JP2017211629A - Lighting control device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a lighting control device that allows a lighting control cell using a polarizer to be properly attached to a curved surface and has advanced light transmission performance and light shielding performance.SOLUTION: A lighting control device 10 includes: a light transmissive plate 21 containing a UV inhibiting component to inhibit transmission of the UV; a lighting control cell 22; and an optically transparent adhesive film 24 disposed between the lighting control cell 22 and a curved surface 20 of the light transmissive plate 21. On the curved surface 20 of the light transmissive plate 21, one side of the lighting control cell 22 is bonded via the optically transparent adhesive film 24. The lighting control cell 22 includes a first polarizer, a second polarizer, a first resin substrate, a second resin substrate, a first electrode layer, a second electrode layer, a first alignment film, a second alignment film, a sealant, and a liquid crystal layer.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a light control device capable of adjusting light transmittance, and more particularly, to a light control device including a liquid crystal drive type light control cell attached to a curved surface.

  2. Description of the Related Art Conventionally, a light control device that can change the light transmittance is known. For example, an SPD (Suspended Particle Device) using suspended particles whose alignment state varies depending on whether or not an electric field is applied is known. . Also, an EC (Electrochromic) type light control device, a light control device using a polymer dispersed liquid crystal (PDLC), a gas chromic light control device, a thermochromic light control device, and a photochromic light control device. A dimmer is also known.

  For example, Patent Document 1 discloses a laminate film used for SPD. In the SPD described in Patent Document 1, a suspension in which suspended particles are mixed in a liquid medium is used, and particles are randomly arranged in a power-off state where an electric field is not applied to block light transmission. On the other hand, particles are aligned in a power-on state where an electric field is applied, and most of light incident on the SPD (cell) passes through the SPD. Therefore, the user can change the light transmittance of the SPD by controlling the electric field applied to the suspension.

JP 2011-189751 A

  As a method for adjusting the light transmittance by the light control cell, a method using a liquid crystal and a polarizing plate in addition to the above-described SPD can be considered. A light control cell of a type using a liquid crystal and a polarizing plate can be simply configured, and can secure a very high light shielding performance.

  For example, when a dimming cell is applied to a vehicle window or the like, the transmittance of light in the visible light wavelength region (ie, visible light) is suppressed to less than 1% in order to properly block sunlight when blocking light. In some cases, it may be required to be suppressed to 0.5% or less. However, the light control cell using the above-described SPD has a visible light transmittance of about 1% to 5% at the time of light shielding, and thus is not necessarily suitable for applications such as vehicles with respect to light shielding performance. On the other hand, a light control cell using a polarizing plate can reduce the visible light transmittance during light shielding to 0.1% or less, and has practically sufficient light shielding performance for applications such as vehicles.

  In addition, when the light control cell using SPD and the light control cell using a polarizing plate are compared, the light control cell using the polarizing plate is used in various aspects such as design, cost, driving voltage, and driving speed. Is excellent. For example, the color when the light control cell using SPD is shielded is “blue”, whereas the color when the light control cell using the polarizing plate is shielded is “black”. In general, black is easier to harmonize colors than blue, and from the viewpoint of design, it is easier to select the color of other colors arranged around the light control cell. In addition, a dimming cell using SPD has a higher manufacturing cost, a higher driving voltage, and a lower driving speed than a dimming cell using a polarizing plate.

  As described above, since the light control cell using the polarizing plate is superior in performance from the light control cell using SPD, the “light control cell using the polarizing plate” is very useful. .

  On the other hand, in order to enable application of the dimming cell for various uses, there is an increasing need for a dimming cell that can be applied not only to a flat surface but also to a curved surface. Therefore, a technique for appropriately applying a “light control cell using a polarizing plate” capable of ensuring desired light transmission characteristics and light shielding characteristics to a curved surface is desired.

  In general, a glass substrate is widely used as a substrate for holding an electrode for controlling the orientation of a liquid crystal member. However, a glass substrate is a very hard and inflexible member. Therefore, the shape of the light control cell including the glass substrate is fixed, and the shape of the light control cell cannot be changed after the light control cell is manufactured. Therefore, although the light control cell using a glass base material is effectively applicable to a plane, it cannot necessarily be applied appropriately to a curved surface that can have various curvatures. On the other hand, by using a flexible resin substrate instead of a glass substrate, the shape of the dimming cell can be changed even after the dimming cell is manufactured, depending on the curved surface to be attached. It is also possible to bend the dimming cell.

  However, it is not always easy to properly attach a dimming cell composed of a plurality of members having various rigidity and elasticity to a curved surface, and the sheet-like dimming cell may be distorted such as wrinkles when attached. is there. Such distortions such as wrinkles not only adversely affect the optical characteristics of the dimming cell, thereby deteriorating the original light transmission performance and light shielding performance, but also detrimental to the product design.

  In addition, although the light control cell using SPD as disclosed in the above-mentioned Patent Document 1 can be formed in a curved surface shape, it is not a type to be attached to an attachment target, so it is necessary to make it in a predetermined shape, It is difficult to flexibly cope with various surface shapes.

  The present invention has been made in view of the above circumstances, and a light control device that can appropriately attach a light control cell using a liquid crystal and a polarizing plate to a curved surface and has high light transmission performance and light shielding performance. The purpose is to provide.

  One embodiment of the present invention includes a light transmission plate that includes a curved surface and includes an ultraviolet light blocking component that inhibits transmission of ultraviolet light, a light control cell, a curved surface of the light transmission plate, and the light control cell. An optically transparent pressure-sensitive adhesive film that adheres one side of the light control cell to the curved surface of the transmission plate, the light control cell being a light transmission plate than the first polarizing plate and the first polarizing plate A second polarizing plate provided at a position spaced from the light polarizing plate, a hard coat layer provided at a position further away from the light transmission plate than the second polarizing plate, and provided between the first polarizing plate and the second polarizing plate, A first resin base disposed on the first polarizing plate side and a second resin base disposed on the second polarizing plate side; provided between the first resin base and the second resin base; 1st electrode layer arrange | positioned at 1 resin base material side, and 2nd electrode arrange | positioned at 2nd resin base material side And a first alignment film disposed between the first electrode layer and the second electrode layer and disposed on the first electrode layer side, a second alignment film disposed on the second electrode layer side, and a first alignment The present invention relates to a light control device that is provided between a film and a second alignment film, and includes a sealing material that partitions a liquid crystal space between the first alignment film and the second alignment film, and a liquid crystal layer provided in the liquid crystal space .

  The curved surface of the light transmission plate may be a three-dimensional curved surface.

The optical transparent adhesive film has a thickness in the direction in which the optical transparent adhesive film and the light control cell are laminated of 50 μm or more and 500 μm or less, preferably 200 μm or more and 300 μm or less, and a room temperature environment (for example, 1 to 30 ° C. (particularly 15 The storage elastic modulus at ˜25 ° C.) is more preferably 1 × 10 ⁷ Pa or more and 1 × 10 ⁸ Pa or less. The loss tangent (tan δ) of the optically transparent adhesive film is preferably 0.5 or more and 1.5 or less, and more preferably 0.7 or more and 1.2 or less. The “loss tangent” here is represented by a ratio of the storage shear modulus (G ′) and the loss shear modulus (G ″) (that is, “G ″ / G ′”).

  At least one of the first resin base material and the second resin base material may include a polycarbonate or a cycloolefin polymer.

  The seal material may have a length in a direction perpendicular to a direction in which the first alignment film, the seal material, and the second alignment film are stacked of 1 mm or more and 5 mm or less.

  The liquid crystal layer preferably has the same pressure as the atmospheric pressure, but more preferably has a negative pressure in the liquid crystal layer with respect to the atmospheric pressure.

  The light control device may further include a retardation compensation film provided between at least one of the first polarizing plate and the first electrode layer and between the second polarizing plate and the second electrode layer.

  The liquid crystal layer may be a VA mode, TN mode, IPS mode, or FFS mode liquid crystal layer.

  The optical axis of the first resin substrate is perpendicular to the optical axis of the second resin substrate, the optical axis of the first resin substrate and the absorption axis of the first polarizing plate are parallel, and the second resin substrate The optical axis and the absorption axis of the second polarizing plate may be parallel.

  The optical axis of the first resin base and the optical axis of the second resin base are parallel, the optical axis of the first resin base is perpendicular to the absorption axis of the first polarizing plate, and the second resin base The optical axis and the absorption axis of the second polarizing plate may be parallel.

  The light control device further includes a retardation compensation film provided between the first resin substrate and the first polarizing plate, and the absorption axis of the first polarizing plate is perpendicular to the absorption axis of the second polarizing plate, The retardation compensation film functions as an A plate, and the slow axis direction of the retardation compensation film is parallel to the optical axis of the first resin base, the optical axis of the second resin base, and the absorption axis of the second polarizing plate. There may be. The light control device further includes a retardation compensation film provided between the second resin base material and the second polarizing plate, and the absorption axis of the first polarizing plate is perpendicular to the absorption axis of the second polarizing plate. The retardation compensation film functions as an A plate, and the slow axis direction of the retardation compensation film is parallel to the optical axis of the first resin substrate, the optical axis of the second resin substrate, and the absorption axis of the first polarizing plate. It may be.

  The light control device further includes a plurality of spacers arranged in at least the liquid crystal space and supporting the first alignment film and the second alignment film, each of the plurality of spacers is represented by Xs, and each of the plurality of spacers When the Vickers hardness value of the portion of the first alignment film with which the tip of the first contact film is expressed by Xf, 16.9 ≦ Xs ≦ 40.2 is satisfied and 11.8 ≦ Xf ≦ 35.9 is satisfied Also good.

