JP2021124678A - Manufacturing method of dimming device - Google Patents

Abstract

To provide a manufacturing method of a dimming device, capable of suppressing a generation of a liquid crystal pool, a phenomenon of a large amount of liquid crystal locally present.SOLUTION: A manufacturing method of a dimming device 10 includes: a step of producing a laminate 30 having a first glass plate 11, a first intermediary body 13, a film 33, a dimming cell 20, a second intermediary body 14 and a second glass plate 12; a step of arranging the laminate 30 inside a vacuum bag 51 and heating the laminate 30 at first temperature while applying degasification; and a step of taking out the laminate 30 from the vacuum bag 51 and heating the laminate 30 at second temperature while applying pressure. The first temperature is lower than the second temperature.SELECTED DRAWING: Figure 6

Description

The present disclosure relates to a method for manufacturing a dimmer.

Conventionally, a dimming member that is used in combination with a translucent member such as a window and can be used for an electronic blind or the like that controls the transmission of external light, a dimming device using such a dimming member, or the like has been proposed. (See, for example, Patent Documents 1 and 2). A liquid crystal film provided with a liquid crystal layer is known as one of such dimming members. This liquid crystal film is produced by sandwiching a liquid crystal material with a transparent resin base material including a transparent electrode, and further sandwiching the liquid crystal material with a linear polarizing plate. Then, the liquid crystal film can change the orientation of the liquid crystal by changing the electric field applied between the transparent electrodes, and can control the amount of transmitted external light.

Japanese Patent No. 6135816 JP-A-2017-187810

When such a liquid crystal film is used as a dimming member that can be used for a roof window, a side window, etc. of an automobile, it is preferable to sandwich the liquid crystal film between a pair of glasses via an interlayer film to form a laminated glass. be. However, in laminated glass with a liquid crystal film sandwiched between them, if the pressure applied to the surface of each member when they are integrally crimped is not uniform, or if the shapes of the glass or interlayer film used do not match vertically, the interlayer film or liquid crystal display Due to the uneven distribution of the liquid crystal, such as when the film is wrinkled, liquid crystal lumps, which is a phenomenon in which a large amount of liquid crystal is locally present, are likely to occur, and the quality and appearance of the laminated glass having a dimming function are deteriorated. There's a problem.

The present embodiment provides a method for manufacturing a dimming device capable of uniformly dispersing liquid crystals in a plane and suppressing the occurrence of liquid crystal lumps, which is a phenomenon in which a large amount of liquid crystals are locally present.

The method for manufacturing a dimming device according to the present embodiment prepares a laminate having a first transparent substrate, a first intermediate, a film, a dimming cell, a second intermediate, and a second transparent substrate. A step of arranging the laminate in a vacuum bag and heating the laminate at a first temperature while degassing, and a step of taking the laminate out of the vacuum bag and pressurizing the laminate. A method for manufacturing a dimming device, comprising a step of heating at a second temperature, wherein the first temperature is lower than the second temperature.

In the method for manufacturing a dimmer according to the present embodiment, in the step of heating the laminated body at the first temperature while degassing, the laminated body is degassed at a degree of vacuum of -100 kPa or more and -10 kPa or less. The first temperature may be 50 ° C. or higher and 90 ° C. or lower.

In the method for manufacturing a dimmer according to the present embodiment, in the step of heating the laminate at a second temperature while pressurizing the laminate, the laminate is pressurized at 0.1 MPa or more and 1.3 MPa or less, and the second The temperature may be 90 ° C. or higher and 140 ° C. or lower.

The method for manufacturing a dimmer according to the present embodiment includes a first transparent substrate, a first intermediate, a film, a dimming cell, a second intermediate, and a second transparent substrate, and the film. A step of producing a laminated body in which a space between the light control cell and the dimming cell and a communication hole for communicating with the outside air are provided, and the laminated body is arranged in a vacuum bag, and the laminated body is first placed. A step of heating at a first temperature while degassing at a degree of vacuum, and a step of arranging the laminate in the vacuum bag and heating and pressurizing the laminate at a second temperature while degassing at a second degree of vacuum. The second vacuum degree is lower than the first vacuum degree, which is a method for manufacturing a dimming device.

In the method for manufacturing a dimmer according to the present embodiment, the first degree of vacuum may be -100 kPa or more and -10 kPa or less.

In the method for manufacturing a dimmer according to the present embodiment, the second degree of vacuum may be −10 kPa or more and -1 kPa or less.

In the method for manufacturing a dimmer according to the present embodiment, the second temperature may be higher than the first temperature.

In the method for manufacturing a dimmer according to the present embodiment, the first temperature may be 50 ° C. or higher and 90 ° C. or lower.

The method for manufacturing a dimmer according to the present embodiment includes a first transparent substrate, a first intermediate, a film, a dimming cell, a second intermediate, and a second transparent substrate, and the film. A step of producing a laminated body in which a space between the light control cell and the dimming cell and a communication hole for communicating with the outside air are provided, and the laminated body is arranged in a vacuum bag, and the laminated body is placed in a second vacuum bag. It is a method for manufacturing a dimmer, comprising a step of heating and pressurizing at a second temperature while degassing at a degree of vacuum, wherein the degree of second vacuum is -10 kPa or more and -1 kPa or less.

In the method for manufacturing a dimmer according to the present embodiment, in the step of heating and pressurizing the laminated body at a second temperature while degassing the laminated body at a second vacuum degree, the laminated body is 0.1 MPa or more and 0.8 MPa or less. The second temperature may be 90 ° C. or higher and 140 ° C. or lower.

The method for manufacturing a dimmer according to the present embodiment includes a first transparent substrate, a first intermediate, a film, a dimming cell, a second intermediate, and a second transparent substrate, and the film. A step of producing a laminate in which a space between the light control cell and the dimming cell and a communication hole for communicating with the outside air are provided, and the lamination in a state where the communication hole is communicated with the outside of the vacuum bag. It is a method of manufacturing a dimming apparatus including a step of arranging a body in the vacuum bag and heating and pressurizing the laminated body while degassing.

In the method for manufacturing a dimmer according to the present embodiment, in the step of heating and pressurizing the laminated body while degassing, the laminated body is degassed at a vacuum degree of -100 kPa or more and -10 kPa or less, and the laminated body is degassed. May be heated to 90 ° C. or higher and 140 ° C. or lower, and may be pressurized at 0.1 MPa or higher and 1.3 MPa or lower.

In the method for manufacturing a dimming device according to the present embodiment, an extension portion is formed by a part of the dimming cell and a part of the film, and the extension portion is formed by the first transparent substrate and the first transparent substrate in a plan view. 2 The communication hole extending outward of the transparent substrate may be formed in the extension portion.

The method for manufacturing a dimmer according to the present embodiment may further include a step of sealing the communication holes.

In the method for manufacturing a dimmer according to the present embodiment, the first intermediate may contain polyvinyl butyral.

In the method for manufacturing a dimming device according to the present embodiment, a spacer may be arranged between the dimming cell and the film.

According to the embodiment of the present disclosure, it is possible to uniformly disperse the liquid crystal in the plane and suppress the occurrence of liquid crystal lumps, which is a phenomenon in which a large amount of liquid crystal is locally present.

FIG. 1 is a perspective view showing a dimming device according to the first embodiment. FIG. 2 is a cross-sectional view showing a dimming device according to the first embodiment. FIG. 3 is an exploded perspective view showing a dimming device according to the first embodiment. 4 (a)-(d) are cross-sectional views showing a method of manufacturing a dimming cell according to the first embodiment. 5 (a)-(c) are cross-sectional views showing a method of manufacturing a dimming cell according to the first embodiment. 6 (a)-(d) are cross-sectional views showing a method of manufacturing a dimmer according to the first embodiment. 7 (a)-(c) are cross-sectional views showing an action when the liquid crystal pool of the dimming cell is eliminated after the dimming device is manufactured. FIG. 8 is a cross-sectional view showing a first modification of the dimmer according to the first embodiment. FIG. 9 is a cross-sectional view showing a second modification of the dimmer according to the first embodiment. FIG. 10 is a cross-sectional view showing a third modification of the dimmer according to the first embodiment. FIG. 11 is an exploded perspective view showing a third modification of the dimmer according to the first embodiment. FIG. 12 is an exploded perspective view showing a fourth modification of the dimmer according to the first embodiment. FIG. 13 is a cross-sectional view showing a fifth modification of the dimmer according to the first embodiment. FIG. 14 is an exploded perspective view showing a fifth modification of the dimmer according to the first embodiment. FIG. 15 is an exploded perspective view showing a sixth modification of the dimmer according to the first embodiment. FIG. 16 is an exploded perspective view showing a seventh modification of the dimmer according to the first embodiment. FIG. 17 is an exploded perspective view showing an eighth modification of the dimmer according to the first embodiment. FIG. 18 is an exploded perspective view showing a ninth modification of the dimmer according to the first embodiment. FIG. 19 is an exploded perspective view showing a tenth modification of the dimmer according to the first embodiment. FIG. 20 is an exploded perspective view showing an eleventh modification of the dimmer according to the first embodiment. FIG. 21 is an exploded perspective view showing a twelfth modification of the dimmer according to the first embodiment. 22 (a)-(d) are cross-sectional views showing a method of manufacturing a dimmer according to the second embodiment. FIG. 23 is a cross-sectional view showing a first modification of the dimmer according to the second embodiment. FIG. 24 is a cross-sectional view showing a second modification of the dimmer according to the second embodiment. 25 (a)-(c) are cross-sectional views showing a method of manufacturing a dimmer according to a third embodiment.

