CN109070550A - 薄玻璃和塑料基板之间层压的轻型阀片 - Google Patents

薄玻璃和塑料基板之间层压的轻型阀片 Download PDF

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Publication number
CN109070550A
CN109070550A CN201780026583.7A CN201780026583A CN109070550A CN 109070550 A CN109070550 A CN 109070550A CN 201780026583 A CN201780026583 A CN 201780026583A CN 109070550 A CN109070550 A CN 109070550A
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CN
China
Prior art keywords
light valve
glass
valve film
substrate
plastic sheet
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Granted
Application number
CN201780026583.7A
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English (en)
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CN109070550B (zh
Inventor
S·范沃里斯
王东燕
S·M·斯洛瓦克
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Research Frontiers Inc
RES FRONTIERS Inc
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Research Frontiers Inc
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    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G02B1/18—Coatings for keeping optical surfaces clean, e.g. hydrophobic or photo-catalytic films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
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    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
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Abstract

本发明公开了一种光阀，包括：具有两个相对的外表面的膜；在每一相对的外表面的至少一部分上的第一层聚合物夹层材料；第一对基板，一个粘附到所述光阀膜第一外表面上的夹层材料上，第二个粘附到所述光阀膜所述第二外表面上的夹层材料上，这些基板由塑料制成；第二层聚合物夹层材料，其施加到所述第一对基板中的每一个基板的外表面的至少一部分上；以及第二对基板，一个粘附到所述第一对基板中的一者的外表面上的夹层上，第二个粘附到所述第一对基板的第二个的外表面上的夹层材料上，所述第二对基板由玻璃制成。

Description

薄玻璃和塑料基板之间层压的轻型阀片
相关申请的交叉引用
本专利申请为非临时申请并且要求于2016年5月3日递交的、由Seth VanVoorhees、Dongyan Wang和Steven M.Slovak申请的、名称为“SUSPENDED PARTICLE DEVICEFILMS LAMINATED BETWEEN THIN GLASS AND PLASTIC SUBSTRATES”、申请号为62/330,967的美国临时专利的优先权。该专利申请的全部内容通过引用并入本文中。
技术领域
本发明涉及用于光阀的膜和膜层压，其包括液体颗粒悬浮液。悬浮颗粒装置在本文中通常称为SPD光阀，或简称为SPD。聚合物分散的液晶光阀膜通常称为PDLC。膜层压在薄玻璃和塑料基板的组合之间。
一般背景