  According to the present invention, the light control cell is appropriately attached to the curved surface of the light transmission plate through the optical transparent adhesive film, and the light control cell including the polarizing plate and the liquid crystal layer exhibits high light transmission performance and light shielding performance. The

FIG. 1 is a schematic cross-sectional view showing an example of a light control device. FIG. 2 is a diagram for explaining a three-dimensional curved surface. FIG. 3 is a schematic cross-sectional view for explaining the layer structure of the optically transparent adhesive film and the light control cell. FIG. 4A is a schematic cross-sectional view for explaining the layer configuration of the first electrode alignment layer. FIG. 4B is a schematic cross-sectional view for explaining the layer configuration of the second electrode alignment layer. FIG. 5 is a schematic cross-sectional view showing a modification of the second polarizing plate (protective layer) and the hard coat layer. FIG. 6 is a diagram illustrating a first resin base material, a second resin base material, a polarizing layer of the first polarizing plate, and a polarizing layer of the second polarizing plate for explaining the first arrangement mode. FIG. 7 is a diagram illustrating a first resin base material, a second resin base material, a polarizing layer of the first polarizing plate, and a polarizing layer of the second polarizing plate, showing a comparative aspect with respect to the first arrangement mode. 8 is a view angle characteristic of the dimming cell (see reference numeral “L1” in FIG. 8) related to the first arrangement mode shown in FIG. 6, and a viewing angle characteristic of the dimming cell related to the comparison mode shown in FIG. (Refer to the reference numeral “L2”). FIG. 9 is a diagram showing a first resin base, a second resin base, a polarizing layer of the first polarizing plate, a polarizing layer of the second polarizing plate, and a retardation compensation film for explaining the second arrangement mode. It is. FIG. 10 is a diagram illustrating a first resin base material, a second resin base material, a polarizing layer of the first polarizing plate, a polarizing layer of the second polarizing plate, and a retardation compensation film, showing a comparative mode with respect to the second arrangement mode. It is. 11 is a view angle characteristic of the dimming cell (see reference numeral “L3” in FIG. 11) related to the second arrangement mode shown in FIG. 9, and a viewing angle characteristic of the dimming cell related to the comparison mode shown in FIG. The reference numeral “L4” of FIG. FIG. 12 is a table showing a state evaluation of bonding of the light control cells (Examples 1 to 3) to the curved surface of the light transmission plate. FIG. 13 is a table showing a state evaluation of bonding of the light control cells (Examples 4 to 9) to the curved surface of the light transmission plate. FIG. 14 is a table showing a state evaluation of bonding of the light control cells (Examples 10 to 12) to the curved surface of the light transmission plate. FIG. 15 is a flowchart showing an outline of the manufacturing process of the light control cell. FIG. 16 is a chart showing test results used for confirmation of the configuration related to the spacer. FIG. 17 is a chart showing test results used for confirming the configuration related to the spacer. FIG. 18 is a chart showing the manufacturing conditions of the spacer. FIG. 19 is a chart showing the manufacturing conditions of the alignment film.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

  The light control device 10 described below can be applied to various technical fields in which adjustment of light transmittance is required, and the application range is not particularly limited. For example, the light control device 10 according to the present invention is used as an arbitrary device that requires switching between light transmission and light shielding, such as a vehicle or a vehicle window (including a skylight), a showcase, and a partition arranged indoors. Is possible. Further, each element constituting the light control device 10 can be manufactured by a known method, and is manufactured by using any lamination technique, photolithography technique, and / or bonding technique.

  In addition, the light control apparatus 10 (light control cell 22 grade | etc.,) Demonstrated below is only illustrating one Embodiment of this invention. Therefore, for example, some of the elements listed below as constituent elements of the light control device 10 may be replaced with other elements or may not be included. In addition, elements not listed below may be included as components of the light control device 10. In addition, in the drawings, there are portions in which the scale, the dimensional ratio, and the like are appropriately changed or exaggerated from those of the actual ones for the convenience of illustration and understanding.

  FIG. 1 is a schematic cross-sectional view showing an example of the light control device 10.

  The light control device 10 of the present embodiment includes a light transmission plate 21 having a curved surface 20, a light control cell 22 in which the transmittance of light (particularly visible light) is variable, and the curved surface 20 and the light control cell of the light transmission plate 21. And an optically transparent adhesive film (OCA) 24 disposed between one side of 22.

  The light transmission plate 21 includes an ultraviolet ray inhibiting component, and transmits visible light while inhibiting ultraviolet ray transmission. The light transmission plate 21 has a curved surface 20 and includes one or a plurality of glass plates. In addition, the light transmission plate 21 does not necessarily include an ultraviolet ray inhibiting component, and the light control cell 22 and the optical transparent adhesive film 24 described later can be applied to the light transmission plate 21 that does not include the ultraviolet ray inhibition component. Is possible. The light transmission plate 21 may have, for example, glass plates (two glass plates in total) disposed on each of the front surface side and the back surface side, or a single glass plate such as tempered glass. May be. The light transmission plate 21 may include a member other than a glass plate. For example, an arbitrary functional layer such as a highly rigid film (for example, a COP (Cyclo Olefin Polymer) resin layer) or a heat reflecting film may be provided. The light transmission plate 21 may be provided.

  The curved surface 20 of the light transmitting plate 21 is not particularly limited, but is typically a two-dimensional curved surface or a three-dimensional curved surface, and the curved surface 20 of the illustrated light transmitting plate 21 is a three-dimensional curved surface. In general, it is not easy to attach the thin-film dimming cell 22 without causing wrinkles on the three-dimensional curved surface. However, according to the “technology for attaching the dimming cell 22 to the light transmission plate 21” described later, the thin film It is easy to affix the light-modulating cell 22 on the three-dimensional curved surface without causing wrinkles.

  FIG. 2 is a diagram for explaining the three-dimensional curved surface 20a. The three-dimensional curved surface 20a referred to here is a two-dimensional curved surface that is bent two-dimensionally around a single axis, or a two-dimensional curved surface that is bent two-dimensionally with different curvatures around a plurality of mutually parallel axes. Are distinct. That is, the three-dimensional curved surface 20a means a surface that is partially or wholly bent around each of a plurality of axes inclined with respect to each other.

One surface of the illustrated light transmission plate 21 (that is, the curved surface 20 to which the optical transparent adhesive film 24 is attached) is bent as shown in FIG. 2 as a whole, and the first direction is centered on the first axis A1. It bends to d1, and also bends in the second direction d2 around the second axis A2.
In the illustrated example, the first axis A1 and the second axis A2 are both inclined with respect to the X direction and the Y direction shown in FIG. 2, and the first axis A1 is perpendicular to the second axis A2. .

  One side of the light control cell 22 is bonded to the curved surface 20 of the light transmission plate 21 via the optical transparent adhesive film 24.

  FIG. 3 is a schematic cross-sectional view for explaining the layer structure of the optical transparent adhesive film 24 and the light control cell 22. As described above, the optical transparent adhesive film 24 is provided on one side of the light control cell 22. A hard coat layer 26 is provided on the other side of the light control cell 22.

  The optically transparent adhesive film 24 of the present embodiment is constituted by a transparent adhesive sheet called OCA, and can be constituted only by an adhesive having a substantially constant film thickness without including a base material. For example, an acrylic adhesive having excellent transparency It can be configured by an agent or the like. The optical transparent adhesive film 24 (OCA) is manufactured by sandwiching an adhesive with a sheet having excellent releasability (separator (release material)), and a laminate of the adhesive and the separator is cut into a desired shape and the separator is removed. The adhesive (optical transparent adhesive film 24) can be attached to the desired location. The optical transparent adhesive film 24 can be formed, for example, by applying a transparent adhesive resin called OCR (Optical Clear Resin).

  The dimming cell 22 has a multi-layer structure, from the optical transparent adhesive film 24 side toward the outside (that is, in a direction away from the light transmission plate 21), as shown in FIG. 3, “protective layer 47, polarizing layer 48, Protective layer 47, adhesive layer 46, first electrode alignment layer 43, liquid crystal layer 49, second electrode alignment layer 44, adhesive layer 46, retardation compensation film 45, adhesive layer 46, protective layer 47, polarizing layer 48, protective layer 47, an adhesive layer 46 and a hard coat layer 26 "are sequentially provided in layers. A laminated structure of “polarizing plate—electrode layer—alignment film—liquid crystal layer—alignment film—electrode layer—polarizing plate—hard coat layer” is formed by these layers.

  That is, the “protective layer 47, the polarizing layer 48 and the protective layer 47” arranged on the light transmission plate 21 side form the first polarizing plate 41, and another “protective layer 47, polarizing layer provided on the hard coat layer 26 side”. 48 and the protective layer 47 "form the second polarizing plate 42. The first polarizing plate 41 of this embodiment is attached to the curved surface 20 of the light transmission plate 21 via the optical transparent adhesive film 24, and the second polarizing plate 42 is from the light transmission plate 21 rather than the first polarizing plate 41. It is provided at a spaced position.

  The polarizing layer 48 of the first polarizing plate 41 and the second polarizing plate 42 is configured by a member that performs a desired polarizing function, and is typically made by stretching PVA (polyvinyl alcohol) doped with an iodine compound. It is done. As a typical arrangement mode of the polarizing layer 48, an aspect called “parallel Nicol” in which the absorption axis of the polarizing layer 48 of the first polarizing plate 41 and the absorption axis of the polarizing layer 48 of the first polarizing plate 41 are parallel to each other. An aspect called “cross Nicol (see FIGS. 6 and 9 described later)” in which the absorption axis of the polarizing layer 48 of the first polarizing plate 41 and the absorption axis of the polarizing layer 48 of the first polarizing plate 41 are perpendicular to each other. There is.

  The protective layer 47 serves to protect the adjacent layer, and can be made of any material that can transmit visible light, and is typically made of TAC (Triacetylcellulose) or acrylic. In addition, the protective layer 47 formed in the several location of the 1st polarizing plate 41 and the 2nd polarizing plate 42 may be comprised with a different material according to a position, and may be comprised with the same material.

  Between the first polarizing plate 41 and the second polarizing plate 42, the first electrode alignment layer 43 is disposed on the first polarizing plate 41 side, and the second electrode alignment layer 44 is disposed on the second polarizing plate 42 side. Each of the first electrode alignment layer 43 and the second electrode alignment layer 44 forms an “electrode layer and alignment film supported by a substrate”.

  FIG. 4A is a schematic cross-sectional view for explaining the layer configuration of the first electrode alignment layer 43. The first electrode alignment layer 43 of the present embodiment has a hard coat layer 53, a first resin base material 29, a hard coat layer 53, an index matching layer 55, a first match, from the first polarizing plate 41 side toward the liquid crystal layer 49 side. The one electrode layer 31 and the first alignment film 33 are sequentially provided in layers.

  FIG. 4B is a schematic cross-sectional view for explaining the layer configuration of the second electrode alignment layer 44. The second electrode alignment layer 44 of the present embodiment includes a second alignment film 34, a second electrode layer 32, an index matching layer 55, a hard coat layer 53, a first coating layer, from the liquid crystal layer 49 side toward the second polarizing plate 42 side. Two resin base materials 30 and a hard coat layer 53 are sequentially provided in layers.

  As described above, between the first resin base material 29 and the second resin base material 30, the first electrode layer 31 disposed on the first resin base material 29 side and the second resin base material 30 side are disposed. The second electrode layer 32 is provided. The first electrode layer 31 and the second electrode layer 32 can be formed as transparent electrodes using various materials such as ITO (Indium Tin Oxide), and are connected with power supply means such as FPC (Flexible Printed Circuits). A voltage is applied. Depending on the voltage applied to the first electrode layer 31 and the second electrode layer 32, the electric field acting on the liquid crystal layer 49 disposed between the first electrode layer 31 and the second electrode layer 32 changes, and the liquid crystal layer The alignment of the liquid crystal member constituting 49 is adjusted.

  Between the first electrode layer 31 and the second electrode layer 32, a first alignment film 33 disposed on the first electrode layer 31 side, and a second alignment film 34 disposed on the second electrode layer 32 side, Is provided. The manufacturing method of the 1st alignment film 33 and the 2nd alignment film 34 is not specifically limited, The 1st alignment film 33 and the 2nd alignment film 34 which have liquid crystal aligning ability can be made with arbitrary methods. For example, the first alignment film 33 and the second alignment film 34 may be formed by performing a rubbing process on a resin layer such as polyimide, or the polymer film is irradiated with linearly polarized ultraviolet light to increase the polarization direction. The first alignment film 33 and the second alignment film 34 may be formed based on a photo-alignment method in which molecular chains are selectively reacted.