(First Embodiment)
Hereinafter, one embodiment will be described with reference to FIGS. 1 to 7.

The dimming device 10 described below can be applied to various technical fields in which adjustment of light transmittance is required, and the scope of application is not particularly limited. The dimming device 10 is, for example, a part for dimming (a part where external light is incident, for example, front, side, rear, etc.) such as a window glass of a building, a showcase, an indoor transparent partition, and a vehicle window. It is arranged in a window such as a roof) and can control the amount of incident light inside a building, a vehicle, or the like.

The dimming device 10 described below merely illustrates one embodiment. Therefore, for example, some of the elements listed below as the constituent elements of the dimming device 10 may be replaced with other elements or may not be included. Further, elements not listed below may be included as components of the dimming device 10. Further, in the drawings, for convenience of illustration and comprehension, the scale, the dimensional ratio, and the like are appropriately changed or exaggerated from those of the actual product.

(Dimmer)
FIG. 1 is a diagram showing a dimming device (laminated glass) 10 according to the present embodiment. The dimming device 10 according to the present embodiment has a three-dimensional shape whose surface shape has a curved surface shape. In FIG. 1, as an example, the dimming device 10 has a shape that is convex toward one surface side. Have. The dimming device 10 is not limited to this, and for example, the surface shape may be a flat shape (that is, a flat plate shape), or a two-dimensional shape having a curved surface shape (for example, a part of a cylinder). It may be a constituent shape) or the like. Here, the three-dimensional shape is not a simple cylindrical surface, but a curved surface that cannot be constructed only by deforming a plane without expansion and contraction, and is a two-dimensional shape (two-dimensional) that is bent two-dimensionally about a single axis. It is distinguished from a two-dimensional shape (two-dimensional curved surface) that is bent two-dimensionally with different curvatures about a plurality of axes parallel to each other. That is, the three-dimensional shape is a shape formed by a surface that is partially or wholly bent around each of a plurality of axes inclined with respect to each other. Further, in the present specification, the plan view means a state viewed from a direction perpendicular to the main surface of the dimming device 10.

As shown in FIG. 1, the dimming device 10 according to the present embodiment includes a first glass plate (first transparent substrate) 11, a first intermediate film (first intermediate) 13, a film 33, and dimming. It includes a cell 20, a second interlayer film (second intermediate body) 14, and a second glass plate (second transparent substrate) 12. The first glass plate 11, the first interlayer film 13, the film 33, the dimming cell 20, the second interlayer film 14, and the second glass plate 12 are laminated and arranged in this order. Further, a void layer G is provided between the film 33 and the light control cell 20.

FIG. 2 is a cross-sectional view showing the layer structure of the dimming device 10 according to the present embodiment, and FIG. 3 is an exploded perspective view showing the layer structure of the dimming device 10 according to the present embodiment. The dimming device 10 of the present embodiment has a three-dimensional surface shape, but in FIGS. 2 and 3, the surface shape of the dimming device 10 is flat in order to facilitate understanding. The figure in the case of the shape is shown.

As shown in FIG. 2, the dimming device 10 includes a first glass plate 11, a second glass plate 12, and a dimming cell 20 arranged between the first glass plate 11 and the second glass plate 12. It has. The dimming cell 20 includes a first laminated body 21 including a first base material 24, a first transparent electrode 25, and a first alignment layer 26, a second base material 27, a second transparent electrode 28, and a second alignment layer 29. A second laminated body 22 including the above, and a liquid crystal layer 23 arranged between the first laminated body 21 and the second laminated body 22 are provided.

The first glass plate (first transparent substrate) 11 and the second glass plate (second transparent substrate) 12 are plate glass having high translucency, which are arranged on the front and back surfaces of the dimming device 10, respectively. The surface shapes of the first glass plate 11 and the second glass plate 12 are three-dimensional shapes having a curved surface shape, and are formed in advance into a shape having a curved surface shape that is convex on one surface side (see FIG. 1). ). In this case, the first glass plate 11 and the second glass plate 12 are formed so that the first glass plate 11 side is convex with respect to the second glass plate 12 side, but the present invention is not limited to this. The second glass plate 12 side may be formed so as to be convex with respect to the glass plate 11 side. Further, in the present embodiment, the first glass plate 11 and the second glass plate 12 have a thickness of 0.5 mm or more and 4 mm or less, and as an example, plate glass having a thickness of 2 mm is used. The first glass plate 11 and the second glass plate 12 may be inorganic glass or resin glass. As the resin glass, for example, polycarbonate, acrylic or the like can be used. When inorganic glass is used as the first glass plate 11 and the second glass plate 12, the dimming device 10 having excellent heat resistance and scratch resistance can be obtained. On the other hand, when resin glass is used as the first glass plate 11 and the second glass plate 12, the weight of the dimming device 10 can be reduced. Further, the first glass plate 11 and the second glass plate 12 may be subjected to surface treatment such as hard coating, if necessary. A transparent resin base material may be used instead of the first glass plate 11 and the second glass plate 12, respectively.

The first interlayer film 13 is a member that joins the first glass plate 11 and the film 33. Similarly, the second interlayer film 14 is a member that joins the second glass plate 12 and the dimming cell 20. The first intermediate film 13 and the second intermediate film 14 may each contain PVB (polyvinyl butyral), and in the present embodiment, the first intermediate film 13 and the second intermediate film 14 are PVB (polyvinyl butyral), respectively. ) A resin sheet is used. As the material of the first intermediate film 13 and the second intermediate film 14, EVA (ethylene-vinyl acetate copolymer), COP (cycloolefin polymer) and the like, which are limited to the PVB, may be used. Further, the thicknesses of the first intermediate film 13 and the second intermediate film 14 may be appropriately selected depending on the material and the like. Specifically, the thickness of the first intermediate film 13 and the second intermediate film 14 may be 300 μm or more and 2.5 mm or less, and as an example, one having a thickness of 760 μm is used. Further, the sizes of the first interlayer film 13 and the second interlayer film 14 may be the same as those of the first glass plate 11 and the second glass plate 12, and the first glass plate 11 and the second glass plate 12 may be the same size. It may be larger than 12.

Further, as shown in FIGS. 2 and 3, the first intermediate film 13 and the second intermediate film 14 are connected to each other by the frame intermediate film 16. The frame interlayer film 16 is a frame-shaped interlayer film in a plan view, and more specifically, a square shape (a quadrangular shape with a hollowed out center) or an interlayer film having a shape obtained by cutting a part of the square shape. Is. The frame interlayer film 16 may be made of the same material as the first intermediate film 13 and the second intermediate film 14. By providing the frame interlayer film 16, it is possible to prevent the side surface of the dimming cell 20 or a part thereof from being exposed to the side surface of the dimming device 10, and also to prevent the intrusion of moisture or the like from the side surface of the dimming device 10. , The water impermeability of the dimmer 10 can be further improved.

Specifically, the frame interlayer film 16 is formed on the thick portion of the dimming cell 20 in the cross-sectional view when the first intermediate film 13 and the second intermediate film 14 are larger than the dimming cell 20 (in a plan view). It is an interlayer film that is formed. The frame intermediate film 16 is formed so as to surround the dimming cell 20 in a plan view, and is a frame-shaped intermediate formed by hollowing out the shape of the dimming cell 20 from the shapes of the first intermediate film 13 and the second intermediate film 14. It is a membrane. In this case, the frame intermediate film 16 is formed between the first intermediate film 13 and the second intermediate film 14 in a portion corresponding to the periphery of the dimming cell 20. Further, a frame intermediate film 16 is also formed between the first intermediate film 13 and the second intermediate film 14 and corresponding to the periphery of the film 33 and the void layer G.

