects from being generated when bonding the optical laminate to the substrates, and has excellent visibility. Also disclosed is an automobile or a window for a building using the smart window.