  In addition to the liquid crystal layer 49, a spacer 52 and a sealing material 36 are provided between the first alignment film 33 and the second alignment film 34, as shown in FIG. That is, a sealing material 36 that partitions the liquid crystal space 35 between the first alignment film 33 and the second alignment film 34 is provided between the first alignment film 33 and the second alignment film 34. The liquid crystal layer 49 is formed by filling the liquid crystal member. The plurality of spacers 52 are disposed at least in the liquid crystal space 35 and are discretely disposed so as to support the first alignment film 33 and the second alignment film 34. Each spacer 52 can be configured by a single member or a plurality of members, and may extend in the stacking direction only in the liquid crystal space 35, or may include one alignment film (for example, the second alignment film 34) and the liquid crystal space 35. You may extend in a lamination direction so that it may penetrate. The spacer 52 may have a core portion and a covering portion, and the covering portion may be in direct contact with the other alignment film (for example, the first alignment film 33). Therefore, for example, the core portion of each spacer 52 extends from the second electrode layer 32 to the first alignment film 33 while penetrating the second alignment film 34 and extends in the liquid crystal space 35, and is the same as the second alignment film 34. A coating portion of the component is provided on the core portion, and the coating portion is in direct contact with the first alignment film 33, whereby the interval (cell gap) between the first alignment film 33 and the second alignment film 34 is set to each spacer. It may be held by 52.

  The sealing material 36 plays a role of preventing leakage of the liquid crystal member constituting the liquid crystal layer 49, and is used for the first electrode alignment layer 43 (first alignment film 33) and the second electrode alignment layer 44 (second alignment film 34). Adheres and fixes the two together. As the sealing material 36, a thermosetting epoxy resin is generally used, and when the liquid crystal member filling method into the liquid crystal space 35 is a vacuum injection method, the epoxy resin sealing material 36 is preferably used. it can. When the ODF (One Drop Fill) method is used as the filling method of the liquid crystal member, a hybrid type material having both thermosetting property and UV curable property (ultraviolet curable property) can be suitably used as the sealing material 36. . This is because when the liquid crystal touches the uncured sealing material 36, an appearance defect is induced. Therefore, it is preferable that the material (composition component of the sealing material 36) constituting the sealing material 36 includes, for example, an ultraviolet curable acrylic resin and an epoxy resin. In addition, from the viewpoint of fixing the first electrode alignment layer 43 (first alignment film 33) and the second electrode alignment layer 44 (second alignment film 34) to each other while preventing leakage of the liquid crystal member, the hardness ( (Hardness) is preferably 20 or more and 90 or less, and more preferably 20 or more and 50 or less, when measured with a durometer (type A according to JIS K6253; 10N load). The sealing material 36 preferably has a glass transition point (glass transition temperature (Tg)) of 0 ° C. or higher and 60 ° C. or lower, and more preferably 0 ° C. or higher and 40 ° C. or lower.

  Further, between the first electrode alignment layer 43 (first alignment film 33) and the second electrode alignment layer 44 (second alignment film 34), the thickness of the liquid crystal layer 49 (that is, the first electrode alignment layer 43 (first alignment film 43)). A plurality of spacers 52 that define a distance between the first alignment film 33) and the second electrode alignment layer 44 (second alignment film 34) are disposed. Each spacer 52 can be composed of various resin materials, and may have a columnar shape such as a truncated cone, or may have a spherical bead shape. The columnar liquid crystal space 35 can be formed at a desired location based on the photolithography technique, and the bead-shaped liquid crystal space 35 is made in advance and dispersed in the liquid crystal space 35.

  The liquid crystal layer 49 of the present embodiment has a negative pressure in the liquid crystal space 35 from the viewpoint of “improving the bonding property of the light control cell 22 to the light transmission plate 21 (that is, preventing distortion of the light control cell 22)”. For example, such a negative pressure is obtained by injecting the liquid crystal member into the liquid crystal space 35 such that the liquid crystal member constituting the liquid crystal layer 49 occupies “less than 100% (preferably about 99%) of the volume of the liquid crystal space 35”. Can be realized. The light control cell 22 of this embodiment is attached to the curved surface 20 of the light transmission plate 21 in a bent state. However, if the liquid crystal space 35 is filled with an excessive liquid crystal member, the flexibility of the light control cell 22 is impaired. Thus, the mounting property of the light control cell 22 to the light transmission plate 21 is deteriorated. Therefore, it is preferable to ensure the flexibility of the light control cell 22 by injecting the liquid crystal member into the liquid crystal space 35 so that the liquid crystal member constituting the liquid crystal layer 49 occupies “about 99% of the volume of the liquid crystal space 35”. . If the amount of liquid crystal member injected is too small relative to the volume of the liquid crystal space 35, bubbles are induced in the liquid crystal space 35, which is not preferable.

  The liquid crystal layer 49 of the present embodiment is a VA (Vertical Alignment) liquid crystal layer, and is “normally black” that is in a light-shielding state when no voltage is applied to the first electrode layer 31 and the second electrode layer 32. The method called is adopted. However, the liquid crystal layer 49 may adopt another driving method. For example, the liquid crystal layer 49 is driven by a TN (Twisted Nematic) method, an IPS (In Plane Switching) method, an FFS (Fringe Field Switching) method, or other methods. May be.

  Between the second polarizing plate 42 and the second electrode layer 32 (second electrode alignment layer 44), a retardation compensation film 45 having a compensation performance corresponding to the driving method of the liquid crystal layer 49 is provided. Then, a retardation compensation film 45 for eliminating the retardation of the VA liquid crystal layer 49 is provided. In the VA method, since the change in phase difference due to the angle is large, the phase difference compensation film 45 of this embodiment has a compensation performance that can effectively compensate for such a change in phase difference. On the other hand, when the liquid crystal layer 49 adopts the TN mode, the phase difference compensation film 45 has a compensation performance for compensating for a phase difference (for example, angle dependency of liquid crystal molecules) of the TN mode liquid crystal layer 49. In the case of the IPS liquid crystal layer 49, since the phase difference is generally small and the change in the phase difference due to the angle is also small, basically no retardation compensation film is often required, and the retardation compensation film 45 is not provided. May be.

Since the phase difference compensation film 45 is not necessarily an essential element, it may not be provided in the light control cell 22, and the installation position is not limited as long as the desired compensation performance can be exhibited.
Typically, “between the first polarizing plate 41 and the first electrode layer 31 (first electrode alignment layer 43)” and “the second polarizing plate 42 and the second electrode layer 32 (second electrode alignment layer 44)”. A phase difference compensation film 45 is provided at least one of “between” and “between”. Therefore, not the position shown in FIG. 3 (that is, between the second electrode alignment layer 44 (hard coat layer 53) and the second polarizing plate 42 (protective layer 47)) and the first polarizing plate 41 (protective layer 47). A retardation compensation film 45 may be provided between the first electrode alignment layer 43 (hard coat layer 53). Further, the retardation compensation film 45 may be provided in two or more layers (that is, in two or more places) as long as the retardation compensation film 45 as a whole can compensate the retardation of the liquid crystal layer 49.

  The hard coat layer 26 is provided at a position farther from the light transmission plate 21 than the second polarizing plate 42, and forms the outermost layer of the light control cell 22 of the present embodiment. The illustrated hard coat layer 26 is fixed to the second polarizing plate 42 via the adhesive layer 46 and can contain any component. For example, the hard coat layer can be formed of the same component (for example, TAC) as the protective layer 47. 26 can be configured. The hard coat layer 26 may be formed directly on the surface of the second polarizing plate 42 (in this embodiment, the protective layer 47) as shown in FIG. For example, a cured film containing fine particles (for example, titanium dioxide) is formed on the surface of the second polarizing plate 42 (on the protective layer 47) using a silicone-based ultraviolet curable resin, and functions as the hard coat layer 26. Also good.

  The functional layers (the first polarizing plate 41, the first electrode alignment layer 43, the second electrode alignment layer 44, the retardation compensation film 45, the second polarizing plate 42, and the hard coat layer 26 shown in FIG. 3) are adjacent to each other. The functional layers are bonded together by the adhesive layer 46 and have an integral laminated structure. The component which comprises this adhesion layer 46 is not specifically limited, The component of the adhesion layer 46 may be determined according to the characteristic of each layer of adhesion | attachment object. In the present embodiment, all the adhesive layers 46 are made of the same material as the optical transparent adhesive film (that is, OCA) 24, but an adhesive layer 46 containing other components such as an ultraviolet curable resin may be used. The pressure-sensitive adhesive layer 46 containing a component different from the pressure-sensitive adhesive layer 46 in other places may be used depending on the arrangement position and the adhesion target.

  In addition, the layer structure of the light transmission plate 21, the optical transparent adhesive film 24, and the light control cell 22 shown in FIG. 3 etc. is only an example, and other functional layers may be provided as a part of the light control cell 22, Other functional units may be additionally provided for the dimming cell 22. For example, although illustration is omitted, a seal protective material that functions as a protective material can be provided from the side of the light control cell 22 and the optical transparent adhesive film 24 to a part of the curved surface 20 of the light transmission plate 21. This seal protector can not only reinforce the adhesive force of the light control cell 22 and the optical transparent adhesive film 24 to the light transmission plate 21, but can also strengthen the adhesive force between adjacent layers of the light control cell 22 and the optical transparent adhesive film 24.

  As a result of earnest research, the present inventor has attached the thin-film dimming cell 22 to the curved surface 20 (particularly a three-dimensional curved surface) without distortion such as wrinkles so as to satisfy the following conditions. And it came to the knowledge that it was preferable to adjust the optical transparent adhesive film 24.

That is, the optical transparent adhesive film 24 has a thickness in the direction in which the optical transparent adhesive film 24 and the light control cell 22 are laminated of 50 μm or more and 500 μm or less, preferably 200 μm or more and 300 μm or less, and a storage elastic modulus in a room temperature environment. Is more preferably 1 × 10 ⁷ Pa or more and 1 × 10 ⁸ Pa or less. The loss tangent (tan δ) of the optical transparent adhesive film 24 is preferably 0.5 or more and 1.5 or less, more preferably 0.7 or more and 1.2 or less.

  The optical transparent adhesive film 24 serves to bond the curved surface 20 of the light transmission plate 21 and the first polarizing plate 41 (protective layer 47), and also the curved surface 20 of the light transmission plate 21 and the first polarizing plate 41 (protective layer). 47) also serves as a cushion to fill in the difference in curvature from that of 47). Therefore, when the thickness in the laminating direction is too small, it becomes difficult for the optical transparent adhesive film 24 to appropriately serve as a cushion. On the other hand, when the thickness in the laminating direction is too large, It becomes difficult to properly fix the first polarizing plate 41 (protective layer 47). On the other hand, if the storage elastic modulus of the optical transparent adhesive film 24 is too large, the rigidity of the entire light control cell 22 increases, and the followability to a curved surface whose shape changes three-dimensionally becomes insufficient. On the other hand, if the storage elastic modulus of the optical transparent adhesive film 24 is too small, the optical transparent adhesive film 24 has too much fluidity, and the first polarizing plate 41 (protective layer 47) with respect to the curved surface of the light transmission plate 21. There is a concern that it becomes difficult to fix the resin properly, reliability such as heat resistance becomes insufficient, and foaming occurs even in a normal use environment. Furthermore, when the storage elastic modulus of the optical transparent adhesive film 24 is too small, the processability of the optical transparent adhesive film 24 is deteriorated, for example, due to the sticking of the paste when the optical transparent adhesive film 24 is cut. Undesirable separation can occur. Therefore, in order to appropriately bond the light control cell 22 to the curved surface 20 without causing distortion such as wrinkles, it is preferable that the thickness and the storage elastic modulus in the stacking direction of the optical transparent adhesive film 24 are in the above range. This inventor newly found out.