The outer circumference of the frame interlayer film 16 may be the same size as the outer circumference of the first glass plate 11 and the second glass plate 12, or may be larger than the outer circumference of the first glass plate 11 and the second glass plate 12. good. Further, the inner circumference of the frame interlayer film 16 may be the same size as the outer circumference of the dimming cell 20, or may be larger than the outer circumference of the dimming cell 20. Further, the inner circumference of the frame interlayer film 16 may be the same size as the outer circumference of the film 33, or may be larger than the outer circumference of the film 33. The width W1 (see FIG. 3) of the frame interlayer film 16 is preferably 0 mm or more and 10 mm or less, and more preferably more than 0 mm and about 1/4 or less of the glass width. Alternatively, the frame interlayer film 16 may be omitted as long as the side surface of the dimming cell 20 or a part thereof is not exposed from the side surface of the dimming device 10.

The light control cell 20 (light control film, liquid crystal film) is a film capable of controlling the amount of transmitted light by changing the applied voltage. The dimming cell 20 is arranged so as to be sandwiched between the first glass plate 11 and the second glass plate 12. The dimming cell 20 has a guest-host type liquid crystal layer using a dichroic dye, and is a member that changes the amount of transmitted light by an electric field applied to the liquid crystal. The dimming cell 20 includes a film-shaped first laminated body 21, a film-shaped second laminated body 22, and a liquid crystal layer 23 arranged between the first laminated body 21 and the second laminated body 22. ing.

As shown in FIG. 2, the first laminated body 21 is formed by laminating a first base material 24, a first transparent electrode 25, and a first alignment layer 26. That is, the first base material 24, the first transparent electrode 25, and the first alignment layer 26 are laminated and arranged in this order from the first interlayer film 13 side. The second laminated body 22 is formed by laminating a second base material 27, a second transparent electrode 28, and a second alignment layer 29. That is, the second base material 27, the second transparent electrode 28, and the second alignment layer 29 are laminated and arranged in this order from the second interlayer film 14 side.

Further, a plurality of bead spacers 31 are arranged between the first laminated body 21 and the second laminated body 22. The liquid crystal layer 23 is packed and arranged between the plurality of bead spacers 31 between the first laminated body 21 and the second laminated body 22. The plurality of bead spacers 31 may be arranged irregularly or regularly, respectively.

The dimming cell 20 is based on the guest host liquid crystal composition provided on the liquid crystal layer 23 by driving the first transparent electrode 25 and the second transparent electrode 28 provided on the first laminated body 21 and the second laminated body 22. The orientation of the liquid crystal material is changed, thereby changing the amount of transmitted light.

The first base material 24 and the second base material 27 are made of a transparent resin, and a flexible film can be applied. As the first base material 24 and the second base material 27, a transparent resin film having a small optical anisotropy and a transmittance of 80% or more at a wavelength in the visible region (380 nm or more and 800 nm or less) can be applied. desirable. Examples of the material of the transparent resin film include an acetyl cellulose resin such as triacetyl cellulose (TAC), a polyester resin such as polyethylene terephthalate (PET) and polyethylene naphthalate (PEN), polyethylene (PE), and polypropylene (PP). , Polypropylene-based resins such as polystyrene, polymethylpentene, EVA, vinyl-based resins such as polyvinyl chloride and polyvinylidene chloride, acrylic resins, polyurethane-based resins, polysulfone (PEF), polyether sulfone (PES), polycarbonate ( Examples thereof include resins such as PC), polysulfone, polyether (PE), polyether ketone (PEK), (meth) acronitrile, cycloolefin polymer (COP), and cycloolefin copolymer. As the material of the transparent resin film, resins such as polycarbonate, cycloolefin polymer, and polyethylene terephthalate are particularly preferable. The thickness of the transparent resin film used as the first base material 24 and the second base material 27 depends on the material, but can be appropriately selected within the range in which the transparent resin film has flexibility. The thickness of the first base material 24 and the second base material 27 may be 50 μm or more and 200 μm or less, respectively. In the present embodiment, a polyethylene terephthalate film having a thickness of 100 μm is applied as an example of the first base material 24 and the second base material 27.

The first transparent electrode 25 and the second transparent electrode 28 are composed of a transparent conductive film laminated on the first base material 24 and the second base material 27 (transparent resin film), respectively. As the transparent conductive film, various transparent electrode materials applied to this kind of transparent resin film can be applied, and examples thereof include a transparent metal thin film having an oxide-based total light transmittance of 50% or more. .. Examples thereof include tin oxide-based, indium oxide-based, and zinc oxide-based.

Examples of the tin oxide (SnO ₂ ) system include nesa (tin oxide SnO ₂ ), ATO (Antimony Tin Oxide), and fluorine-doped tin oxide. Examples of the indium oxide (In ₂ O ₃ ) system include indium oxide, ITO (Indium Tin Oxide), and IZO (Indium Zinc Oxide). Examples of the zinc oxide (ZnO) system include zinc oxide, AZO (aluminum-doped zinc oxide), and gallium-doped zinc oxide. In the present embodiment, the transparent conductive film constituting the first transparent electrode 25 and the second transparent electrode 28 is formed of ITO.

The bead spacer 31 is a member that defines the thickness (cell gap) of the portion of the liquid crystal layer 23 excluding the outer peripheral portion. In this embodiment, a spherical bead spacer is used as the bead spacer 31. The diameter of the bead spacer 31 may be in the range of 1 μm or more and 20 μm or less, preferably 3 μm or more and 15 μm or less. The bead spacer 31 can be widely applied to a structure made of an inorganic material such as silica, a structure made of an organic material, a structure having a core-shell structure combining these, and the like. Further, the bead spacer may be formed in a rod shape such as a cylindrical shape, an elliptical pillar shape, or a polygonal pillar shape in addition to the spherical shape. Further, although the bead spacer 31 is manufactured by a transparent member, a colored material may be applied as necessary to adjust the color.

In the present embodiment, the bead spacer 31 is provided on the second laminated body 22, but the present invention is not limited to this, and both the first laminated body 21 and the second laminated body 22 or the first laminated body 22 are not limited to the bead spacer 31. It may be provided only in the laminated body 21. Further, the bead spacer 31 does not necessarily have to be provided. Alternatively, a columnar spacer may be used instead of the bead spacer 31 or together with the bead spacer 31.

The first alignment layer 26 and the second alignment layer 29 are members for orienting the liquid crystal molecule group contained in the liquid crystal layer 23 in a desired direction. The first alignment layer 26 and the second alignment layer 29 are formed by a photo-alignment layer. As the photo-alignment material applicable to the photo-alignment layer, various materials to which the photo-orientation method can be applied can be widely applied, and examples thereof include a photodegradable type, a photodimerization type, and a photoisomerization type. can. In this embodiment, a photodimerized material is used. Examples of the photodimerized material include cinnamates, coumarins, benzylidenephthalimidines, benzylidene acetophenone, diphenylacetylene, stillbazole, uracil, quinolinone, maleimido, and polymers having a cinnamicylene acetic acid derivative. Among them, a polymer having one or both of cinnamate and coumarin is preferably used because of its good orientation-regulating power.

A rubbing oriented layer may be used instead of the photo oriented layer. The rubbing alignment layer may not be subjected to the rubbing treatment, or may be subjected to the rubbing treatment to form a fine line-shaped uneven shape to prepare the alignment layer. In the present embodiment, the dimming cell 20 includes the first alignment layer 26 and the second alignment layer 29, but is not limited to this, and does not include the first alignment layer 26 and the second alignment layer 29. It may be in the form.

A guest host liquid crystal composition and a dichroic dye composition can be widely applied to the liquid crystal layer 23. The guest host liquid crystal composition may contain a chiral agent so that when the liquid crystal material is horizontally oriented, it is oriented in a spiral shape in the thickness direction of the liquid crystal layer 23. Further, between the first laminated body 21 and the second laminated body 22, an annular or frame-shaped sealing material 32 is arranged so as to surround the liquid crystal layer 23 in a plan view. The sealing material 32 integrally holds the first laminated body 21 and the second laminated body 22, and prevents leakage of the liquid crystal material. A thermosetting resin such as an epoxy resin or an acrylic resin, an ultraviolet curable resin, or the like can be applied to the sealing material 32.