已知光阀用于调制光已有八十多年。它们已被提议用于以下时间的许多应用，包括例如字母数字显示器和电视显示器；用于灯具、照相机、显示器和光纤的过滤器；以及窗户、天窗、玩具、遮阳板、眼镜、护目镜、镜子、后视镜，光管等，以根据具体情况控制通过其或从其反射的光量。窗户的例子包括但不限于商业建筑、温室和住宅的建筑窗户；用于机动车辆、船只、火车、飞机和航天器的窗户、遮阳板和天窗；用于门的窗户，包括窥视孔，以及用于诸如烤箱和冰箱之类的器具的窗户，包括其隔间。
如本文所用，术语“光阀”是指由间隔开一小段距离的两个壁形成的格室，其中至少一个壁是透明的。壁上具有电极，通常为透明导电涂层形式。可选地，导电涂层可以以图案的形式沉积在壁上，使得可以选择性地激活光阀的不同部分。另外，壁上的电极可以在其上具有薄的透明电介质外涂层。格室包含光调制元件(在本文中有时称为可激活材料)，其可以但不限于是颗粒的液态悬浮液，或者可选地，整个元件的全部或一部分可包括塑料膜，颗粒的液态悬浮液的液滴分布其中。
对于SPD，液体悬浮液(在本文中有时称为液体光阀悬浮液或简称为光阀悬浮液)包含悬浮在液体悬浮介质中的小颗粒。在没有施加电场的情况下，SPD光阀的液体悬浮液中的颗粒可能由于布朗运动而呈现随机位置。因此，进入格室的光束被反射、透射或吸收，这取决于格室结构、颗粒的性质和浓度以及光的能量含量。因此，使用这种类型的粒子运动的光阀在关闭状态下相对较暗。然而，当施加通过光阀中的液体光阀悬浮液的电场时，颗粒变得对齐，并且对于许多悬浮液，大部分光可以通过格室。因此，光阀在ON状态下相对透明。可替选地，液体悬浮介质中的颗粒可以通过其他类型的电泳粒子运动实现ON和OFF状态。ΔT定义为ON和OFF状态之间可见光透射的差异。
对于许多应用，对于全部或部分可激活材料(即光调制元件)优选是塑料膜而不是液体悬浮液。例如，在用作可变透光窗的光阀中，其中分布有液体悬浮液液滴的塑料膜优于单独的液体悬浮液，因为流体静力压效应，通过使用膜可以避免例如与光阀悬浮的高柱相关的膨胀，并且也可以避免可能的泄漏风险。使用塑料膜的另一个优点是，在塑料膜中，颗粒通常仅存在于非常小的液滴中，因此，当膜被电压反复激活时，颗粒不会明显聚集。
本文所用的术语“SPD光阀膜”是指包括用于或意图用于光阀的颗粒悬浮液的一个或多个膜或薄片。这种光阀膜通常包括含有分散的颗粒的一种或多种液体的不连续液滴相(液体光阀悬浮液)，这种不连续相分散在整个固体连续基板相中，所述相包封在一个或多个刚性或柔性固体膜或片内。上述组合相被称为固化的SPD乳液，其形成光阀膜的一部分，有时也称为膜或膜层。SPD光阀膜和/或光阀膜的层压件还可包括一个或多个附加层，例如但不限于膜、涂层、片或其组合，其可为光阀膜提供一个或多个例如，(1)耐刮擦性，(2)保护免受防紫外线辐射，(3)红外能量反射，(4)将所施加的电场或磁场传输给可激活材料的导电性，(5)电介质外涂层，(6)颜色着色，(7)光伏，和(8)声学控制。附加层可以用本领域技术人员已知的压敏粘合剂(PSA)夹层粘附到所述光阀膜上，或者在层压过程中使用额外的夹层夹层，如下面发明的发明内容中所讨论的。
用于SPD膜的通常(但非限制性)构造具有五层，即，从一侧到另一侧：(1)第一聚对苯二甲酸乙二醇酯(“PET”)塑料片，方便地，厚度为5-7密耳，(2)在所述第一PET片的内表面上，非常薄的透明的氧化铟锡(“ITO”)导电涂层或替代的导电涂层，其用作或能够用作电极，(3)固化(即交联)SPD乳液层，通常厚度为2-5密耳，以及(4)第二ITO涂层，其用作或能够用作(5)第二PET塑料基板的内表面上的电极。如前所述，可任选地，将提供其他功能的附加层添加到上述示例性SPD膜中。通常，诸如铜箔、导电织物等的材料固定到电极上，使得材料延伸超出SPD膜的周边，以便于将膜方便地连接到合适的电压电源。此外，SPD膜可以例如层压有透明的热熔粘合剂膜和/或玻璃或更厚的透明塑料薄片，以提供强度和刚性，并保护组合单元的各个部分免受环境应力的影响，否则可能损害其性能特点。例如，参见转让给本发明的受让人的美国专利7,361,252。
美国专利5,409,734举例说明了一种非交联的光阀膜，其通过从均相溶液中相分离而制成。通过乳液的交联(固化)制成的光阀膜也是已知的。本发明的膜特别涉及后一种膜的用途，即包含通过交联乳液形成的层的膜，以及由此制备的层压膜。例如，参见美国专利5,463,491和5,463,492、以及7,361,252，它们都转让给了本发明的受让人。各种类型的SPD乳液及其固化方法描述在美国专利6,301,040、6,416,827和6,900,923B2中，所有这些专利均转让给了本发明的受让人。这些膜及其变型可以通过将膜暴露于(1)紫外线辐射，(2)电子束或(3)热，来实现交联固化。