  Moreover, the 1st resin base material 29 and the 2nd resin base material 30 can be comprised with various transparent film materials, and it is desirable to be comprised with film materials with small optical anisotropies, such as COP. In particular, from the viewpoint of appropriately attaching the light control cell 22 to the curved surface 20, it is preferable that at least one of the first resin base material 29 and the second resin base material 30 includes polycarbonate. The constituent materials, shapes, and / or sizes of the first resin base material 29 and the second resin base material 30 may be the same or different from each other.

  The length of the sealing material 36 in the direction perpendicular to the stacking direction (the direction in which the first alignment film 33, the sealing material 36, and the second alignment film 34 are stacked) (that is, the width direction) is 1 mm or more and 5 mm or less. Is preferable, and 1.5 mm is particularly preferable.

  The smaller the length of the sealing material 36 in the width direction is, the lower the rigidity of the entire light control cell 22 can be, and it is easier to bond the light control cell 22 to the curved surface 20 without causing wrinkles or other distortions. Become. On the other hand, if the length of the sealing material 36 in the width direction is too small, “sealing of the liquid crystal layer 49 in the liquid crystal space 35” or “first electrode alignment layer 43 (first alignment film 33) and second electrode alignment” will be described. The original function of the sealing material 36 called “adhesion with the layer 44 (second alignment film 34)” is impaired. Considering these circumstances comprehensively, the inventor newly found that the length in the width direction of the sealing material 36 is preferably 1 mm or more and 5 mm or less (more preferably 1.5 mm) as described above. .

  Thus, generally, the one where the rigidity of the laminate constituting the light control cell 22 is smaller is more likely to be deformed according to the curved surface 20 of the light transmission plate 21, and the light control cell 22 can be formed without causing distortion such as wrinkles. Bonding to the curved surface 20 is easy. However, the light control cell 22 cannot be appropriately bonded to the curved surface 20 of the light transmission plate 21 if the laminate has a sufficiently small rigidity, and the optical transparent adhesive film 24 and the light control cell 22 have appropriate conditions. The present inventors have newly found that it exists.

  Further, the light transmittance (particularly the total light transmittance) of the light control cell 22 is preferably 30% or more, and more preferably 35% or more. Here, “total light transmittance” indicates the ratio of the total transmitted light beam to the parallel incident light beam of the test piece, and the “total transmitted light beam” in the case of a diffusible sample includes a diffused transmitted light beam (diffusion component). The details of the total light transmittance can be determined based on “JIS (Japan Industrial Standards) 7375: 2008”. It is possible to calculate the total light transmittance based on the “ratio of light transmitted through the light control cell 22” obtained with reference to the light intensity at a wavelength of 555 nm of the light before passing through the light control cell 22. The color of the light control cell 22 is preferably “black” in consideration of harmony with other peripheral members, but “achromatic color other than black” is also preferable.

Note that distortion such as wrinkles of the light control cell 22 due to the bonding of the light transmission plate 21 to the curved surface 20 is particularly likely to occur at the beginning of the bonding process (that is, the bonding start region).
Based on the knowledge, the light control device 10 (the light transmission plate 21, the optical transparent adhesive film 24, and the light control cell 22) is attached with a place that is not originally intended for optical use or a place that is difficult to be visually recognized by the user. By bonding the dimming cell 22 to the curved surface 20 of the light transmission plate 21 as a combination start region, the substantial influence of distortion of the dimming cell 22 can be reduced. Therefore, for example, by setting a region outside the sealing material 36 where the liquid crystal layer 49 is not provided as a bonding start region, the “effect due to distortion generated in the light control cell 22” with respect to the light passing through the liquid crystal layer 49 is substantially reduced. Can be reduced. Therefore, the first electrode alignment layer 43 and the second electrode alignment layer 44 (especially the first electrode layer 31 and the second electrode layer 32) are extended to the outside of the sealing material 36, and a “first electrode such as FPC is formed in the extended portion. When the “feeding means for the layer 31 and the second electrode layer 32” is connected, the “area to which the feeding means is connected” is used as a bonding start area, and the dimming cell 22 is transmitted from the area to the light transmission plate. By bonding to the curved surface 20 of 21, the distortion generated in the light control cell 22 can be effectively hidden. In particular, the position where the feeding means such as FPC is connected in the extended portions of the first electrode layer 31 and the second electrode layer 32 is relatively long from the region (active area) where the liquid crystal layer 49 is provided. It is easy to keep the distortion of the dimming cell 22 that occurs in the bonding start area within the range of the inactive area.

  As described above, according to the light control device 10 according to the present embodiment, the light control cell 22 can be appropriately bonded to the curved surface 20 of the light transmission plate 21 via the optical transparent adhesive film 24 without distortion. . In particular, according to the light control cell 22 of the present embodiment, the light control is performed by a combination of the polarizing plates (the first polarizing plate 41 and the second polarizing plate 42) and the alignment control of the liquid crystal layer 49, and thus a simple configuration. High light transmission performance and light shielding performance can be realized.

  Moreover, the light control cell 22 of this embodiment is comprised by the combination of the member which did not contain rigid elements, such as glass, and was rich in the softness | flexibility. Therefore, the “light bonding of the light control cell 22 to the curved surface 20”, which has been difficult in the case of using glass as the base material for supporting the first electrode layer 31 and the second electrode layer 32, is accurate in the light control cell 22 of the present embodiment. Can be done well.

  Generally, the light control cell using a resin base material has low rigidity, and such a low rigidity light control cell is deformed relatively easily when an external force is directly applied, and the optical characteristics of the liquid crystal layer are disturbed. The Therefore, if the dimmer is used in an environment where external forces such as vibration are suddenly or continuously applied to the low-rigidity dimmer cell, the orientation of the liquid crystal member of the liquid crystal layer is disturbed and the original optical function May not be sufficiently exhibited, and a phenomenon such as flickering may occur in the light observed through the light control device. However, since the light control cell 22 (liquid crystal layer 49) of the present embodiment is attached to the light transmission plate 21 having relatively high rigidity and is firmly supported, the disturbance of liquid crystal alignment caused by external force is effectively reduced. And can avoid such a phenomenon as flickering.

In addition, as an aspect which attaches the light control cell 22 with respect to the light transmission plate 21 which has two or more glass plates, the aspect which arrange | positions the light control cell 22 between two glass plates, and the outer side of two glass plates A mode in which the dimming cell 22 is arranged can be considered. When the dimming cell 22 is disposed between two glass plates, the dimming cell 22 can adjust the transmittance of light incident on the glass plate while protecting the dimming cell 22 with the glass plate. .
However, a relatively large force (compression force, shearing force, etc.) may be applied between the two glass plates, but the polarizing plate (the first polarizing plate 41 and the second polarizing plate 42) is provided. The light cell 22 is not necessarily resistant to the force applied from the outside. Moreover, although the temperature between glass plates becomes very high depending on use environment, a polarizing plate does not necessarily have excellent high temperature resistance. Therefore, when the light control cell 22 having a polarizing plate is disposed between two glass plates, the light control cell 22 can be crushed or deteriorated so that the light control cell 22 can perform a desired light control function. There is a concern that it will disappear.

  On the other hand, in a mode in which the light control cell 22 is attached to the outer surface of the light transmission plate 21 as in the light control device 10 of the present embodiment shown in FIGS. Thermal performance is not high. Therefore, the light control device 10 according to the present embodiment continuously performs a desired light control function even though the light control cell 22 includes the polarizing plates (the first polarizing plate 41 and the second polarizing plate 42). It can be demonstrated. Further, by using the dimming cell 22 that satisfies the above-described conditions that facilitates bonding of the dimming cell 22 to the curved surface 20 without causing distortion such as wrinkles, the light transmission performance and light shielding of the dimming cell 22 are achieved. The light control cell 22 can be appropriately bonded to the light transmission plate 21 according to the specific bending condition of the curved surface 20 that can have various shapes without excessively degrading the performance.

<Directivity between absorption axis of polarizing plate and optical axis of substrate for VA system>
When the driving method of the liquid crystal layer 49 is the VA method, “the direction of the absorption axis of the polarizing layer 48 of the first polarizing plate 41 and the second polarizing plate 42” and “the first electrode alignment layer 43 and the second electrode alignment layer 44 Regarding the directions of the optical axes of the base materials (the first resin base material 29 and the second resin base material 30), there is the following relationship.

<First Arrangement Mode>
FIG. 6 is a diagram showing a first resin base material 29, a second resin base material 30, a polarizing layer 48 of the first polarizing plate 41, and a polarizing layer 48 of the second polarizing plate 42 for explaining the first arrangement mode. It is.

  In this aspect, the optical axis of the first resin base material 29 is perpendicular to the optical axis of the second resin base material 30 (see the optical axis directions “Db1” and “Db2” in FIG. 6). The absorption axis of the polarizing layer 48 is perpendicular to the absorption axis of the polarizing layer 48 of the second polarizing plate 42 (see the absorption axis directions “Da1” and “Da2” in FIG. 6), and the optical axis direction of the first resin base material 29. Db1 is parallel to the absorption axis direction Da1 of the polarizing layer 48 of the first polarizing plate 41, and the optical axis direction Db2 of the second resin substrate 30 is parallel to the absorption axis direction Da2 of the polarizing layer 48 of the second polarizing plate 42. is there.

  As described above, the first resin base material 29 and the second resin base material 30 are arranged so that “the optical axis direction Db1 of the first resin base material 29 is perpendicular to the optical axis direction Db2 of the second resin base material 30”. By doing so, the phase difference imparted to the transmitted light by the first resin base material 29 can be canceled by the phase difference imparted by the second resin base material 30. Therefore, the phase difference imparted to the transmitted light by the first resin base material 29 and the second resin base material 30 can be reduced as a whole.

  Further, “the optical axis direction Db1 of the first resin base material 29 and the absorption axis direction Da1 of the polarizing layer 48 of the first polarizing plate 41 are parallel” and “the optical axis direction Db2 of the second resin base material 30”. 1st resin base material 29, 2nd resin base material 30, the 1st polarizing plate 41, and the 2nd polarizing plate 42 are arranged so that the absorption axis direction Da2 of polarizing layer 48 of the 2nd polarizing plate 42 may become parallel. By doing so, it is possible to suppress “deterioration of viewing angle characteristics and deterioration of light shielding rate during light shielding (that is, during black display)” due to the optical anisotropy of the first resin base material 29 and the second resin base material 30. it can. That is, the resin base material (first resin base material 29 and second resin base material 30) having optical anisotropy inherently affects the transmitted light, and in particular, the light control cell 22 including the VA liquid crystal layer 49. The (light control device 10) deteriorates the viewing angle and the light shielding rate during light shielding. On the other hand, as in the present embodiment, “the optical axis directions Db1 and Db2 of the first resin base material 29 and the second resin base material 30 disposed before and after the liquid crystal layer 49 with respect to the stacking direction are perpendicular to each other” and “liquid crystal The optical axis direction of the base material and the absorption axis direction of the polarizing plate arranged on the same side through the layer 49 (that is, “the optical axis direction Db1 of the first resin base material 29 and the absorption of the polarizing layer 48 of the first polarizing plate 41”). By making the “axis direction Da1” and “the optical axis direction Db2 of the second resin base material 30 and the absorption axis direction Da2 of the polarizing layer 48 of the second polarizing plate 42” parallel ”, the viewing angle and the light shielding rate at the time of light shielding Can be prevented from worsening.