The dimming cell 20 applies an orientation restricting force for pre-tilting the first alignment layer 26 and the second alignment layer 29 in a certain direction so that the orientation of the guest host liquid crystal composition at the time of shading is when an electric field is applied. It is composed of the set vertically oriented layers, which is configured as normally clear. It should be noted that this setting at the time of light transmission may be configured as a normal dryk when an electric field is applied. Here, the normal-reading structure is a structure in which the transmittance is minimized when no voltage is applied to the liquid crystal display, resulting in a black screen. Normal clear is a structure in which the transmittance is maximized and becomes transparent when no voltage is applied to the liquid crystal display.

Although the dimming cell 20 of the present embodiment shows an example including the guest host type liquid crystal layer 23, the present invention is not limited to this. The dimming cell 20 may be configured to include a liquid crystal layer 23 such as a TN (Twisted Nematic) method, a VA (Vertical Alignment) method, or an IPS (In-Plane-Switching) method that does not use a dichroic dye composition. When such a liquid crystal layer 23 is provided, it can function as a light control film by further providing a linearly polarizing layer on the surfaces of the first base material 24 and the second base material 27, respectively.

In the present embodiment, the film 33 is arranged between the light control cell 20 and the first interlayer film 13. The film 33 is arranged between the first base material 24 and the first intermediate film 13 of the dimming cell 20, and is bonded to the first intermediate film 13. The film 33 is made of a transparent resin and may be a flexible resin film. As the film 33, it is desirable to apply a transparent resin film having a small optical anisotropy and a transmittance of 80% or more in a wavelength in the visible region (380 nm or more and 800 nm or less). As the material of the transparent resin film, the same material as the transparent resin film used for the first base material 24 and the second base material 27 described above can be used. Alternatively, as the film 33, a functional film such as an infrared (IR) reflective film or an ultraviolet (UV) cut film may be used. Further, the film 33 has a dimming cell, an AR (Anti-Reflection) film, an AG (Anti-Glare) film, a reflective polarizing film, a dimming film having a dimming method other than the liquid crystal, or a defroster function. It may be a film. The thickness of the film 33 may be, for example, 50 μm or more and 250 μm or less, and preferably 100 μm or more and 125 μm or less, although it depends on the material thereof. Further, the planar shape of the film 33 is smaller than the planar shape of the first intermediate film 13 and the second intermediate film 14. Further, the planar shape of the film 33 is preferably larger than the planar shape of the entire dimming cell 20, and particularly preferably larger than the planar shape of the liquid crystal layer 23 located inside the sealing material 32. As a result, since the film 33 covers the entire liquid crystal layer 23, it is possible to suppress the occurrence of liquid crystal pools, which is a phenomenon in which a large amount of liquid crystal is locally present in a part of the liquid crystal layer 23, in the entire in-plane area. Alternatively, the planar shape of the film 33 may be made smaller than the inside of the sealing material 32 of the light control cell 20 (liquid crystal layer 23) to induce a liquid crystal pool in a region where the film 33 does not exist. The portion (outer circumference) in which the liquid crystal pool is guided in this way can be hidden when the dimming device 10 is arranged in a vehicle window or the like. In addition, functional films such as infrared (IR) reflective film, ultraviolet (UV) cut film, AR (Anti-Reflection) film, and AG (Anti-Glare) film are added between the film 33 and the dimming cell 20. You may. In this case, the functional film may be attached to the film 33 or the light control cell 20. Further, the functional film may be added between the first interlayer film 13 and the film 33.

Further, a void layer G is provided between the light control cell 20 and the film 33. The void layer G is formed in the space between the first base material 24 of the light control cell 20 and the film 33. That is, the first base material 24 of the light control cell 20 and the film 33 are not bonded to each other and are arranged at regular intervals in the thickness direction. The void layer G is filled with air, but the present invention is not limited to this, and a gas such as nitrogen or an inert gas may be filled. The thickness of the void layer G is, for example, larger than 0 μm and 10000 μm or less, and preferably 0.1 μm or more and 100 μm or less. The planar shape of the void layer G may be substantially the same as the planar shape of the film 33. By forming the void layer G between the dimming cell 20 and the film 33 in this way, as will be described later, the cell gap defect of the dimming cell 20 is reduced, and it is locally localized in a part of the liquid crystal layer 23. It is possible to suppress the occurrence of liquid crystal pools, which is a phenomenon in which a large amount of liquid crystal is present. Further, by providing the gap layer G between the light control cell 20 and the film 33, the heat insulating property of the light control device 10 can be improved, and the heat retention of the vehicle or building in which the light control device 10 is arranged can be improved. can. Further, when the dimming cell 20 is in a light-shielded state, the dimming device 10 is viewed from the first glass plate 11 side due to reflection at the interface between the dimming cell 20 and the void layer G and the interface between the film 33 and the void layer G. Is observed mirror-like.

As shown in FIG. 3, the dimming device 10 is connected to the dimming controller 91, and the sensor device 92 and the user operation unit 93 are connected to the dimming controller 91. The dimming controller 91 can control the dimming state of the dimming device 10, switch between blocking and transmitting light by the dimming device 10, and can change the light transmittance in the dimming device 10. Specifically, the dimming controller 91 is connected to the external electrode substrate 35 of the dimming device 10 and adjusts the electric field applied to the liquid crystal layer 23 of the dimming device 10 to orient the liquid crystal molecules in the liquid crystal layer 23. By changing the light, the light blocking and transmission by the dimming device 10 can be switched, and the light transmittance can be changed.

The dimming controller 91 can adjust the electric field applied to the liquid crystal layer 23 based on an arbitrary method. The dimming controller 91 adjusts the electric field applied to the liquid crystal layer 23 according to, for example, the measurement result of the sensor device 92 or an instruction (command) input by the user via the user operation unit 93, and the dimming device 10 adjusts the electric field. It is possible to switch between blocking and transmitting light, and to change the transmittance of light. Therefore, the dimming controller 91 may automatically adjust the electric field applied to the liquid crystal layer 23 according to the measurement result of the sensor device 92, or manually according to the user's instruction via the user operation unit 93. May be adjusted to. The measurement target by the sensor device 92 is not particularly limited, and for example, the brightness of the usage environment may be measured. In this case, the light blocking and transmission switching and the light transmittance change by the dimming device 10 are used. It is done according to the brightness of the environment. Further, it is not always necessary that both the sensor device 92 and the user operation unit 93 are connected to the dimming controller 91, and only one of the sensor device 92 and the user operation unit 93 may be connected. ..

The external electrode substrate 35 is sandwiched between the first laminated body 21 and the second laminated body 22. In the region where the external electrode substrate 35 is formed, the first laminated body 21 and the second laminated body 22 have an electrode protruding piece 36 that protrudes outward in the plane direction. The external electrode substrate 35 is embedded inside the projecting piece 36 for electrodes. As shown by the arrows in FIG. 3, the external electrode substrate 35 and the projecting piece 36 for the electrode are sandwiched between the frame intermediate film 16 and the second intermediate film 14, and are outside the frame intermediate film 16 and the second intermediate film 14. It protrudes toward you. However, the present invention is not limited to this, and the external electrode substrate 35 and the projecting piece 36 for the electrode may be sandwiched between the frame intermediate film 16 and the first intermediate film 13.

(Manufacturing method of dimming cell)
Next, a method of manufacturing the dimming cell 20 of the dimming device 10 according to the present embodiment will be described with reference to FIGS. 4 (a)-(d) and 5 (a)-(c). 4 (a)-(d) and 5 (a)-(c) are cross-sectional views showing a method of manufacturing the dimming cell 20 according to the present embodiment.

First, as shown in FIG. 4A, the second base material 27 supplied in a roll shape is prepared. Subsequently, as shown in FIG. 4B, a second transparent electrode 28 made of, for example, ITO is formed on the second base material 27 by sputtering or the like using a sputtering device. At this time, the transparent electrode may be patterned so as to have a predetermined pattern shape.

Next, as shown in FIG. 4C, the coating liquid according to the second alignment layer 29 is applied onto the second base material 27 on which the second transparent electrode 28 is formed, and then exposed to the second orientation. Layer 29 is made. In this way, the second laminated body 22 in which the second base material 27, the second transparent electrode 28, and the second alignment layer 29 are laminated is prepared.

In the same manner as in the steps shown in FIGS. 4A to 4C, the first laminated body 21 in which the first base material 24, the first transparent electrode 25, and the first alignment layer 26 are laminated is also prepared. do.