这种来自美国专利6,900,923B2实施例5的膜的非限制性实例通过如下制备：将0.002g Irgacure 819(Ciba Specialty Chemicals)光引发剂(“PI”)溶解在2mL氯仿中，并加入到实施例1中所述的1g基板聚合物中。PI溶液与基板聚合物充分混合，通过将混合物置于真空烘箱内在60℃下达30分钟除去氯仿溶剂。向其中加入0.62g含有甲基丙烯酸月桂酯/HEMA悬浮聚合物的聚碘化物晶体糊剂(0.56g，在该专利的实施例3中合成)。将所得混合物充分混合，并使用刮刀，将所得乳液涂布到导电涂布的聚酯基板上，作为2密耳厚的涂层，其与空白导电涂布的聚酯基板配合，并用紫外线辐射固化(8600mJ/cm2/min)持续2分30秒。本申请中引用的所有专利和专利申请以及其他参考文献均通过引用并入本文。
各种液体光阀悬浮液在本领域中是公知的，并且这种悬浮液可根据其中本领域技术人员熟知的技术容易地配制。如上所述，术语液体光阀悬浮液，当在本文中使用时，是指其中分散有多个小颗粒的液体悬浮介质。液体悬浮介质包括一种或多种非水电阻液体，其中优选地，溶解至少一种类型的聚合物稳定剂，其作用是降低颗粒聚集的趋势并使颗粒保持分散和悬浮。
可用于本发明的液体光阀悬浮液可包括先前提出的任何所谓的液体悬浮介质现有技术，其用于光阀中以悬浮颗粒。本领域已知的可用于本发明的液体悬浮介质包括但不限于美国专利4,247,175、4,407,565、4,772,103、5,409,734、5,461,506、5,463,492和6,936,193B2中公开的液体悬浮介质，其公开内容通过引用并入本文。通常，选择通常溶解在其中的悬浮介质和/或聚合物稳定剂中的一种或两种，以使悬浮颗粒保持在重力平衡状态。
当使用时，聚合物稳定剂可以是单一类型的固体聚合物，其与颗粒表面结合，但也溶解在包含液体悬浮介质的一种或多种非水液体中。可替选地，可以有两种或更多种固体聚合物稳定剂作为聚合物稳定剂体系。例如，颗粒可以涂有第一种固体聚合物稳定剂(例如硝化纤维素)，实际上在溶解时为颗粒提供平滑表面涂层，以及一种或多种其它类型的固体聚合物稳定剂，当溶解时与第一种固体聚合物稳定剂结合或相关，并且还溶解在液体悬浮介质中以为颗粒提供分散和空间保护。而且，液体聚合物稳定剂可以有利地使用，特别是在SPD光阀膜中，如例如美国专利5,463,492中所述。
无机和有机颗粒可以用在光阀悬浮液中，并且这种颗粒可以是在电磁光谱的可见部分中吸收光或反射光。
传统的SPD光阀通常使用胶体尺寸的颗粒。如本文所用，术语胶体是指颗粒通常具有的最大尺寸为平均1微米或更小。优选地，用于或意图用于SPD光阀悬浮液的大多数多卤化物或非多卤化物类型的颗粒具有的最大尺寸平均0.3微米或更小，更优选地平均小于蓝光波长的一半(即，小于2000埃)，以保持光散射极低。
光阀膜的另一个例子是PDLC膜。与SPD膜类似，包含液晶的PDLC膜分散在液体聚合物中，随后聚合物凝固或固化。随着聚合物从液体变为固体，液晶变得与固体聚合物不相容，并在整个固体聚合物中形成液滴。固化条件影响液滴的尺寸，进而影响包括这种膜的“智能窗”的最终操作性能。通常，聚合物和液晶的液体混合物放置在两个玻璃或塑料基板之间，在其内部包括透明导电材料的薄层，随后固化聚合物，从而形成“智能窗”的基本夹层结构。该结构实际上是电容器。
在这种情况下，来自电源的电极附着到透明电极。在没有施加电压的情况下，液晶随机地排列在液滴中，导致光在通过智能窗组件时散射。这导致半透明的“乳白色”外观。当向电极施加电压时，在玻璃上的两个透明电极之间形成的电场使液晶对齐，允许光以非常小的散射穿过液滴并导致透明状态。
本发明的背景技术
在一些情况下，如上所述，需要SPD层压件或PDLC层压件，其中使用透明的热熔粘合剂膜(夹层)，将膜夹在透明玻璃或塑料片之间。存在这样的应用，例如但不限于飞机、建筑和汽车窗户，其中还需要用于形成层压件的轻质层压件，其还防止水分经由基板的面进入层压件的内部。因此，本发明的目的是构造一种层压件，该层压件包括在膜的两个相对侧上的薄的、轻质玻璃基板和塑料基板。
SPD膜现有技术的缺陷
SPD膜，特别是包含多碘化物颗粒的那些SPD膜对水分敏感，因为如果水分与固化的SPD乳液接触，它会导致SPD膜的降解，包括SPD膜的变色和其光学性能的降低，例如ΔT的损失。水分可以通过层压件的边缘进入SPD层压件。因此，已经开发了用于密封SPD层压件边缘的材料和方法，以防止水分渗入其中，如例如美国专利8,670,173和美国专利公开US2016/0282645A1中所述。
与玻璃相比，塑料(诸如丙烯酸树脂和聚碳酸酯)更容易受到水分渗透。因此，仅由塑料基板组成的SPD层压件可以允许水分渗透通过SPD层压件的相对两面。然而，与通过玻璃基板制成的SPD层压件相比，用塑料基板制成的SPD层压件具有重量轻、改善的紫外线防护和抗冲击性的优点。