  FIG. 7 is a diagram showing the first resin base material 29, the second resin base material 30, the polarizing layer 48 of the first polarizing plate 41, and the polarizing layer 48 of the second polarizing plate 42, showing a comparison mode with respect to the first arrangement mode. It is. In the comparative mode shown in FIG. 7, the optical axis direction Db1 of the first resin base material 29 is perpendicular to the optical axis direction Db2 of the second resin base material 30, and the absorption axis direction Da1 of the polarizing layer 48 of the first polarizing plate 41. Is perpendicular to the absorption axis direction Da2 of the polarizing layer 48 of the second polarizing plate 42, and the optical axis direction Db1 of the first resin substrate 29 is perpendicular to the absorption axis direction Da1 of the polarizing layer 48 of the first polarizing plate 41. The optical axis direction Db2 of the second resin substrate 30 is perpendicular to the absorption axis direction Da2 of the polarizing layer 48 of the second polarizing plate 42.

  8 is a view angle characteristic of the dimming cell 22 related to the first arrangement mode shown in FIG. 6 (see reference sign “L1” in FIG. 8) and a viewing angle characteristic of the dimming cell 22 related to the comparison mode shown in FIG. FIG. 8 shows a symbol “L2”). The viewing angle characteristics L1 and L2 shown in FIG. 8 are obtained by using the dimmer 10 having the configuration shown in FIG. 1, FIG. 3, FIG. 4A, and FIG. It was obtained by measuring the transmittance while changing the azimuth angle at 60 degrees. The horizontal axis in FIG. 8 indicates the azimuth angle (°), and the vertical axis indicates the total light transmittance (%) including the diffusion component. Note that “azimuth angle = 0 °” illustrated in FIG. 8 corresponds to one side of the absorption axis direction Da1 of the polarizing layer 48 of the first polarizing plate 41.

  The “total light transmittance” here indicates the ratio of the total transmitted light beam to the parallel incident light beam of the test piece, and the “total transmitted light beam” in the case of a diffusible sample indicates the diffused transmitted light beam (diffuse component). Including. The details of the total light transmittance can be determined based on “JIS (Japan Industrial Standards) 7375: 2008”. A “halogen lamp with a dichroic mirror” was used as a light source for measuring the total light transmittance. The total light transmittance is calculated by “the ratio of the light that passes through the light control cell 22” obtained with reference to the light intensity at the wavelength of 555 nm of the light before passing through the light control cell 22 to be measured. Therefore, when the light intensity at the wavelength of 555 nm before being transmitted through the light control cell 22 is represented by “100 (%)”, the light intensity value (%) at the visible light wavelength after transmission through the light control cell 22 is completely changed. The light transmittance can be expressed. The thickness of the light control cell 22 used for the measurement was about 0.55 mm, and a haze meter HM-150 from Murakami Color Research Laboratory was used as a measuring device.

  As is clear from FIG. 8, the first arrangement mode shown in FIG. 6 (see the reference symbol “L1” in FIG. 8) is compared with the comparison mode shown in FIG. 7 (see the reference symbol “L2” in FIG. 8). Thus, it can be seen that the amount of variation in the transmittance with the change in the azimuth angle can be reduced, and the dimming cell 22 (the dimming device 10) having excellent viewing angle characteristics can be provided.

  Further, with regard to the magnitude of the transmittance (total light transmittance) itself, the transmittance L1 of the dimming cell 22 according to the first arrangement mode is more comprehensive than the transmittance L2 of the dimming cell 22 according to the comparative mode. It can be seen that the light control cell 22 according to the first arrangement mode can exhibit excellent light shielding performance.

<Second Arrangement Mode>
FIG. 9 shows the first resin base material 29, the second resin base material 30, the polarizing layer 48 of the first polarizing plate 41, the polarizing layer 48 of the second polarizing plate 42, and the positions for explaining the second arrangement mode. It is a figure which shows the phase difference compensation film 45a.

  In this embodiment, a retardation compensation film 45 a is provided between the first polarizing plate 41 and the first electrode alignment layer 43. The retardation compensation film 45 a is adhered to the first polarizing plate 41 (protective layer 47) via an adhesive layer (OCA) 46, and the first electrode alignment layer 43 via another adhesive layer (OCA) 46. It is adhered to (hard coat layer 53 (see FIG. 4A)) and functions as an A plate. In the retardation compensation film 45a functioning as the A plate, the refractive index (nx) in the x direction in the film plane is larger than the refractive index (ny) in the y direction perpendicular to the x direction. The refractive index (nz) in the vertical z direction becomes equal to the refractive index (ny) in the y direction (that is, the relationship “nx> ny = nz” is satisfied). Although the material which comprises the phase difference compensation film 45a is not specifically limited, The phase difference compensation film 45a of this embodiment is comprised by the biaxially stretched transparent film made by COP.

  The optical axis of the first resin base material 29 is parallel to the optical axis of the second resin base material 30 (see the optical axis directions “Db1” and “Db2” in FIG. 9), and the polarizing layer 48 of the first polarizing plate 41. Is perpendicular to the absorption axis of the polarizing layer 48 of the second polarizing plate 42 (see the absorption axis directions “Da1” and “Da2” in FIG. 9), and the optical axis direction Db1 of the first resin base material 29 is The polarizing axis 48 of the first polarizing plate 41 is perpendicular to the absorption axis direction Da1 of the polarizing plate 48, and the optical axis direction Db2 of the second resin substrate 30 is parallel to the absorption axis direction Da2 of the polarizing layer 48 of the second polarizing plate 42. .

  As described above, the first resin base material 29 and the second resin base material 29 so that the optical axis direction Db1 of the first resin base material 29 and the optical axis direction Db2 of the second resin base material 30 are parallel (match). By disposing the resin base material 30, the first resin base material 29 and the second resin base material 30 can be continuously supplied while being fed from the rolls. In general, the first resin base material 29 and the second resin base material 30 are formed in a roll state, sequentially fed out from the roll, and cut into a shape and size corresponding to each light control cell 22 and used. On the other hand, the base material made of resin has optical anisotropy such that the stretching direction becomes the direction of the optical axis by the stretching process in the manufacturing process, and in the roll state, the longitudinal direction (that is, the feeding direction) is light. Generally, it is the direction of the axis. Therefore, when the optical axis direction Db1 of the first resin base material 29 and the optical axis direction Db2 of the second resin base material 30 coincide with each other as in this arrangement mode, the first resin base material 29 fed out from the roll is used. And the 2nd resin base material 30 drawn | fed out from a roll can be continuously overlap | superposed, paying out, without adjusting a direction. Therefore, for example, the hard coat layer 53, the index matching layer 55, the first electrode layer 31 and the first electrode layer 31 as shown in FIGS. 4A and 4B are formed on the first resin base material 29 and the second resin base material 30 fed out from the roll. By providing the two-electrode layer 32, the first alignment film 33, and the second alignment film 34, the long first electrode alignment layer 43 and the second electrode alignment layer 44 can be produced, and a large-area adjustment is possible. The optical cell 22 can be mass-produced efficiently.

  The first resin base material 29 and the second resin base material 30 so that “the optical axis direction Db1 of the first resin base material 29 and the optical axis direction Db2 of the second resin base material 30 are parallel (match)”. Is arranged, the optical anisotropy of the first resin base material 29 and the second resin base material 30 strongly affects the transmitted light of the light control cell 22, and for example, when the light is shielded (that is, when black is displayed), the viewing angle Characteristics and shading rate may be deteriorated. In order to suppress such deterioration of the viewing angle characteristics and the light shielding rate, in this arrangement mode, the optical axis direction Db2 of the second resin substrate 30 and the absorption axis direction Da2 of the polarizing layer 48 of the second polarizing plate 42 are parallel. The polarizing layer 48 of the 2nd resin base material 30 and the 2nd polarizing plate 42 is arrange | positioned so that it may become. In addition, the phase difference compensation film 45a and the second resin base material 30 are disposed so that the slow axis direction Dc of the phase difference compensation film 45a and the optical axis direction Db2 of the second resin base material 30 are parallel to each other. In addition, the polarizing layer 48 and the second polarized light of the first polarizing plate 41 are set so that the absorption axis direction Da1 of the polarizing layer 48 of the first polarizing plate 41 is perpendicular to the absorption axis direction Da2 of the polarizing layer 48 of the second polarizing plate 42. A polarizing layer 48 of the plate 42 is disposed. Thereby, it is possible to suppress “deterioration of viewing angle characteristics and deterioration of light shielding rate during light shielding (that is, during black display)” due to the optical anisotropy of the first resin base material 29 and the second resin base material 30. .

  As a modification of the second arrangement mode shown in FIG. 9, the second resin base material 30 and the second polarizing plate 42 are not between the first resin base material 29 and the polarizing layer 48 of the first polarizing plate 41. A retardation compensation film 45 a that functions as an A plate may be provided between the polarizing layer 48 and the polarizing layer 48. In this case, the slow axis direction Dc of the retardation compensation film 45a is such that the optical axis direction Db1 of the first resin base material 29, the optical axis direction Db2 of the second resin base material 30, and the polarizing layer 48 of the first polarizing plate 41 Each member is arranged so as to be parallel to the absorption axis direction Da1. Even with such an arrangement, “the deterioration of the viewing angle characteristics and the deterioration of the light shielding rate during light shielding (that is, during black display)” due to the optical anisotropy of the first resin base material 29 and the second resin base material 30 are caused. Can be suppressed.

  FIG. 10 shows the first resin base material 29, the second resin base material 30, the polarizing layer 48 of the first polarizing plate 41, the polarizing layer 48 of the second polarizing plate 42, and the position, showing a comparative mode with respect to the second arrangement mode. It is a figure which shows the phase difference compensation film 45a. 10, the optical axis direction Db1 of the first resin base material 29 is parallel to the optical axis direction Db2 of the second resin base material 30, and the absorption axis direction Da1 of the polarizing layer 48 of the first polarizing plate 41. Is perpendicular to the absorption axis direction Da2 of the polarizing layer 48 of the second polarizing plate 42, but the optical axis direction Db1 of the first resin substrate 29 is parallel to the absorption axis direction Da1 of the polarizing layer 48 of the first polarizing plate 41. The optical axis direction Db2 of the second resin substrate 30 is perpendicular to the absorption axis direction Da2 of the polarizing layer 48 of the second polarizing plate 42.