Subsequently, as shown in FIG. 4D, the bead spacer 31 is arranged on the second orientation layer 29 of the second laminated body 22. In addition to wet / dry spraying, various arrangement methods can be widely applied to the arrangement of the bead spacer 31. For example, beads are randomly applied on the second alignment layer 29 by partially applying a coating liquid produced by dispersing the bead spacer 31 together with a resin component in a solvent, and then sequentially executing drying and firing treatments. The spacer 31 may be arranged to hold the spacer 31 so that it is difficult to move. Although not shown, the outer circumference of the bead spacer 31 may be covered with the second alignment layer 29. Specifically, by mixing the bead spacer 31 with the coating liquid related to the second alignment layer 29 to form the second alignment layer 29, the bead spacer 31 is thinly covered and held by the second alignment layer 29. Can be in the form of

Next, as shown in FIG. 5A, the sealing material 32 is applied onto the second alignment layer 29 of the second laminated body 22 using a dispenser. The sealing material 32 is applied in a frame shape so as to surround the portion where the liquid crystal layer 23 is produced.

Next, as shown in FIGS. 5 (b) and 5 (c), the second laminated body 22 and the first laminated body 21 are laminated with each other, and the liquid crystal layer 23 is arranged. During this period, first, as shown in FIG. 5B, the liquid crystal constituting the liquid crystal layer 23 is dropped onto the region surrounded by the sealing material 32. At this time, the liquid crystal layer 23 is inside the sealing material 32 and is filled around the bead spacer 31.

Subsequently, as shown in FIG. 5C, the second laminated body 22 on which the liquid crystal layer 23 is arranged and the first laminated body 21 prepared in advance are laminated and pressed against each other. Then, the sealing material 32 is semi-cured by irradiating with ultraviolet rays and then heated, whereby the first laminated body 21 and the second laminated body 22 are integrated. Then, the laminated body of the first laminated body 21 and the second laminated body 22 produced in this manner is trimmed to be cut into a desired size.

As described above, after arranging the liquid crystal layer 23, it is preferable that the second laminated body 22 and the first laminated body 21 are laminated with each other, but the present invention is not limited to this, and the second laminated body 22 and the first laminated body 21 are not limited to this. The liquid crystal layer 23 may be arranged after the bodies 21 are laminated on each other. After that, by attaching the external electrode substrate 35 (see FIG. 3) between the first laminated body 21 and the second laminated body 22, the dimming cell 20 according to the present embodiment can be obtained.

(Manufacturing method of dimmer)
Next, a method of manufacturing the dimming device 10 (laminated glass processing method) according to the present embodiment will be described with reference to FIGS. 6 (a)-(d). 6 (a)-(d) are cross-sectional views showing a method of manufacturing the dimming device 10.

First, as shown in FIG. 6A, the first glass plate 11, the first interlayer film 13, the film 33, the dimming cell 20, the second interlayer film 14, and the second glass plate 12 are formed. The laminated body 30 to have is produced. In this case, the first glass plate 11 and the second glass plate 12 are prepared, and the first glass plate 11 and the second glass plate 12 provide the first interlayer film 13, the frame interlayer film 16, the film 33, and the dimming cell 20. A laminated body 30 is produced by sandwiching the second interlayer film 14. At this time, in the laminated body 30, a gap g is formed between the film 33 and the light control cell 20. Here, the first glass plate 11 and the second glass plate 12 are preformed with a curved surface shape having a three-dimensional surface shape.

Next, the laminate 30 is placed in the bag (vacuum bag) 51, and the laminate 30 is degassed and heated at the first temperature T1.

At this time, first, as shown in FIG. 6B, the laminated body 30 is enclosed in the bag 51. The bag 51 is preferably made of rubber or silicon having flexibility and airtightness. A ventilation pipe 52 is connected to the bag 51.

Next, as shown in FIG. 6C, after the laminated body 30 is sealed in the bag 51, the laminated body 30 is arranged together with the bag 51 in the heating device 53. The device used as the heating device 53 is not particularly limited as long as the laminated body 30 can be sufficiently heated, and examples thereof include a device for an oven and an autoclave.

Subsequently, the laminate 30 together with the bag 51 is heated at the first temperature T1 and a predetermined time. In this case, the first temperature T1 is lower than the second temperature T2 described later. As a result, when the laminated body 30 is degassed and heated at the first temperature T1, the first intermediate film 13, the second intermediate film 14, and the frame intermediate film 16 of the laminated body 30 are completely cured. It can be suppressed.

Further, the first temperature T1 is a temperature equal to or higher than the softening temperature of the first intermediate film 13, the second intermediate film 14, and the frame intermediate film 16. The first temperature T1 is preferably 50 ° C. or higher and 90 ° C. or lower, and may be 70 ° C. or lower as an example. When the first temperature T1 is 50 ° C. or higher, the first intermediate film 13, the second intermediate film 14, and the frame intermediate film 16 can be softened, and the first glass plate 11 and the first intermediate film of the laminated body 30 can be softened. 13. The frame interlayer film 16, the film 33, the dimming cell 20, the second interlayer film 14, and the second glass plate 12 can be temporarily crimped. Further, when the first temperature T1 is 90 ° C. or lower, it is possible to effectively prevent the first intermediate film 13, the second intermediate film 14 and the frame intermediate film 16 of the laminated body 30 from being completely cured. Can be done. When the first interlayer film 13 contains PVB (polyvinyl butyral), the first temperature T1 may be 60 ° C. or higher and 80 ° C. or lower.

Further, the time for heating the laminated body 30 may be, for example, 10 minutes or more and 120 minutes or less. In this case, for example, the temperature inside the heating device 53 may be raised from room temperature to the first temperature T1 over about 10 minutes. Next, while the temperature inside the heating device 53 is maintained at the first temperature T1, the laminate 30 may be heated for about 1 minute or more and 60 minutes or less, for example, 2 minutes. After that, the temperature in the heating device 53 may be lowered from the first temperature T1 to room temperature over about 60 minutes.

At this time, the air in the bag 51 is sucked by a pump (not shown) through the ventilation pipe 52. As a result, the air remaining between the members of the laminated body 30 can be sucked, and the crimping failure due to the remaining air bubbles or the like inside the dimming device 10 can be suppressed.

Here, the laminated body 30 may be degassed at a degree of vacuum of −100 kPa or more and −10 kPa or less, or may be degassed at −100 kPa as an example. By degassing the laminate 30 at a degree of vacuum of -100 kPa or more, it is possible to prevent the dimming cell 20 and the film 33 from being in close contact with each other. Further, by degassing the laminated body 30 at a vacuum degree of −10 kPa or less, the air remaining between the members of the laminated body 30 is effectively sucked, and air bubbles or the like remain inside the dimming device 10. Crimping defects can be effectively suppressed. In the present specification, the degree of vacuum means a static pressure of atmospheric pressure (0 kPa) or less, and is expressed using a gauge pressure. Further, in the present specification, the "vacuum degree of ~ kPa or more" means the vacuum degree based on the pressure defined by the value equal to or more than the value indicated by the symbol "~". That is, for example, "vacuum degree of -100 kPa or more" is a concept including "vacuum degree of -90 kPa", and for example, "deaeration at a vacuum degree of -100 kPa or more" means "-90 kPa. It is degassed by the degree of vacuum. " Similarly, the "vacuum degree of ~ kPa or less" means the vacuum degree based on the pressure defined by the value of the value or less indicated by the symbol "~". For example, "vacuum degree of -10 kPa or less" is a concept including "vacuum degree of -20 kPa". For example, "vacuum degree of -10 kPa or less" means "vacuum degree of -20 kPa". It includes being degassed with.

In this way, the laminate 30 in which the first glass plate 11, the first interlayer film 13, the frame interlayer film 16, the film 33, the dimming cell 20, the second intermediate film 14, and the second glass plate 12 are temporarily pressure-bonded is formed. can get. At this time, the film 33 and the dimming cell 20 are not directly bonded to each other.

Subsequently, the laminated body 30 is taken out from the bag 51, and the laminated body 30 is heated at a second temperature while being pressurized.

When the laminate 30 is heated at the second temperature T2 while being pressurized, first, as shown in FIG. 6D, the bag 51 and the laminate 30 are taken out from the heating device 53, and then the laminate 30 is taken out from the bag 51. After that, the laminated body 30 is arranged in the heating / pressurizing device 54. The device used as the heating / pressurizing device 54 is not particularly limited as long as the laminated body 30 can be sufficiently heated and pressurized, and examples thereof include a device for an oven and an autoclave.

