Smart Window Lamination Pressure Sequencing to Prevent Liquid Crystal Mura
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Solution Overview
Problem
Conventional smart windows with fixed transmittance lead to issues such as difficulty in visibility at night or glare during the day due to fixed light blocking, and the manufacturing process of transmittance variable optical laminates often results in liquid crystal mura due to uneven pressure distribution during glass bonding.
Innovation Solution
A method for manufacturing smart windows involving a two-step bonding process at different pressures to minimize pressure on the liquid crystal layer, incorporating a gap and surface protective layers to prevent mura, and eliminating the need for a separate substrate for the conductive layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single-step bonding process is used to bond substrate to film laminate, then manufacturing efficiency is improved, but uneven pressure distribution occurs on the liquid crystal layer causing liquid crystal mura
Solution Approach 1:
The bonding process is divided into multiple sequential steps with different pressure levels. The patent applies a first pressure in a first step and then applies a second pressure (different from the first) in a second step, allowing each step to address specific bonding requirements while preventing uneven pressure distribution that causes liquid crystal mura.
2Strength
If high pressure is applied during glass bonding to ensure strong adhesion, then bonding strength is improved, but liquid crystal mura occurs due to excessive pressure on the liquid crystal layer
Solution Approach 1:
The bonding process dynamically adjusts pressure levels across different steps. The patent specifies applying a first pressure in a first step and then a second pressure in a second step, where the pressure values are different, allowing the process to adapt pressure to the specific needs of each bonding stage while preventing damage to the liquid crystal layer.
Solution Approach 2:
The patent changes the pressure parameter between different bonding steps. By specifying different pressure values for the first and second steps, the process optimizes bonding strength while preventing excessive pressure on the liquid crystal layer, thus avoiding liquid crystal mura.
3Device complexity
If conventional bonding process is used without multiple steps, then process simplicity is maintained, but liquid crystal mura occurs due to uneven pressure distribution
Solution Approach 1:
The bonding process is segmented into multiple steps with different pressure applications. The patent divides the bonding process into a first step with first pressure and a second step with second pressure, which may be different from the first pressure, allowing precise control over pressure distribution to prevent 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 method produces high-quality smart windows with reduced thickness and no liquid crystal mura, suitable for various applications including vehicles and buildings, by gradually bonding the laminate components to evenly distribute pressure.
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
a step of laminating a film laminate including an optical laminate, an adhesive layer, and a substrate
Data Source
AI summary
Disclosed are a method for manufacturing a smart window and a smart window manufactured thereby. The method includes: a step of laminating a film laminate including an optical laminate, an adhesive layer, and a substrate; a pre-bonding step; and a main bonding step, wherein the main bonding step includes: step a) of maintaining a laminate resulting from the pre-bonding step at a pressure of 3.5 to 10 bar for 15 to 60 minutes; and step b) of maintaining a laminate resulting from step a) at a reduced pressure of 1 bar to 3 bar for 70 to 100 minutes. According to the disclosure, the unevenness of the pressure applied to the liquid crystal layer during glass bonding may be eliminated, thereby manufacturing a smart window in which the uneven distribution of liquid crystals does not occur.