  11 shows the viewing angle characteristics of the dimming cell 22 related to the second arrangement mode shown in FIG. 9 (see “L3” in FIG. 11) and the viewing angle characteristics of the dimming cell 22 related to the comparative mode shown in FIG. 11 (see reference numeral “L4” in FIG. 11). Note that the viewing angle characteristics L3 and L4 shown in FIG. 11 are the phase difference compensation film 45a (see FIG. 9 and FIG. 9) instead of the phase difference compensation film 45 (see FIG. 3) in the configuration shown in FIGS. 1, 3, 4A and 4B. The light control device 10 is used, and the transmittance is obtained by measuring the transmittance while changing the azimuth angle with the polar angle set to 60 degrees in the light-shielded state (that is, the power supply OFF state). The horizontal axis of FIG. 11 indicates the azimuth angle (°), and the vertical axis indicates the total light transmittance (%) including the diffusion component. Note that “azimuth angle = 0 °” illustrated in FIG. 11 corresponds to one side of the absorption axis direction Da1 of the polarizing layer 48 of the first polarizing plate 41. The total light transmittance was measured in the same manner as in the case shown in FIG.

  As is clear from FIG. 11, the second arrangement mode shown in FIG. 9 (see “L3” in FIG. 11) compares with the comparative mode shown in FIG. 10 (see “L4” in FIG. 11). Thus, it can be seen that the amount of variation in the transmittance with the change in the azimuth angle can be reduced, and the dimming cell 22 (the dimming device 10) having excellent viewing angle characteristics can be provided.

  Further, regarding the size of the transmittance (total light transmittance) itself, the transmittance L3 of the light control cell 22 according to the second arrangement mode is more overall than the transmittance L4 of the light control cell 22 according to the comparison mode. It can be seen that the light control cell 22 according to the second arrangement mode can exhibit excellent light shielding performance.

<Example>
Next, various examples relating to the verification results of the bonding performance of the light control cell 22 to the light transmission plate 21 will be described.

  FIG. 12 is a table showing a state evaluation of bonding of the light control cell 22 (Examples 1 to 3) to the curved surface 20 of the light transmission plate 21.

  In the light control device 10 of Example 1 and Example 3, the same light control cell 22 is used, but the planar size of the light transmission plate 21 (X direction size and Y direction size in the direction perpendicular to the stacking direction), The thickness (length in the stacking direction (Z-direction size)) and the curvature of the curved surface 20 of the light transmission plate 21 are different. In FIG. 12, “1800R” indicates the curvature of a curve drawn by a circle having a radius of 1800 mm, and “1400R” indicates the curvature of a curve drawn by a circle having a radius of 1400 mm.

  The dimming cell 22 used in the dimming device 10 of Example 1 and Example 3 has a planar size (X direction size and Y direction size perpendicular to the stacking direction) of 280 mm (X direction size) and 288 mm. (Y direction size), thickness (length in the stacking direction (Z direction size)) is 0.63 mm, and base material (see the first resin base material 29 and the second resin base material 30 in FIG. 3). Polycarbonate is used as the electrode substrate, an ITO film using this polycarbonate substrate is used as the electrode substrate, and a dye system that has a proven track record in liquid crystal displays (LCD) and car navigation applications as a polarizing layer (see polarizing layer 48 in FIG. 3). In addition, as a spacer (see spacer 52 in FIG. 3) provided in the liquid crystal layer 49, a large number of randomly arranged elements having a diameter of 6 μm are used. A hybrid seal material 36 using a UV spacer and a UV curable resin and a thermosetting resin, and having a length in the width direction (length in a direction perpendicular to the stacking direction) of 1.5 mm. Was used.

  On the other hand, in the light control apparatus 10 of Example 2, the same light transmission plate 21 as Example 3 is used, and plane size (X direction size and Y direction size perpendicular to the stacking direction) is 423 mm (X direction size). And 337 mm (Y-direction size), and the thickness (length in the stacking direction (Z-direction size)) was 0.7 mm. Further, the dimming cell 22 used in the dimming device 10 of Example 2 has a planar size (X direction size and Y direction size perpendicular to the stacking direction) of 280 mm (X direction size) and 280 mm (Y direction). Size), the thickness (length in the stacking direction (Z-direction size)) is 0.54 mm, and COP is used as a base (see the first resin base 29 and the second resin base 30 in FIG. 3). A COP biaxial plate for VA compensation is used as an optical compensation film of a polarizing plate (see the polarizing layer 48 in FIG. 3), and a cross-sectional diameter of 15 μm as a spacer (see the spacer 52 in FIG. 3) provided in the liquid crystal layer 49 And a plurality of columnar spacers spaced apart at a pitch of 230 μm were used, and a sealing material 36 having a length in the width direction (length in a direction perpendicular to the stacking direction) of 5 mm was used. The other structure of the light control cell 22 of Example 2 was the same as that of the light control cell 22 of Examples 1 and 3 described above.

  The other structure of the light modulation apparatus 10 which concerns on Examples 1-3 was the same as that of the structure shown in FIG.

  In the light control device 10 of the above-described first to third embodiments, when the dimming cell 22 is bonded to the light transmission plate 21 by visual observation, noticeable distortion is observed in the light control cells 22 of the first and third embodiments. While no wrinkles were generated, wrinkles were conspicuous in the light control cell 22 of Example 2, and the light control cell 22 could not be properly bonded to the light transmission plate 21.

  FIG. 13 is a table showing a state evaluation of bonding of the light control cell 22 (Examples 4 to 9) to the curved surface 20 of the light transmission plate 21.

  In Examples 4 to 9, “light control cell 22 having different characteristics” is pasted on “light transmissive plate 21 having the same characteristics” via “optical transparent adhesive film 24 having the same characteristics”, and light is transmitted. The state of the light control cell 22 attached to the transmission plate 21 was evaluated. Specifically, the light transmission plate 21 had a planar size of 423 mm (length in the X direction) and 337 mm (length in the Y direction), and a thickness (length in the Z direction) of 0.7 mm.

  The dimming cell 22 mainly includes a base material (see the first resin base material 29 in FIG. 4A and the second resin base material 30 in FIG. 4B), the shape of the spacer 52, and the length in the width direction of the sealing material 36 (see FIG. 13 “see seal width”), the first polarizing plate 41 (see in particular “polarizing layer 48” in FIG. 3) and the second polarizing plate 42 (see in particular “polarizing layer 48” in FIG. 3) as shown in FIG. Was changed as appropriate.

  The item “substrate” in FIG. 13 represents the components of the substrate actually used, and COP (Examples 4, 6 and 7) or polycarbonate (Examples 5 and 8 to 9) was used.

  In the item of “spacer” in FIG. 13, “columnar” indicates that a plurality of cylindrical spacers 52 having a cross-sectional diameter of 15 μm are spaced apart at a pitch of 230 μm, and “bead-shaped” indicates a diameter of 6 μm. It shows that a plurality of spherical spacers 52 having the following are arranged at random.

  In the “seal width” of FIG. 13, “5 mm (+ margin 5 mm)” indicates that the length of the sealing material 36 in the direction perpendicular to the stacking direction is 5 mm and is opposite to the liquid crystal layer 49 via the sealing material 36. 3 shows a state in which the first electrode alignment layer 43 and the second electrode alignment layer 44 protrude by 5 mm in the direction perpendicular to the stacking direction. Further, “1.5 mm (+ margin 0 mm)” means that the length of the sealing material 36 in the direction perpendicular to the stacking direction is 1.5 mm, and the stacking direction is opposite to the liquid crystal layer 49 via the sealing material 36. The first electrode alignment layer 43 and the second electrode alignment layer 44 protrude by 0 mm with respect to the direction perpendicular to the direction (that is, the first electrode alignment layer 43 and the second electrode alignment layer 44 do not protrude from the sealing material 36). Indicates.

  In FIG. 13, “first polarizing plate” indicates a member of the polarizing layer 48 of the first polarizing plate 41, and “second polarizing plate” indicates a member of the polarizing layer 48 of the second polarizing plate 42. “Iodine-based (with COP biaxial compensator)” in FIG. 13 is an iodine-based polarizer, and a polarizing layer 48 is constituted by a polarizer to which a COP plate having biaxial optical compensation performance is attached. “Iodine-based” indicates that the polarizing layer 48 is composed of an iodine-based polarizer (without an optical compensator), and “Dye-based” indicates that a dye-based polarizer (without an optical compensator) It shows that the polarizing layer 48 is configured.

  The “bonding state” in FIG. 13 indicates the state of the light control cell 22 bonded to the curved surface 20 of the light transmission plate 21 via the optical transparent adhesive film 24 (particularly, the degree and presence of distortion such as wrinkles). In “Very Bad” (Example 4), a very conspicuous wrinkle is generated in the dimming cell 22, and a cylindrical wrinkle portion called tunneling is formed in the dimming cell 22, so that the dimming cell 22 can be used practically. Indicates that there is no state. In “Bad” (Example 5), a noticeable wrinkle occurs in the dimming cell 22, tunneling is formed in the dimming cell 22, and the dimming cell 22 is in a state where it is not easy to use practically. Show. “Average” (Example 6) indicates that a small tunneling is formed in the dimming cell 22 although the wrinkles generated in the dimming cell 22 are not noticeable. “Good” (Example 7) shows that the light control cell 22 is slightly inconspicuous but the tunneling is not formed, and the light control cell 22 is in a practical state. In “Excellent” (Examples 8 to 9), distortion such as wrinkles was not confirmed in the light control cell 22, and the light control cell 22 was attached to the light transmission plate 21 in a very good state. It shows that the cell 22 is in a state of exhibiting good light transmission performance and light shielding performance.

  The other configuration of the light control device 10 according to Examples 4 to 9 was the same as the configuration illustrated in FIG.

  From the results shown in FIG. 13, it can be seen that the bonding state of the light control cell 22 is improved in the light control device 10 of Examples 5 to 7 compared to the light control device 10 of Example 4. The light control cell 22 of Example 5 is the same as that of Example 5 except that polycarbonate is used instead of COP as the base material (see the first resin base material 29 in FIG. 4A and the second resin base material 30 in FIG. 4B). It has the same configuration as the four light control cells 22. Therefore, it can be seen that polycarbonate is preferable as a constituent material of the first resin base material 29 and the second resin base material 30. In addition, the light control cell 22 of Example 6 includes an “iodine-based polarizer to which a COP plate having biaxial optical compensation performance is attached” as the polarizing layer 48 of the first polarizing plate 41 and the second polarizing plate 42. It has the same configuration as the light control cell 22 of Example 4 except that a “dye polarizer” is used instead of an “iodine polarizer”. Therefore, it can be seen that a dye-based polarizer is preferable as a constituent material of the polarizing layer 48 of the first polarizing plate 41 and the second polarizing plate 42. Further, in the light control cell 22 of Example 7, the width of the sealing material 36 is 1.5 mm and there is no extension of the first electrode alignment layer 43 and the second electrode alignment layer 44 (that is, “margin = 0 mm”). Except for this, it has the same configuration as the light control cell 22 of the fourth embodiment. Therefore, it can be seen that the width of the sealing material 36 in the direction perpendicular to the stacking direction is preferably 1.5 mm. If the width of the sealing material 36 is too thin, the light control cell 22 may be broken due to a decrease in the adhesion of the sealing material 36. On the other hand, if the width of the sealing material 36 is too large, the followability of the sealing material 36 to a curved surface whose shape changes three-dimensionally may be insufficient.