Here, as described above, the first glass plate 11, the first intermediate film 13, the frame intermediate film 16, the film 33, the dimming cell 20, the second intermediate film 14, and the second glass plate 12 of the laminated body 30 are It is temporarily crimped. In this case, the void g formed between the film 33 and the light control cell 20 may be crushed. On the other hand, as described above, the film 33 and the dimming cell 20 are not directly bonded to each other. Therefore, even when the gap g formed between the film 33 and the dimming cell 20 is crushed, the film 33 and the dimming cell 20 can be combined by taking out the laminate 30 from the bag 51. Air can enter in between. As a result, even when the void g is crushed, the void g can be formed again between the film 33 and the light control cell 20.

Subsequently, the laminate 30 is heated at the second temperature T2 and a predetermined time. The second temperature T2 is a temperature equal to or higher than the softening temperature of the first intermediate film 13, the second intermediate film 14, and the frame intermediate film 16. The second temperature T2 may be 90 ° C. or higher and 140 ° C. or lower, and as an example, it may be 130 ° C. or higher. When the second temperature T2 is 90 ° C. or higher, the first intermediate film 13, the second intermediate film 14, and the frame intermediate film 16 of the laminated body 30 can be effectively cured. Further, when the second temperature T2 is 140 ° C. or lower, it is possible to prevent the first intermediate film 13, the second intermediate film 14, the frame intermediate film 16 and the like of the laminated body 30 from being damaged by heat. Can be done. When the first interlayer film 13 contains PVB (polyvinyl butyral), the second temperature T2 may be 120 ° C. or higher and 140 ° C. or lower.

Further, the time for heating the laminated body 30 may be, for example, 120 minutes or more and 500 minutes or less. In this case, for example, the temperature inside the heating / pressurizing device 54 may be raised from room temperature to the second temperature T2 over about 80 minutes. Next, the laminate 30 may be heated for about 60 minutes or more and 70 minutes or less, for example, 50 minutes, while the temperature inside the heating / pressurizing device 54 is maintained at the second temperature T2. After that, the temperature inside the heating / pressurizing device 54 may be lowered from the second temperature T2 to room temperature over about 220 minutes.

Further, the laminated body 30 is pressurized in the heating / pressurizing device 54. At this time, the laminated body 30 may be pressurized at 0.1 MPa or more and 1.3 MPa or less, and as an example, it may be pressurized at 0.2 MPa. By pressurizing the laminated body 30 at 0.1 MPa or more, the first intermediate film 13, the second intermediate film 14 and the frame intermediate film 16 of the laminated body 30 can be effectively cured. Further, when the laminated body 30 is pressurized at 1.3 MPa or less, it is possible to prevent the light control cell 20 and the film 33 from being in close contact with each other too much. Even if the laminated body 30 is pressurized at 0.8 MPa or more and 1.3 MPa or less in order to cure the first intermediate film 13, the second intermediate film 14 and the frame intermediate film 16 of the laminated body 30 more effectively. good.

In this way, the first intermediate film 13, the second intermediate film 14, and the frame intermediate film 16 are melted, and the first glass plate 11, the first intermediate film 13, the frame intermediate film 16, the film 33, and the adjustment of the laminate 30 are formed. The optical cell 20, the second interlayer film 14, and the second glass plate 12 are crimped (mainly crimped) and integrally joined to obtain a dimming device 10. At this time, the film 33 and the dimming cell 20 are not directly bonded to each other. Further, when the laminated body 30 is heated at the second temperature while being pressurized, the laminated body 30 is not degassed. Therefore, the void layer G formed between the film 33 and the light control cell 20 is not crushed, and the void layer G is formed between them. By providing such a void layer G, the pressure applied to the liquid crystal layer 23 of the dimming cell 20 is released after the dimming device 10 is manufactured, so that the liquid crystal layer 23 is unevenly distributed in the dimming cell 20. Even if there is, the uneven distribution of the liquid crystal layer 23 is naturally eliminated.

By the way, during the laminated glass processing for manufacturing the dimming device 10 in this way, pressure is applied to each member of the laminated body 30. At this time, the original cell gap (thickness of the liquid crystal layer 23) is maintained at the portion where the spacer (bead spacer 31) is located, but when the space is separated from the bead spacer 31, the value becomes smaller than the original cell gap value. .. If the cell gap is uneven, the quality of the dimming device 10 may be deteriorated, such as poor appearance or non-uniform dimming function.

On the other hand, according to the present embodiment, the manufacturing method of the dimmer 10 is a step of arranging the laminated body 30 in the vacuum bag 51 and heating the laminated body 30 at the first temperature T1 while degassing the laminated body 30. The first temperature T1 is lower than the second temperature T2, including a step of taking out the laminate 30 from the vacuum bag 51 and heating the laminate 30 at the second temperature T2 while pressurizing the laminate 30. In this case, by heating the laminated body 30 at the first temperature T1 while degassing, the first glass plate 11, the first intermediate film 13, the frame intermediate film 16, the film 33, and the dimming cell 20 of the laminated body 30. The second interlayer film 14 and the second glass plate 12 can be temporarily crimped. Further, when the temporarily crimped laminated body 30 is taken out from the vacuum bag 51, the gap g formed between the film 33 and the dimming cell 20 is crushed by the temporary crimping of the laminated body 30. Also, air can be allowed to enter between the film 33 and the dimming cell 20. As a result, even when the void g is crushed, the void g can be formed again between the film 33 and the light control cell 20. Therefore, the void layer G can be provided between the light control cell 20 and the film 33. As a result, even when a liquid crystal pool (a phenomenon in which a large amount of liquid crystal is locally present) occurs in the liquid crystal layer 23 of the light control cell 20, the pressure applied to the liquid crystal layer 23 is released after the production of the light control device 10. At that time, the dimming cell 20 naturally moves so that the cell gap (thickness of the liquid crystal layer 23) becomes uniform in the void layer G (see FIGS. 7A and 7C). Therefore, the liquid crystal pool of the dimming cell 20 is eliminated, the liquid crystal layer 23 of the dimming cell 20 can be uniformly distributed in the plane, and the quality and appearance of the dimming device 10 can be improved.

Further, by providing the gap layer G between the dimming cell 20 and the film 33, the heat insulating property of the dimming device 10 is improved, and the heat retention inside the vehicle or building in which the dimming device 10 is provided is maintained. You can improve your sex.

(Modification example)
Next, various modifications of the present embodiment will be described with reference to FIGS. 8 to 21. 8 to 21 are diagrams showing a dimming device according to a modified example of the present embodiment, respectively. 8 to 21, the same parts as those shown in FIGS. 1 to 7 are designated by the same reference numerals, and detailed description thereof will be omitted.

(First modification)
FIG. 8 shows the dimming device 10A according to the first modification. In the dimming device 10A shown in FIG. 8, a plurality of spacers 34 are provided in the gap layer G between the dimming cell 20 and the film 33. As the spacer 34, a spherical bead spacer having the same configuration as the bead spacer 31 of the dimming cell 20 described above may be used. The plurality of spacers 34 may be arranged regularly or irregularly in a plan view. In this case, the diameter of the spacer 34 may be larger than 0 μm and may be in the range of 10000 μm or less, and is preferably in the range of 1 μm or more and 100 μm or less from the viewpoint of visibility. Alternatively, as the spacer 34, a columnar spacer may be used. By arranging the spacer 34 in the void layer G in this way, the thickness of the void layer G can be secured. As a result, the dimming cell 20 and the film 33 can be prevented from sticking to each other, and rainbow-shaped unevenness and liquid crystal accumulation can be suppressed in the liquid crystal layer 23. Further, the dimming cell 20 and the film 33 may be prevented from sticking to each other by roughening the surface of the film 33 instead of the spacer 34 or by roughening the surface of the film 33 together with the spacer 34.

By the way, when a plurality of spacers 34 are provided in the gap layer G between the light control cell 20 and the film 33, the light control cell 20 is pressed by the spacer 34 in the manufacturing process of the light control device 10A to adjust the light control. The uneven shape may be transferred to the surface of the optical cell 20. Specifically, when the laminated body 30 is heated and pressurized at high temperature and high pressure while increasing the degree of vacuum in the bag 51, the light control cell 20 is caused by the spacer 34. There is a high possibility that the uneven shape will be transferred to the surface. Then, when the uneven shape is transferred to the surface of the dimming cell 20, there is a possibility that the dimming cell 20 may have unevenness like a citron skin.