发明内容
在一个实施方案中，光阀层压件包括薄的轻质玻璃和塑料基板。这些是在高温、高湿度环境中制备和测试的，以表明薄玻璃防止水分通过层压件的表面进入层压件。玻璃基板以及塑料基板(作为包括光阀层压件的外基板组或内基板组)的位置由本领域技术人员所熟知的具体预期应用决定。可用于本发明的玻璃的实例包括但不限于钢化玻璃、退火玻璃、低铁玻璃、低辐射玻璃、UV阻挡玻璃和化学强化玻璃，例如由康宁公司生产的玻璃以及也由康宁生产的玻璃。玻璃基板的厚度应该在0.55mm至2.0mm的范围内，优选地在0.55mm至1.10mm的范围内。
此外，作为层压件的外部基板的抗微生物玻璃与一种或多种塑料基板的组合使用，将赋予所得光阀有益的健康安全性能。抗微生物剂破坏或抑制微生物，特别是病原微生物的生长。抗微生物玻璃与离子银组分一起配制作为玻璃表面上的抗微生物剂。这种健康安全特性在许多应用中是有用的，例如在医疗设施和博物馆展示中，以通过与光阀接触来减少有害细菌的转移。塑料基板提供强度和刚性，以及对光阀层压件的紫外线保护。
如本申请中所用，可用于本发明的塑料包括但不限于聚碳酸酯、聚甲基丙烯酸甲酯(丙烯酸)、聚苯乙烯和聚丙烯。塑料基板的厚度应该在1.0mm至10.0mm的范围内，优选在1.0mm至5.0mm之间。
在需要柔性SPD层压件的情况下，用于层压件的玻璃和塑料基板应各自具有0.10至0.55mm的厚度，优选0.10mm至0.20mm，以允许弯曲最终光阀层压件以用于弯曲应用，而不会损坏光阀层压件。
聚合物夹层材料的片材放置在：(1)膜和层压在其上的最里面的基板之间，即，无论它是由玻璃或塑料形成、涂层玻璃或涂层塑料(见下文)；以及(2)在层压到膜上的最内和最外基板之间。该夹层材料的目的是在层压件形成期间和形成之后，将各种层压件组件保持在一起。在塑料基板的情况下，塑料基板由软化点比聚合物夹层的软化点明显高(即至少10℃)的材料组成，聚合物夹层在层压过程中加热和冷却，以形成层压件。这可以防止塑料片在层压过程中软化和变形。例如，丙烯酸树脂，聚甲基丙烯酸甲酯基板(Tg或软化点为105℃)可用于具有乙烯醋酸乙烯酯(EVA)夹层的层压件中，因为EVA在80℃下熔化。然而，如果夹层是聚乙烯醇缩丁醛(PVB)，则丙烯酸树脂基板不能用作基板，因为PVB在120℃下熔化。另一方面，聚碳酸酯基板(Tg或软化点为157℃)可以安全地与EVA或PVB一起使用。可用于形成本发明聚合物夹层的另一种材料是聚氨酯。
另一个实施方案涉及使用包含上述类型和尺寸的塑料的塑料基板，所述塑料基板在一侧或两侧涂有至少一层薄玻璃，每个所述玻璃层的厚度为0.5微米至2.4微米，优选地为0.5微米至1.5微米，用于形成包括光阀层压件的基板。文献报道玻璃可以涂覆在塑料基板上。例如，“Chamberless plasma deposition of glass coatings on plastics”(GRNowling，M Yajima等人，等离子体源科学技术，14，(2005年)，477页-484页)报道“将高质量玻璃涂覆在塑料上…”，“…一种运行时不需要腔室的大气层等离子体处理方法使得无基板尺寸或者大小的限制。”和“通过“穷人的”ALD方法在玻璃薄膜上涂覆塑料”声明“在环境压力下，不需要真空系统……”和“它可以在低温、室温下运行，当然低于100℃”(参见网站地址：otd.harvard.edu/explore-innovation/technologies/coating-plastics-with-thin-films-of-glass-by-a-poor-mans-ald-method/)。该实施方案的塑料基板具有与如上所述的厚度范围1.0mm至10.0mm相同的范围，优选地为1.0mm至5.0mm。
在另一个实施方案中，上述类型的玻璃基板已经在一侧或两侧涂有至少一层塑料(每个所述涂层的厚度为1微米至25微米，优选地为10微米至25微米)可用作用于形成光阀层压件的基板。玻璃基板任一侧的塑料涂层的厚度通常相等但不一定相等。如上所述，用于涂覆玻璃基板的一种或者多种塑料由具有的熔点比聚合物夹层的熔点明显高(即至少10℃)的材料组成，聚合物夹层在层压过程中加热和冷却，以形成层压件。
具体实施方式
厚度为0.55mm和1.10mm的玻璃板从纽约康宁公司康宁玻璃获得、其具有的商品名为Glass。此外，以商品名OP-2销售的3.175mm厚的丙烯酸树脂塑料片从新泽西帕西波尼的Evonik Performance Materials获得。1.5875mm厚的耐冲击透明聚碳酸酯塑料片从新泽西代顿的McMaster-Carr获得。厚度为0.24mm的Glass NMRtubes从新泽西的瓦恩兰的Wilmad Glass获得。厚度为2.38mm的标准玻璃板用于控制层压件。