  In the light control cells 22 of Examples 8 to 9 shown in FIG. 13, “polycarbonate is used as a constituent material of the first resin base material 29 and the second resin base material 30 (see Example 5)”, “ A dye-based polarizer is used as a constituent material of the polarizing layer 48 of the polarizing plate 41 and the second polarizing plate 42 (see Example 6) ”and“ the width of the sealing material 36 is 1.5 mm and the first electrode orientation Except for the point that there is no extension of the layer 43 and the second electrode alignment layer 44 (see Example 7), it has the same configuration as the light control cell 22 of Example 4. Since the bonding state of the light control cell 22 according to Examples 8 to 9 was in a better state than the light control cell 22 according to Examples 4 to 7, the above considerations of Examples 4 to 7 were appropriate. It is inferred that

  The light control cell 22 of Example 8 and the light control cell 22 of Example 9 have the same configuration except that the shape of the spacer 52 is different, but the light control cell 22 of Example 8 and the light control cell of Example 9 are the same. The bonding state of the optical cell 22 was very good. Therefore, it is presumed that the shape of the spacer 52 has no or very little influence on the bonding state of the light control cell 22.

  FIG. 14 is a table showing a state evaluation of bonding of the light control cell 22 (Examples 10 to 12) to the curved surface 20 of the light transmission plate 21.

  In Examples 10 to 12, the “light control cell 22 having the same characteristics” is attached to the “light transmitting plate 21 having the same characteristics” via the “optical transparent adhesive film 24 having different characteristics”, and the light is transmitted. The state of the light control cell 22 attached to the transmission plate 21 was evaluated. Specifically, the light transmission plate 21 and the light control cell 22 having the same characteristics as those of the above-described Example 8 (FIG. 13) are used, but the thickness in the stacking direction, the storage elastic modulus at room temperature, and the loss tangent are different. An optical transparent adhesive film 24 was used. These physical properties of Examples 10 to 12 shown in FIG. 14 are set such that the frequency is set to 10 Hz (Hertz), the temperature raising condition is set to 5 ° C./min (minutes), and UBM Co., Ltd. It is a value obtained by measurement using a measuring instrument “Rheogel E4000”. FIG. 14 shows the storage elastic modulus and loss tangent at 25 ° C. and 50 ° C., respectively.

  With regard to the item of “bonding state of light control cell” in FIG. 14, “Average” (Example 10) indicates a state in which some distortion is observed in the light control cell 22. “Good” (Example 11) indicates that the dimming cell 22 has a distortion smaller than that of the dimming cell 22 of Example 10, but the dimming cell 22 is in a relatively good state. . “Excellent” (Example 12) indicates that there is no distortion in the dimming cell 22 and the dimming cell 22 is in a very good state.

From the viewpoint of improving the bonding state of the light control cell 22 to the light transmission plate 21, the storage elastic modulus of the optical transparent adhesive film 24 is preferably smaller (for example, Example 10 ( It can be seen that “2.9 × 10 ⁷ Pa / 25 ° C.”) and Example 11 (“1.1 × 10 ⁷ Pa / 25 ° C.”) are used. Furthermore, it is preferable that the loss tangent of the optical transparent adhesive film 24 is small (see, for example, Example 10 (“0.95 / 25 ° C.”), Example 11 (“0.90 / 25 ° C.”)) and Example 12 ( “0.41 / 25 ° C.”). Moreover, although it is thought that the one where the thickness of the optical transparent adhesive film 24 regarding a lamination direction is thicker is preferable, when Examples 10-12 are compared, the storage elastic modulus of the optical transparent adhesive film 24 rather than the thickness of the optical transparent adhesive film 24 and It is considered that the loss tangent has a greater influence on the bonding state of the light control cell 22 with respect to the light transmission plate 21.

<Detailed configuration of spacer>
Hereinafter, an example of a preferable relationship between “the hardness of the spacer 52” and “the hardness of the portion where the tip of the spacer 52 abuts” will be described.

  In the embodiment described below, the spacer 52 is formed in a columnar shape or a truncated cone shape using a photoresist by the manufacturing process of the light control cell 22 shown in FIG. That is, in the manufacturing process of the light control cell 22, manufacture of the 1st laminated body (refer code | symbol "SP1" of FIG. 15), manufacture of the 2nd laminated body (refer code | symbol "SP2" of FIG. 15), liquid crystal cell (FIG. 3 (refer to reference numeral “SP3” in FIG. 15) and lamination of these members (refer to reference numeral “SP4” in FIG. 15) are sequentially performed. In addition, in the manufacturing process SP1 of the first stacked body, the manufacturing process SP1-1 of the electrode (that is, the “second electrode layer 32”), the manufacturing process SP1-2 of the spacer 52, and the alignment layer (that is, the “second alignment film 34”). )) Manufacturing process SP1-3. Although not shown, the manufacturing process SP2 of the second stacked body includes a manufacturing process of the electrode (that is, the first electrode layer 31) and a manufacturing process of the alignment layer (that is, the “first alignment film 33”). . Thus, the spacers 52 are manufactured, and in this embodiment, the Vickers hardness value Xs of each spacer 52 is 16.9 or more and 40.2 or less (that is, “16.9 ≦ Xs ≦ 40.2” is satisfied). The Vickers hardness value Xf of the portion of the first electrode alignment layer 43 (especially the first alignment film 33) with which the tip of the spacer 52 abuts is set to be 11.8 or more and 35.9 or less (that is, “ 11.8.ltoreq.Xf.ltoreq.35.9 "), which further improves the reliability of the spacer as compared with the prior art. In addition, the value of Vickers hardness is a measured value under the conditions described in the following examples.

  For example, in the case where each spacer 52 is configured only by the core portion without the covering portion (that is, when the spacer 52 includes the core portion but does not include the covering portion), a plurality of spacers (core portions) 52 are provided. The above Xs is represented by each Vickers hardness value, and the above Xf is represented by the Vickers hardness value of the portion of the first alignment film 33 where the tips of the plurality of spacers 52 abut. On the other hand, when the covering portion is provided on the core portion and each spacer 52 is configured mainly by a combination of the core portion and the covering portion (that is, when the spacer 52 includes the core portion and the covering portion), each spacer 52 Xs is expressed by the Vickers hardness value of the core portion and the covering portion, and the Xf is determined by the Vickers hardness value of the portion of the first alignment film 33 where the covering portion covering each tip of the plurality of spacers 52 abuts. expressed. Here, “the Vickers hardness value of the core portion and the covering portion of each spacer 52” means a Vickers hardness value measured in a state where the core portion is covered with the covering portion.

  When the Vickers hardness value Xf of the portion of the first electrode alignment layer 43 (particularly the first alignment film 33) with which the tip of the spacer 52 abuts is less than 11.8, the tip of the spacer 52 faces due to the pressing force during use. As a result, the cell gap becomes non-uniform or local alignment failure occurs. Further, in this case, the first resin base material 29 may be scratched due to contact during assembly of the spacer 52 or a crack may be generated when the whole is bent.

  When the Vickers hardness value Xs of the spacer 52 is less than 16.9, the spacer 52 is crushed by the external pressure, the cell gap is reduced, and a desired cell gap cannot be obtained. Further, when the Vickers hardness value Xs of the spacer 52 exceeds 40.2, or the Vickers hardness value Xf of the portion of the first electrode alignment layer 43 (particularly the first alignment film 33) with which the tip of the spacer 52 abuts is 35.9. Even if it exceeds, the cell gap may be reduced or scratches or cracks may occur.

  However, the Vickers hardness value Xs of the spacer 52 is 16.9 or more and 40.2 or less, and the Vickers hardness value Xf of the first electrode alignment layer 43 (particularly the first alignment film 33) with which the tip of the spacer 52 abuts is If it is set to be 11.8 or more and 35.9 or less, these problems can be solved at once, and the reliability related to the spacer 52 can be further improved as compared with the related art.

〔Test results〕
FIG. 16 and FIG. 17 are charts showing test results used for confirming the configuration related to this spacer. The embodiment in FIGS. 16 and 17 has the same configuration except that the configuration regarding the spacer 52 and the alignment layer with which the spacer 52 abuts is different. More specifically, in the light control cells of these examples, the spacer 52 is provided only in the lower laminate (see the second electrode alignment layer 44), and the manufacturing conditions relating to the spacer 52 are adjusted. The Vickers hardness value Xs of the spacer 52 was changed. Further, by adjusting the conditions for manufacturing the first alignment film 33, the Vickers hardness value Xf of the portion of the first electrode alignment layer 43 (particularly the first alignment film 33) with which the tip of the spacer 52 abuts was changed. .

  That is, the spacer 52 is coated with the coating liquid related to the spacer 52, dried, and then selectively exposes a portion for manufacturing the spacer 52 by mask exposure using an exposure apparatus. Note that this is a case of a negative type photoresist. On the contrary, in a positive type photoresist, a portion other than the portion where the spacer 52 is disposed is selectively exposed. After that, the spacer 52 is subjected to a process such as rinsing by selectively removing an unexposed part or an exposed part by a development process, and a process such as drying is executed as necessary.

  In this exposure process, there is a case where the photoresist is heated in advance to perform a so-called half-cured photoresist, or the exposure process is performed in a heated environment. In some cases, after the treatment is performed, the reaction is promoted by performing a heat treatment. The hardness value Xs of the spacer 52 is the selection of the photoresist material related to the spacer 52, the coating process, the exposure process, the heating temperature in baking in the oven, the heating temperature in the developing process, the setting of time, the exposure light quantity and the exposure time. , And according to the setting of the mask cap.

  In this embodiment, the Vickers hardness value Xs of the spacer 52 is 14.8, 16.9, 22.2, 40.2, or 51 by adjusting the heating temperature and time in the exposure step and the development step, respectively. 4 was produced (see the second electrode alignment layer 44) (FIG. 18). The hardness is adjusted by using the lower laminate (see the second electrode alignment layer 44), which is manufactured by adjusting the manufacturing conditions of the spacer 52, respectively. This is a measurement value obtained by disassembling and measuring the optical cell 22 once manufactured. Further, this measurement value is a measurement result obtained by measuring 12 points in each dimming cell and averaging the remaining 10 points excluding the maximum value and the minimum value.

The spacer 52 was manufactured in a cylindrical shape having a diameter of 9 μm and a height of 6 μm. In addition, the spacers 52 are regularly arranged at a pitch of 110 μm in two directions orthogonal to the in-plane direction of the second resin base material 30. Accordingly, the ratio (occupancy) of the spacers 52 on the second resin base material 30 is 0.5% (= ((9/2) ² × 3) / (110) ² ).

  Increasing the occupation ratio of the spacer 52 reduces the stress applied to each spacer, thereby reducing the phenomenon that the spacer 52 is crushed or the tip penetrates, but the transmittance is deteriorated, The shading rate may deteriorate. However, when the occupation ratio of the spacer 52 is small, optical characteristics such as transmittance and light shielding ratio can be secured, but it is unavoidable that the spacer 52 is crushed or the tip penetrates. Accordingly, the occupation ratio of the spacer 52 is desirably 0.5% or more and 10% or less.