On the other hand, as described above, in the method of manufacturing the dimming device according to the present embodiment, the laminated body 30 is arranged in the bag 51, and the laminated body 30 is degassed and heated at the first temperature T1. The first temperature T1 is lower than the second temperature T2, and the step of taking out the laminate 30 from the bag 51 and heating the laminate 30 at the second temperature T2 while pressurizing the laminate 30 is provided. .. Therefore, in the step of heating the laminate 30 at the first temperature T1 while degassing, the first temperature T1 is lower than the second temperature T2, and therefore, due to the spacer 34, the surface of the dimming cell 20 It is possible to suppress the transfer of the uneven shape. Further, in the step of heating the laminated body 30 at the second temperature T2 while pressurizing the laminated body 30, since the laminated body 30 is taken out from the bag 51, it is possible to prevent the light control cell 20 from being pressed by the spacer 34. It is possible to prevent the uneven shape from being transferred to the surface of the light control cell 20. Therefore, even when a plurality of spacers 34 are provided in the gap layer G between the light control cell 20 and the film 33, it is possible to prevent the light control cell 20 from having uneven skin-like texture. be able to.

(Second modification)
FIG. 9 shows the dimming device 10B according to the second modification. In the dimming device 10B shown in FIG. 9, an additional film 33A is arranged between the dimming cell 20 and the second interlayer film 14. Further, a void layer G is provided between the light control cell 20 and the additional film 33A. As the additional film 33A, a film having the same configuration as that of the film 33 may be used. As described above, since the void layers G are provided on both side surfaces (first intermediate film 13 side and second intermediate film 14 side) of the dimming cell 20, the fluidity of the liquid crystal layer 23 of the dimming cell 20 It is possible to more effectively suppress the formation of liquid crystal pools in the liquid crystal layer 23. Further, since there are films on both the first glass plate 11 side and the second glass plate 12 side with respect to the dimming cell 20, when the dimming cell is in a light-shielding state, the first glass plate 11 side and the second glass plate 12 side. It is observed in the same mirror surface shape when viewed from either side of the glass plate 12.

(Third variant)
10 and 11 show a dimming device 10C according to a third modification. In the dimming device 10C shown in FIGS. 10 and 11, an extension portion 61 is formed by a part of the dimming cell 20 and a part of the film 33. The extension portion 61 projects outward from the dimming device 10C in the plane direction. Further, the extension portion 61 has a substantially rectangular shape in a plan view, and extends outward from the first glass plate 11 and the second glass plate 12. In this case, the first base material 24 of the light control cell 20 has a projecting piece 24a projecting outward, and the film 33 has a projecting piece 33a projecting outward. The extension portion 61 is composed of a projecting piece 24a of the dimming cell 20 and a projecting piece 33a of the film 33. The projecting piece 24a of the first base material 24 and the projecting piece 33a of the film 33 forming the extension portion 61 have the same shape as each other.

In the present embodiment, a communication hole (vent hole) 62 for communicating the void layer G between the light control cell 20 and the film 33 and the outside air is provided. The communication hole 62 is formed inside the extension portion 61, and specifically, is provided in the gap between the first base material 24 and the film 33 in the extension portion 61. In this case, even if air escapes from the void layer G between the light control cell 20 and the film 33 during the laminated glass processing, the void layer G is restored by injecting a gas such as air or nitrogen from the communication hole 62. Can be done. As a result, it is possible to prevent a liquid crystal pool from forming in the liquid crystal layer 23 of the dimming cell 20. After restoring the void layer G between the light control cell 20 and the film 33, the communication hole 62 may be sealed with an adhesive, a liquid interlayer film, or the like. The place where the extension portion 61 (extension portion 61) is provided is not limited, but it is preferable that the extension portion 61 is provided in a place other than the vicinity of the corner portion of the dimming cell 20 in order to suppress the occurrence of wrinkles and the like.

Further, the width W2 (FIG. 11) of the extension portion 61 is preferably 5 mm or more and 40 mm or less, and more preferably 10 mm or more and 20 mm or less. By setting the above range, the width W2 of the extension portion 61 can be suppressed to be narrow, and the liquid crystal display due to the distortion of the communication hole 62 can be less likely to occur. Further, in the embodiment, it is desirable that the width W3 (FIGS. 10 and 11) of the frame interlayer film 16 at least the portion where the communication hole 62 is formed is narrower than the other portions. Specifically, it is preferable that the width W3 of the frame interlayer film 16 is about 0 mm or more and 10 mm or less. As a result, it is possible to secure a wide air passage through the communication hole 62, and it is possible to easily improve the liquid crystal pool. Further, when a plurality of spacers 34 are provided in the gap layer G between the light control cell 20 and the film 33 (FIG. 8), it is preferable to provide the spacers 34 in the extension portion 61 as well. The communication hole 62 may be any one capable of communicating the void layer G between the light control cell 20 and the film 33 and the outside air with each other. For example, the extension portion 61 may be formed over the entire side of the first base material 24 of the dimming cell 20 and the film 33.

(Fourth modification)
FIG. 12 shows the dimming device 10D according to the fourth modification. In the dimming device 10D shown in FIG. 12, an extension portion 61 is formed by a part of the dimming cell 20 and a part of the film 33 as in the third modification (FIGS. 10 and 11). .. The extension portion 61 projects outward from the dimming device 10D in the plane direction. Further, a communication hole (vent hole) 62 for communicating the gap layer G between the light control cell 20 and the film 33 and the outside air is provided. In this modification, the frame interlayer film 16 is a plan view in which one side of the four sides of the first base material 24 (second base material 27) and the film 33 of the dimming cell 20 in which the communication hole 62 is provided is missing. It has a U-shape. As described above, since the frame interlayer film 16 does not exist on one side where the communication hole 62 is provided, it is possible to easily inject a gas such as air or nitrogen from the communication hole 62. In addition to the U-shape, the planar shape of the frame interlayer film 16 is, for example, (i) a frame shape in which only the portion provided with the communication hole 62 is missing, and (ii) a shape having only two opposite sides (“=”). (Shape), (iii) Dots are provided only at the four corners, (iv) L-shaped shapes are provided only at the four corners, and (v) Only two diagonal corners are provided. The shape may be (vi) a shape excluding only the four corners. Other configurations are substantially the same as those of the third modification shown in FIGS. 10 and 11.

(Fifth variant)
13 and 14 show a dimming device 10E according to a fifth modification. In the dimming device 10E shown in FIGS. 13 and 14, a communication tube 63 is arranged between the dimming cell 20 and the film 33. The communication pipe 63 projects outward from the dimming device 10E in the plane direction. That is, the communication pipe 63 has an elongated pipe shape and extends outward from the first glass plate 11 and the second glass plate 12. In this case, the communication tube 63 is sandwiched between the first base material 24 of the dimming cell 20 and the film 33. Further, in this modification, a communication hole (vent hole) 62A for communicating the gap layer G between the light control cell 20 and the film 33 and the outside air is provided. The communication hole 62A is formed inside the communication pipe 63 in the radial direction. In this case, even if air escapes from the void layer G between the light control cell 20 and the film 33 during the laminated glass processing, the void layer G can be restored by injecting air through the communication hole 62A. As a result, it is possible to prevent a liquid crystal pool from forming in the liquid crystal layer 23 of the dimming cell 20.

(Sixth variant)
FIG. 15 shows the dimming device 10F according to the sixth modification. In the dimming device 10F shown in FIG. 15, a plurality of (two) extension portions 61A and 61B are formed by a part of the dimming cell 20 and a part of the film 33. The two extension portions 61A and 61B project outward from the dimmer 10F in the plane direction, respectively. That is, each of the extension portions 61A and 61B has a substantially rectangular shape in a plan view and extends outward from the first glass plate 11 and the second glass plate 12. The two extension portions 61A and 61B are located on the same side of the dimmer 10F, but the present invention is not limited to this, and the two extension portions 61A and 61B may be located on different sides. In this case, each of the extension portions 61A and 61B is formed by the projecting piece 24a of the first base material 24 and the projecting piece 33a of the film 33, respectively. In this modification, communication holes (vent holes) 62B and 62C for communicating the gap layer G between the light control cell 20 and the film 33 and the outside air are provided. The communication holes 62B and 62C are formed in the extension portions 61A and 61B, respectively, and are specifically provided in the gap between the first base material 24 and the film 33 in the extension portions 61A and 61B. By providing a plurality of (two) communication holes (vent holes) 62B and 62C in this way, even if air escapes from the void layer G between the light control cell 20 and the film 33 during laminated glass processing, even if air escapes from the gap layer G between the light control cell 20 and the film 33. Air can be injected through the communication holes 62B and 62C to easily restore the void layer G. In addition, the configurations of the extension portions 61A and 61B are substantially the same as the configurations of the extension portions 61 shown in FIGS. 10 and 11.