在NMR玻璃管、标准2.38mm厚玻璃层压件和用上述玻璃和塑料基板制备的层压件上执行初始加热/高湿度测试，以确定这些样品防止水分渗透的能力。如此制备的层压件将湿气敏感性指示条包含在层压堆叠中，该层压堆叠位于层压件内与SPD膜相邻的位置。指示条也密封在NMR管内。用于这些层压件的指示条是湿度检测条，20％-80％，部件号33813-2080，从www.indigo.com网站的Indigo Instruments获得。
如前述美国专利7,361,252中所述制备标准SPD光阀层压件。在转让给本发明的受让人的美国专利7,361,252中发现了层压SPD膜的方法的非限制性概述，该专利涉及产生“堆叠”，其依次包括第一玻璃板、第一层夹层板、包括固化的SPD乳液的SPD膜，其夹在两个涂有ITO的PET基板片之间，其中铜箔母线附接到ITO涂层并从ITO涂层突出，第二层夹层板和第二玻璃板，它们基本上彼此一致地定位。将堆叠放入压片机(Carver Press)内的真空袋中并施加强真空(大于29英寸汞柱)。然后，将压机的压板布置成接触未层压的堆叠的外侧，并将它们的温度升高以影响堆叠内的夹层的熔化。然后，冷却压板，以固化夹层，该夹层将堆叠粘附到SPD层压件中。
此外，还制备了用玻璃和塑料基板形成的层压件。这些层压件之一的铺层(layup)的非限制性实例是薄玻璃/夹层/塑料/夹层/SPD膜/夹层/塑料/夹层/薄玻璃。如本文所用，“薄”玻璃板是指厚度≤1.10mm的玻璃板。
为了防止水分进入通过样品层压件的边缘，将聚异丁烯(PIB)的框架结合到层压件中，如美国公开US 2016/0282645 A1中所述。将聚异丁烯耐水性材料的框架集成到堆叠中，该堆叠从玻璃的外边缘开始直到堆叠中与SPD膜相邻的位置。因此，考虑到PIB框架的存在，渗透到层压件中的任何水分都可归因于水分通过层压件的面(而不是通过层压件的边缘)进入层压件。使用两个框架使得在层压件外突出的铜箔在两侧被PIB材料包围。
使用由Byk-Gardner制造的色球可见分光光度计(Color Sphere VisibleSpectrophotometer)，通过向层压件的突出的母线施加100V/60Hz的电场，测量每个SPD光阀层压件的初始ΔT或可见光透射率范围(ON状态透射率-OFF状态透射率),以用于获得ON状态透射率。在湿度测试期间定期重复这些光学测量。
如在转让给本发明的受让人的美国公开US 2016/0282645 A1中所公开的，用于在高温/高湿度环境中测试样品的过程如下：将SPD层压件、没有SPD膜的层压件和其他具有不同配置的样品放置在干燥器的上部，干燥器的下部具有水槽。带孔的陶瓷板防止样品与干燥器底部的水直接接触。将此干燥器放置在60℃的烘箱中产生高温、高湿度环境，SPD膜和SPD层压件通常不会暴露在这样的环境。然而，制造了这些极端条件以便在合理的时间段内获得有意义的测试结果。将含有样品的水分饱和的干燥器置于60℃的烘箱中，针对以下一种或多种，定期评价样品：1)由湿度指示条检测到的层压件内存在的水分，2)层压件内的清晰夹层外观从透明到浑浊/模糊的变化，以及3)层压件内SPD膜的ΔT变化。正(+)ΔT变化表明，在测试期间，暴露于60℃温度期间，SPD膜的透光范围增加。这是由于聚碘化物颗粒在SPD膜内的分散得到改善，不应视为功能性损失。
结果和讨论
表格1
60℃高湿度测试结果(玻璃、玻璃/塑料层压件)
所有层压件(lam)均采受PIB框架保护：
“Glass0.55-RegularGlass lam”也被标记为“薄厚玻璃lam”。
“Glass0.55”是厚度为0.55mm的Glass。
“Glass1.10”是厚度为1.10mm的Glass。
“标准玻璃”的厚度为2.38mm。
是3.175mm厚的丙烯酸塑料。
“聚碳酸酯”塑料的厚度为1.5875mm。
表1提供了含有层压件的非SPD膜和其他样品的60℃高湿度测试结果。使用NMR玻璃管的测试表明，低至0.24mm的玻璃厚度作为防潮层仍然非常有效。例如，火焰密封的0.24mm厚的NMR玻璃管已经在60℃高湿度室中达435天，没有观察到湿气指示带的颜色变化，并且测试继续。
将Glass基板制成的双层层压件(0.55mm厚和1.10mm厚)在60℃高湿室中暴露247天，然后观察到颜色变化，并且这些层压件中的湿气指示带和清晰夹层变得模糊。表1中的标记为“(薄-厚)”的层压件由0.55mm薄玻璃和2.38mm标准玻璃组成，并且在每个玻璃基板附近放置单独的湿度指示条。如果水分首先通过薄玻璃基板，则在与厚玻璃基板相邻的湿度指示条改变颜色之前，与薄玻璃相邻的湿度指示条将改变颜色。将该层压件暴露在60℃的高湿度室中284天，然后观察到两个湿气指示条的颜色变化。相反，层压件内的指示条用丙烯酸树脂基板(Acrylite/)和聚碳酸酯基板(聚碳酸酯/聚碳酸酯)制成在60℃高湿度室中分别暴露6天和2天后变色。这两种层压件中的清晰夹层变得模糊。这表明，不同厚度的塑料基板允许水分在短时间后渗透。