  On the other hand, the first alignment film 33 of the first electrode alignment layer 43 on which the spacer 52 abuts is manufactured by applying a coating liquid, drying and thermosetting, and the conditions for this thermosetting The Vickers hardness value Xf was set to a desired value by adjusting (heating temperature and heating time) and the like. Thereby, in the Example, the 1st electrode orientation layer 43 whose Vickers hardness value Xf is 10.2, 11.8, 24.8, 35.9, or 38.5 was manufactured (FIG. 19). The hardness value Xf is a first electrode alignment layer having a different hardness with respect to the first alignment film 33 of the first electrode alignment layer 43, which is a surface on which the spacer 52 abuts by adjusting the manufacturing conditions of the first alignment film 33. 43, and the light control cell 22 is once manufactured by using the first electrode alignment layer 43, and then measured by disassembling and measuring. In addition, this measurement value is a measurement result of an average value of 10 points which are measured at 12 points and are left excluding the maximum value and the minimum value.

  The Vickers hardness values Xs and Xf were measured using a PICODETOR HM500 manufactured by Helmut Fischer. The measurement was performed under the measurement conditions of a maximum load of 100 mN with an indentation speed of 300 mN / 20 sec, a release speed of 300 mN / 20 sec, and a creep time of 5 seconds.

  In each of the examples of FIGS. 16 and 17, a dimming cell was manufactured and tested using the first electrode alignment layer 43 and the second electrode alignment layer 44 thus manufactured. 16 and 17, in the state where the light control cell is placed on a smooth surface having high hardness by a surface plate, a load corresponding to 0.8 MPa is applied and then the cell gap is measured to reduce the cell gap. Judged. The weighting time is 24 hours. Further, after weighting in this way, the upper laminated body including the first alignment film 33 and the lower laminated body including the second alignment film 34 are peeled off, and the spacer 52 is observed with a microscope. The reduction of the cell gap was observed by observing "spacer collapse", and the portion where the spacer 52 abuts was observed with a microscope to observe the penetration of the tip of the spacer 52 (film penetration).

  Here, in this microscopic observation, a front view, a perspective view, and a cross section are observed using a technique such as SEM, and the presence or absence of deformation of the spacer 52 is visually confirmed. If deformation of the spacer 52 is confirmed, the situation is confirmed. According to the above, the presence or absence of “cell gap decrease, spacer collapse” was evaluated as ◯ Δ. Accordingly, in FIGS. 16 and 17, “◯” indicates a case where no abnormality related to the corresponding item is observed, and “Δ” indicates a case where abnormality regarding the corresponding item is observed.

  Similarly, if the area where the spacer 52 abuts is perspective using a technique such as SEM and a depression (recess) is confirmed, “film penetration” is determined as “△”, and the recess is not recognized. “Film penetration” was evaluated as “◯”.

  In the state where the first electrode alignment layer 43 and the second electrode alignment layer 44 are stacked and a load corresponding to 0.1 MPa is applied, the relative positions of the first electrode alignment layer 43 and the second electrode alignment layer 44 are set to 0. 0. Displacement was performed at 1 cm / sec, and the occurrence of scratches was confirmed visually. Here, when the occurrence of scratches is confirmed in more than half of the plurality of samples, the item “scratch” in FIGS. 16 and 17 is indicated by “Δ”, and conversely, scratches are observed in more than half of the plurality of samples. When the occurrence is not confirmed, the item “scratch” is indicated by “◯”.

  In the state of the light control cell, the light control cell is wound around a cylindrical mandrel having a diameter of 2 mm in accordance with the bending test of JIS K5600-5-1, and the base material (first resin base material 29 and second resin base material). 3), the presence or absence of cracks was confirmed. In this test, when the occurrence of cracks in the substrate was confirmed in more than half of the plurality of samples, the item of “crack” in FIG. 16 and FIG. 17 is indicated by “△”. When the generation of cracks in the substrate is not confirmed in more than half, the item of “crack” is indicated by “◯”.

  As is apparent from the measurement results of FIGS. 16 and 17, when the Vickers hardness value Xs of the spacer 52 is less than 16.9 (Examples 30 and 32), a decrease in the cell gap is observed. Then, penetration of the spacer tip into the film, scratches and cracks were observed. When the Vickers hardness value Xf of the portion of the first electrode alignment layer 43 (particularly the first alignment film 33) with which the tip of the spacer 52 abuts is less than 11.8 (Examples 20 and 22), scratches and cracks are generated. Observed, and in Example 22, penetration of the spacer tip into the film was observed.

  In addition, when the Vickers hardness value Xs of the spacer 52 exceeds 40.2 (Examples 31 and 33), in Example 31, a decrease in the cell gap and penetration of the spacer tip into the film are observed. Observed. Further, when the Vickers hardness value Xf of the portion of the first electrode alignment layer 43 (particularly the first alignment film 33) with which the tip of the spacer 52 abuts exceeds 35.9 (Examples 21 and 23), the cell gap is reduced and scratched. Was observed, and in Example 23, cracks were observed.

  However, in Examples 13 to 19 and 24-29, these phenomena ("cell gap reduction", "film penetration", "scratch" and "crack" shown in FIGS. 16 and 17) are not observed, As a result, it was confirmed that the reliability of the spacer 52 can be sufficiently secured.

  The present invention is not limited to the above-described embodiments and modifications, and can include various aspects to which various modifications that can be conceived by those skilled in the art can be included. It is not limited to the matter of. Therefore, various additions, modifications, and partial deletions can be made to each element described in the claims and the specification without departing from the technical idea and spirit of the present invention.

DESCRIPTION OF SYMBOLS 10 Light control apparatus 20 Curved surface 20a Three-dimensional curved surface 21 Light transmission plate 22 Light control cell 24 Optical transparent adhesion film 26 Hard coat layer 29 1st resin base material 30 2nd resin base material 31 1st electrode layer 32 2nd electrode layer 33 First alignment film 34 Second alignment film 35 Liquid crystal space 36 Sealing material 41 First polarizing plate 42 Second polarizing plate 43 First electrode alignment layer 44 Second electrode alignment layer 45 Phase difference compensation film 45a Phase difference compensation film 46 Adhesive layer 47 Protective layer 48 Polarizing layer 49 Liquid crystal layer 52 Spacer 53 Hard coat layer 55 Index matching layer

Claims (18)

A light transmissive plate having a curved surface;
A dimming cell;
A light control device comprising: an optical transparent adhesive film that is disposed between the curved surface of the light transmission plate and the light control cell, and adheres one side of the light control cell to the curved surface of the light transmission plate.   The light control device according to claim 1, wherein the light transmission plate has higher rigidity than the light control cell.   The light control device according to claim 1, wherein the light control cell includes a liquid crystal layer of a VA method, a TN method, an IPS method, or an FFS method.   The said light control cell is a light control apparatus as described in any one of Claims 1-3 containing a resin base material. The optical transparent adhesive film has a thickness in the direction in which the optical transparent adhesive film and the light control cell are laminated of 50 μm or more and 500 μm or less, and a storage elastic modulus in a room temperature environment is 1 × 10 ⁷ Pa or more and 1 ×. It is 10 < ⁸ > Pa or less, The light modulation apparatus as described in any one of Claims 1-4.   The light control device according to any one of claims 1 to 5, wherein the optical transparent adhesive film has a loss tangent of 0.5 to 1.5.   The light control device according to claim 1, wherein the curved surface of the light transmission plate is a three-dimensional curved surface. The light transmission plate includes an ultraviolet light blocking component that blocks ultraviolet light transmission,
The dimming cell is
A first polarizing plate and a second polarizing plate provided at a position farther from the light transmission plate than the first polarizing plate;
A hard coat layer provided at a position farther from the light transmission plate than the second polarizing plate;
A first resin substrate disposed between the first polarizing plate and the second polarizing plate and disposed on the first polarizing plate side; and a second resin substrate disposed on the second polarizing plate side; ,
A first electrode layer disposed between the first resin base material and the second resin base material and disposed on the first resin base material side and a second electrode disposed on the second resin base material side Layers,
A first alignment film disposed between the first electrode layer and the second electrode layer and disposed on the first electrode layer side; and a second alignment film disposed on the second electrode layer side;
A sealing material provided between the first alignment film and the second alignment film and defining a liquid crystal space between the first alignment film and the second alignment film;
The light control apparatus as described in any one of Claims 1-7 containing the liquid crystal layer provided in the said liquid crystal space.   The light control device according to claim 8, wherein at least one of the first resin base material and the second resin base material includes a polycarbonate or a cycloolefin polymer.   10. The light control device according to claim 8, wherein the sealing material has a length in a direction perpendicular to a direction in which the first alignment film, the sealing material, and the second alignment film are stacked of 1 mm or more and 5 mm or less. .   The light control device according to claim 8, wherein the liquid crystal layer has a negative pressure in the liquid crystal space.   The phase difference compensation film provided further in at least any one between the said 1st polarizing plate and the said 1st electrode layer, and between the said 2nd polarizing plate and the said 2nd electrode layer is further provided. The light modulation apparatus as described in any one of these.   The light control device according to any one of claims 8 to 12, wherein the liquid crystal layer is a TN liquid crystal layer or a VA liquid crystal layer. The optical axis of the first resin substrate is perpendicular to the optical axis of the second resin substrate;
The optical axis of the first resin substrate and the absorption axis of the first polarizing plate are parallel,
The light control device according to claim 13, wherein an optical axis of the second resin substrate and an absorption axis of the second polarizing plate are parallel to each other. The optical axis of the first resin base and the optical axis of the second resin base are parallel,
The optical axis of the first resin substrate is perpendicular to the absorption axis of the first polarizing plate;
The light control device according to claim 13, wherein an optical axis of the second resin substrate and an absorption axis of the second polarizing plate are parallel to each other. A phase difference compensation film provided between the first resin base material and the first polarizing plate;
The absorption axis of the first polarizing plate is perpendicular to the absorption axis of the second polarizing plate,
The retardation compensation film functions as an A plate,
The slow axis direction of the retardation compensation film is parallel to the optical axis of the first resin substrate, the optical axis of the second resin substrate, and the absorption axis of the second polarizing plate. Dimming device. A phase difference compensation film provided between the second resin substrate and the second polarizing plate;
The absorption axis of the first polarizing plate is perpendicular to the absorption axis of the second polarizing plate,
The retardation compensation film functions as an A plate,
The slow axis direction of the retardation compensation film is parallel to the optical axis of the first resin substrate, the optical axis of the second resin substrate, and the absorption axis of the first polarizing plate. Dimming device. A plurality of spacers disposed in at least the liquid crystal space and supporting the first alignment film and the second alignment film;
When the Vickers hardness value of each of the plurality of spacers is represented by Xs, and the Vickers hardness value of the portion of the first alignment film in contact with each of the plurality of spacers is represented by Xf, 16.9 ≦ Xs ≦ The light control device according to any one of claims 8 to 17, wherein 40.2 is satisfied and 11.8 ≦ Xf ≦ 35.9 is satisfied.

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