最后，采用以下配置制成的丙烯酸树脂和玻璃混合层压件：Glass0.55/Glass0.55，分别在60℃高湿度室中暴露163天和181天，然后观察湿气指示条的颜色变化，这些层压件中的清晰夹层变得模糊。上述混合层压件中的一者还具有从层压件突出的铜箔母线，以模拟在层压件内部存在的SPD膜。如上所述，该层压件在观察到湿气指示条变色之前已经在60℃高湿室中181天。在该层压件上使用双框架PIB，以防止水分进入层压件的边缘，在该边缘处，铜箔离开层压件。数据清楚地表明，该测试的60℃温度和高湿度环境在仅仅暴露几天后，允许水分通过塑料基板层压件的表面。以下事实证实玻璃是防潮的理想选择：最薄的全玻璃0.24mm NMR管样品测试持续435天而不会使得水分渗透。尽管单独使用玻璃或玻璃和塑料制成的层压件最终显示出层压件内存在水分，但是湿气指示条检测所需的最少161天的事实强烈表明水分通过层压件的边缘进入层压件。如上所述，尽管PIB框架被结合到层压件中以防止水分通过层压件的边缘进入，但是测试条件的严苛性可能使水分最终在基板之间通过并通过层压件的边缘。相同的解释也适用于下面表2的适用结果。
表2
60℃高湿度测试结果(SPD：玻璃，玻璃/塑料层压件)
所有层压件(lam)均为双PI B保护框架，并且具有从边缘突出的铜导线。
“Glass0.55”是Glass，其厚度为0.55mm。
“Glass1.10”是Glass，其厚度为1.10mm。
“标准玻璃”是厚度为2.38mm的标准玻璃。
是3.175mm厚的丙烯酸塑料。
表2提供了含SPD膜的层压件的60℃高湿度测试结果。结果类似于表1中含有非SPD的层压件的结果。例如，在60℃的高湿度室暴露306天的玻璃基板(玻璃/SPD/玻璃)制成的SPD层压件没有观察到湿气指示条的颜色变化，这些层压件中的清晰夹层没有变得模糊，并且层压件内的SPD膜已经获得了5.60的透射点。暴露392天后，观察到湿气指示条的颜色变化，层压件中的清晰夹层变得模糊，层压件内的SPD膜损失了14.02个透射点。如上面表1的结果所述，通过层压件边缘进入的水分是造成392天暴露结果的原因。
采用以下配置制成的玻璃和丙烯酸树脂混合层压件：Glass0.55//SPD/Glass0.55，已经在60℃高湿度室中保持141天，湿气指示条没有观察到颜色变化，层压件中的清晰夹层不变得模糊，层压件内的SPD膜增加了4.18个透光点。曝光212天后，观察到湿气指示条发生颜色变化，层压件中的清晰夹层变得模糊，但是层压件内的SPD膜仍然具有5.30的透射率。最后，在暴露227天后，层压件内的SPD膜在施加电压时不再起作用。据信，水分存在于层压件内部15天最终导致故障，例如短路，这使得SPD样品无法操作，并且我们能够测量SPD膜的可见透射率，这将是透光点的显著损失。
在使用以下配置制成的丙烯酸树脂和玻璃混合层压件的情况下：Glass0.55/SPD/Glass0.55/层压件已经在60℃的高湿度室中达55天，没有观察到湿气指示条的颜色变化，但是层压件中的清晰夹层变得模糊，层压件内的SPD膜损失了2.82个透射点。由于这种层压件具有塑料作为最外层基板，所以水分能够渗透穿过并使和Glass之间的清晰夹层变得混浊，这被认为是SPD膜测量的透射损失的原因。然而，Glass防止水分进一步渗透到SPD膜定位在其中的层压件。在暴露306天后，仍然没有观察到湿气指示条的颜色变化，层压件中的清晰夹层保持模糊，并且层压件内的SPD膜现在损失了8.70个透射点。最后，在暴露392天后，观察到湿气指示条的颜色变化，并且当施加电压时，层压件中的SPD膜不再起作用，这可能是由于短路造成的。对于需要具有抗冲击和抗刮擦外表面的SPD层压件的应用，这种结构是优选的。
最后，对于/SPD/层压件，在60℃高湿度室中暴露仅仅6天后，观察到湿气指示条的颜色变化，层压件中的清晰夹层变得模糊，并且在暴露27天后，在层压件内的SPD膜已经损失了6.50个透射点。这证实了仅用塑料基板制成的SPD层压件可以快速地使水分通过基板表面，并对SPD层压件的外观和性能产生不利影响。这些结果表明，用薄玻璃和塑料层压件组合制成的SPD层压件可保护SPD膜免受由于湿气暴露导致的降解，同时，提供轻质、高强度、抗冲击和紫外线防护。

Claims (37)

1.一种层压光阀膜，形成光阀的光调制元件，所述层压膜包括：
a)具有相对的第一外表面和第二外表面的光阀膜；
b)施加到所述光阀膜的所述相对的第一外表面和第二外表面的每一者的至少一部分上的第一层聚合物夹层材料；
c)第一对基板，其中所述第一对基板中的一个施加并粘附到施加在所述光阀膜的相对的所述第一外表面上的夹层材料上，并且所述第一对基板中的第二个施加并粘附到施加在所述光阀膜的相对的所述第二外表面上的夹层材料上，所所述一对基板由选自包括塑料和玻璃的组的材料形成；
d)施加到所述第一对基板中的每一个基板的外表面的至少一部分上的第二层聚合物夹层材料；以及
e)第二对基板，其中所述第二对基板中的一个被施加并粘附到施加在施加在所述第一对基板中的一者的外表面上的夹层上，并且所述第二对基板中的第二个被施加并粘附到施加在所述第一对基板的第二个的外表面上的夹层材料上，所述第二对基板由选自包括塑料和玻璃的组的材料形成，其条件是，当所述第一对基板由塑料形成时，所述第二对基板由玻璃形成，反之亦然。
2.根据权利要求1所述的层压光阀膜，其中所述膜包括：
a)固化的悬浮颗粒装置乳液，其具有分布在整个所述固化的乳液中的多个未交联的液体光阀悬浮液液滴；以及
b)第一塑料片和第二塑料片，所述第一塑料片和第二塑料片位于所述固化的乳液的外部并夹住所述固化的乳液，其中，一层薄的、透明的导电涂层位于每个所述第一塑料片和第二塑料片的内表面上，与所述固化的乳液相邻，所述涂层用作电极，以使得施加的电场通过所述固化的乳液。
3.根据权利要求1所述的层压光阀膜，其中所述膜包括：
a)含有分散在固化的聚合物中的液晶的液滴；以及
b)第一塑料片和第二塑料片，所述第一塑料片和第二塑料片位于所述固化的聚合物的外部并夹住所述固化聚合物，其中，一层薄的、透明的导电涂层位于每个所述第一塑料片和第二塑料片的内表面上，与所述固化的乳液相邻，所述涂层用作电极，以使得施加的电场通过所述固化的乳液。
4.根据权利要求1所述的层压光阀膜，其中所述光阀膜还包括固定到所述电极的导电材料，使得所述材料延伸超出所述层压光阀膜的周边，以允许连接所述膜到合适的电压电源。
5.根据权利要求1所述的层压光阀膜，其中所述第一对基板由玻璃形成，所述第二对基板由塑料形成。
6.根据权利要求1所述的层压光阀膜，其中所述第一对基板由塑料形成，所述第二对基板由玻璃形成。
7.根据权利要求1所述的层压光阀膜，其中，用于形成所述基板的所述玻璃选自包括以下的组：钢化玻璃、退火玻璃、低铁玻璃、低辐射玻璃、紫外阻挡玻璃、化学强化玻璃和抗菌玻璃。
8.根据权利要求1所述的层压光阀膜，其中每个所述玻璃基板的厚度范围为0.55mm至2.0mm。
9.根据权利要求8所述的层压光阀膜，其中每个所述玻璃基板的厚度范围为0.55mm至1.10mm。
10.根据权利要求1的层压光阀膜，其中，用于形成所述基板的所述塑料选自包括以下的组：聚碳酸酯、聚甲基丙烯酸甲酯、聚苯乙烯和聚丙烯。
11.根据权利要求1所述的层压光阀膜，其中每个所述塑料基板的厚度范围为1.0mm至10.0mm。
12.根据权利要求11所述的层压光阀膜，其中每个所述塑料基板的厚度范围为1.0mm至5.0mm。
13.根据权利要求1所述的层压光阀膜，其中所述玻璃基板和所述塑料基板各自具有范围从0.10mm至0.55mm的厚度，以允许所述层压光阀膜弯曲，以用于弯曲应用而不损坏所述膜。
14.根据权利要求1所述的层压光阀膜，其中用于形成所述塑料基板的所述材料的软化点比所述聚合物夹层材料的软化点高至少10℃。
15.根据权利要求14所述的层压光阀膜，其中所述聚合物夹层材料选自包括以下的组：乙烯醋酸乙烯酯(EVA)、聚乙烯醇缩丁醛(PVB)和聚氨酯。
16.一种层压光阀膜，形成光阀的光调制元件，所述层压膜包括：
a)具有相对的第一外表面和第二外表面的光阀膜；
b)施加到所述光阀膜的所述第一外表面和第二外表面的至少一部分上的聚合物夹层材料的层；以及
c)基板对，其中所述基板对中的一个施加并粘附到施加在所述光阀膜的相对的所述第一外表面上的夹层材料上，并且所述基板的第二个施加并粘附到施加在所述光阀膜的相对的所述第二表面上的夹层材料上，所述基板的每一者由在塑料的一侧或者两侧涂覆至少一层玻璃图层而形成，所述玻璃涂层的厚度范围为0.5微米至2.4微米。
17.根据权利要求16所述的层压光阀膜，其中每个所述基板的塑料部分的厚度范围在1.0mm至10.0mm之间。
18.根据权利要求17所述的层压光阀膜，其中每个所述基板的所述塑料部分的厚度范围在1.0mm至5.0mm之间。
19.根据权利要求16所述的层压光阀膜，其中每个所述基板上的所述玻璃涂层的厚度范围为0.5微米至1.5微米。
20.根据权利要求16所述的层压光阀膜，其中所述膜包括：
a)固化的悬浮颗粒装置乳液，其具有分布在整个所述固化的乳液中多个未交联的液体光阀悬浮液液滴；以及
b)第一塑料片和第二塑料片，所述第一塑料片和第二塑料片位于所述固化的乳液的外部并夹住所述固化的乳液，其中，一层薄的、透明的导电涂层位于每个所述第一塑料片和第二塑料片的内表面上，与所述固化的乳液相邻，所述涂层用作电极，以使得施加的电场通过所述固化的乳液。
21.根据权利要求16所述的层压光阀膜，其中所述膜包括：
a)含有分散在固化的聚合物中的液晶的液滴；以及
b)第一塑料片和第二塑料片，所述第一塑料片和第二塑料片位于所述固化的聚合物的外部并夹住所述固化聚合物，其中，一层薄的、透明的导电涂层位于每个所述第一塑料片和第二塑料片的内表面上，与所述固化的乳液相邻，所述涂层用作电极，以使得施加的电场通过所述固化的乳液。
22.根据权利要求16所述的层压光阀膜，其中所述光阀膜还包括固定到所述电极的导电材料，使得所述材料延伸超出所述层压光阀膜的周边，以允许连接所述膜到合适的电压电源。
23.根据权利要求16所述的层压光阀膜，其中，用于涂覆所述塑料的所述玻璃选自包括以下的组：钢化玻璃、退火玻璃、低铁玻璃、低辐射玻璃、紫外阻挡玻璃、化学强化玻璃和抗菌玻璃。
24.根据权利要求16的层压光阀膜，其中用于形成所述基板的所述塑料选自包括以下的组：聚碳酸酯、聚甲基丙烯酸甲酯、聚苯乙烯和聚丙烯。
25.根据权利要求16的层压光阀膜，其中用于形成所述塑料基板的所述材料的软化点比所述聚合物夹层材料的软化点高至少10℃。
26.根据权利要求25所述的层压光阀膜，其中所述聚合物夹层材料选自包括以下的组：乙烯醋酸乙烯酯(EVA)、聚乙烯醇缩丁醛(PVB)和聚氨酯。
27.一种层压光阀膜，形成光阀的光调制元件，所述层压膜包括：
a)具有相对的第一外表面和第二外表面的光阀膜；
b)施加到所述光阀膜的所述第一外表面和第二外表面的至少一部分上的聚合物夹层材料的层；以及
c)基板对，其中所述基板对中的一个施加并粘附到施加在所述光阀膜的相对的所述第一外表面上的夹层材料上，并且所述基板的第二个施加并粘附到施加在所述光阀膜的相对的所述第二表面上的夹层材料上，所述基板的每一者由在玻璃的一侧或者两侧上涂覆至少一层塑料涂层形成，每个所述基板的所述玻璃的厚度范围为0.55mm至2.0mm。
28.根据权利要求27所述的层压光阀膜，其中所述玻璃任一侧的所述塑料涂层可以具有相同的厚度，或者其中一侧的厚度可以与另一侧的涂层的厚度不同。
29.根据权利要求27所述的层压光阀膜，其中每个所述基板上的所述塑料涂层的厚度范围从1微米至25微米。
30.根据权利要求29所述的层压光阀膜，其中，每个所述基板上的所述塑料涂层的厚度范围为10微米至25微米。
31.根据权利要求27所述的层压光阀膜，其中所述膜包括：
a)固化的悬浮颗粒装置乳液，其具有分布在整个固化乳的液中的多个未交联的液体光阀悬浮液液滴；以及
b)第一塑料片和第二塑料片，所述第一塑料片和第二塑料片位于所述固化的乳液的外部并夹住所述固化的乳液，其中，一层薄的、透明的导电涂层位于每个所述第一塑料片和第二塑料片的内表面上，与所述固化的乳液相邻，所述涂层用作电极，以使得施加的电场通过所述固化的乳液。
32.根据权利要求27所述的层压光阀膜，其中所述膜包括：
a)含有分散在固化的聚合物中的液晶的液滴；以及
b)第一塑料片和第二塑料片，所述第一塑料片和第二塑料片位于所述固化聚合物的外部并夹住所述固化聚合物，其中，一层薄的、透明的导电涂层位于每个所述第一塑料片和第二塑料片的内表面上，与所述固化的乳液相邻，所述涂层用作电极，以使得施加的电场通过所述固化的乳液。
33.根据权利要求27所述的层压光阀膜，其中所述光阀膜还包括固定到所述电极的导电材料，使得所述材料延伸超出所述层压光阀膜的周边，以允许连接所述膜到合适的电压电源。
34.根据权利要求27所述的层压光阀膜，其中，用于形成所述基板的所述玻璃选自包括以下的组：钢化玻璃、退火玻璃、低铁玻璃、低辐射玻璃、紫外阻挡玻璃、化学强化玻璃和抗菌玻璃。
35.根据权利要求27所述的层压光阀膜，其中所述塑料由选自包括以下的组的材料形成：聚碳酸酯、聚甲基丙烯酸甲酯、聚苯乙烯和聚丙烯。
36.根据权利要求27的层压光阀膜，其中用于涂覆所述基板的所述材料的软化点比所述聚合物夹层材料的软化点高至少10℃。
37.根据权利要求36的层压光阀膜，其中所述聚合物夹层材料选自包括以下的组：乙烯醋酸乙烯酯(EVA)、聚乙烯醇缩丁醛(PVB)和聚氨酯。
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CN109070550B (zh) 2021-12-31
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