(7th variant)
FIG. 16 shows a dimming device 10G according to a seventh modification. In the dimming device 10G shown in FIG. 16, an additional film 33A is arranged between the dimming cell 20 and the second interlayer film 14. A void layer G is provided between the light control cell 20 and the additional film 33A. Further, an extension portion 61C is formed by a part of the dimming cell 20 and a part of the film 33. The extension portions 61C each project from the dimming device 10G toward the outside in the plane direction. That is, the extension portion 61C has a substantially rectangular shape in a plan view, and extends outward from the first glass plate 11 and the second glass plate 12. In this case, the extension portion 61C is formed by a protruding piece 24a of the first base material 24, a protruding piece 27a of the second base material 27, a protruding piece 33a of the film 33, and a protruding piece 33b of the additional film 33A. In this modification, a communication hole (vent hole) 62D for communicating the gap layer G between the light control cell 20 and the film 33 and the outside air is provided. The communication hole 62D is provided in the gap between the first base material 24 and the film 33 in the extension portion 61C. Further, a communication hole (vent hole) 62E for communicating the void layer G between the light control cell 20 and the additional film 33A and the outside air is provided. The communication hole 62E is provided in the gap between the first base material 24 and the additional film 33A in the extension portion 61C. In addition, the configuration of the extension portion 61C is substantially the same as the configuration of the extension portion 61 shown in FIGS. 10 and 11.

(8th variant)
FIG. 17 shows the dimming device 10H according to the eighth modification. In the dimming device 10H shown in FIG. 17, an additional film 33A is arranged between the dimming cell 20 and the second interlayer film 14. A void layer G is provided between the light control cell 20 and the additional film 33A. Further, a plurality of (two) extension portions 61D and 61E are formed by a part of the dimming cell 20 and a part of the film 33. The two extension portions 61D and 61E project outward from the dimmer 10H, respectively, in the plane direction. That is, each of the extension portions 61D and 61E has a substantially rectangular shape in a plan view, and extends outward from the first glass plate 11 and the second glass plate 12. In this case, one extension portion 61D is formed by the projecting piece 24a of the first base material 24 and the projecting piece 33a of the film 33. Further, a communication hole (vent hole) 62F for communicating the gap layer G between the light control cell 20 and the film 33 and the outside air is provided. The communication hole 62F is formed in one of the extension portions 61D, and specifically, is provided in the gap between the first base material 24 and the film 33 in the extension portion 61D. The other extension 61E is formed by a projecting piece 27a of the second base material 27 and a projecting piece 33b of the additional film 33A. Further, a communication hole (vent hole) 62G for communicating the void layer G between the light control cell 20 and the additional film 33A and the outside air is provided. The communication hole 62G is formed in the other extension portion 61E, and specifically, is provided in the gap between the second base material 27 and the additional film 33A in the other extension portion 61E. In addition, the configurations of the extension portions 61D and 61E are substantially the same as the configurations of the extension portions 61 shown in FIGS. 10 and 11.

(9th variant)
FIG. 18 shows the dimming device 10I according to the ninth modification. In the dimming device 10I shown in FIG. 18, the peripheral edge of the dimming cell 20 and the peripheral edge of the film 33 are adhered to each other by the sealing material 64. The sealing material 64 is provided along the peripheral edge of the void layer G. As the sealing material 64, the same material as the sealing material 32 of the dimming cell 20 described above can be used, and in addition to the same material as the sealing material 32, a thermosetting resin such as an epoxy resin or an acrylic resin or ultraviolet curing can be used. A sex resin or the like can be applied. The width W4 of the sealing material 64 may be 0.1 mm or more and 50 mm or less. The sealing material 64 is applied along the peripheral edge of the first base material 24 of the light control cell 20, and is formed by laminating the light control cell 20 and the film 33 and then curing the light control cell 20 by, for example, ultraviolet rays (UV) or heat. May be done. The sealing material 64 may be provided on substantially the entire peripheral edge of the light control cell 20 and the film 33, or may be provided only on a part of the peripheral edge of the light control cell 20 and the film 33. By integrating the dimming cell 20 and the film 33 in this way, the rigidity of the dimming cell 20 and the film 33 is increased, and the occurrence of wrinkles and the occurrence of liquid crystal lumps can be suppressed. Further, since the void layer G between the light control cell 20 and the film 33 and the frame interlayer film 16 do not come into direct contact with each other, deterioration of the frame intermediate film 16 due to air or the like is suppressed. Further, since the dimming cell 20 and the film 33 are integrated, the step of laminating them can be simplified. Further, in FIG. 18, since the distance between the dimming cell 20 and the film 33 can be adjusted by the sealing material 64, the light reflected on the surface of the dimming cell 20 and the light reflected on the surface of the film 33 interfere with each other. , It is possible to prevent the occurrence of rainbow unevenness. In this case, a spacer (for example, the same as the bead spacer 31 described above) may be mixed in the sealing material 64 to adjust the distance between the light control cell 20 and the film 33.

(10th variant)
FIG. 19 shows a dimming device 10J according to a tenth modification. In the dimming device 10J shown in FIG. 19, an extension portion 61 is formed by a part of the dimming cell 20 and a part of the film 33. Further, the peripheral edge of the light control cell 20 and the peripheral edge of the film 33 are adhered to each other by the sealing material 64. The sealing material 64 is also formed on both edges in the width direction of the extension portion 61, and in the extension portion 61, the first base material 24 of the dimming cell 20 and the film 33 are adhered to each other by the sealing material 64. .. The sealing material 64 is not provided at the base end portion of the extension portion 61, and the communication between the communication hole 62 and the void layer G is not hindered.

(11th variant)
FIG. 20 shows a dimming device 10K according to the eleventh modification. In the dimming device 10K shown in FIG. 20, an extension portion 61 is formed by a part of the dimming cell 20 and a part of the film 33. Further, the two opposing sides of the light control cell 20 and the film 33 are adhered to each other by the sealing material 64, respectively. Specifically, of the four sides of the dimming cell 20 and the film 33, the side on which the extension portion 61 is formed and the side facing the side on which the extension portion 61 is formed are adhered to each other by the sealing material 64. There is. Further, in the extension portion 61, the first base material 24 of the dimming cell 20 and the film 33 are adhered to each other by the sealing material 64. The sealing material 64 is also formed on both end edges in the width direction of the extension portion 61. Other configurations are substantially the same as the configurations shown in FIG.

(12th variant)
FIG. 21 shows a dimming device 10L according to a twelfth modification. In the dimming device 10L shown in FIG. 21, a part of the frame interlayer film 16 is cut out to form a communication hole (vent hole) 62H. The communication hole 62H communicates the void layer G between the light control cell 20 and the film 33 with the outside air. The communication hole 62H has a shape such that the frame interlayer film 16 is removed in the width direction. Further, the communication hole 62H may not be formed on both of the frame interlayer films 16, or may be formed on only one of the frame intermediate films 16. In this case, even if air escapes from the gap layer G between the light control cell 20 and the film 33 during the laminated glass processing, air can be injected from the communication hole 62H to restore the gap layer G. As a result, it is possible to prevent a liquid crystal pool from forming in the liquid crystal layer 23 of the dimming cell 20.

(Second Embodiment)
Next, a second embodiment will be described with reference to FIG. The second embodiment shown in FIG. 22 is mainly in that when the laminated body 30 is heated and pressurized at the second temperature T2, the laminated body 30 is degassed at a second degree of vacuum. Is different from. In FIG. 22, the same parts as those in the first embodiment are designated by the same reference numerals, and detailed description thereof will be omitted.

In the present embodiment, first, as shown in FIG. 22A, the first glass plate 11, the first interlayer film 13, the film 33, the dimming cell 20, the second interlayer film 14, and the second A laminated body 30 is produced which has two glass plates 12 and is provided with a communication hole 62 for communicating the space between the film 33 and the dimming cell 20 and the outside air.

Next, the laminate 30 is placed in the bag (vacuum bag) 51, and the laminate 30 is heated at the first temperature T1 while being degassed at the first degree of vacuum.

At this time, first, as shown in FIG. 22B, the laminated body 30 is enclosed in the bag 51.

Next, as shown in FIG. 22 (c), after the laminated body 30 is sealed in the bag 51, the laminated body 30 is arranged together with the bag 51 in the heating device 53.

Subsequently, the laminate 30 together with the bag 51 is heated at the first temperature T1 and a predetermined time. The time for heating the laminate 30 may be, for example, 10 minutes or more and 120 minutes or less. In this case, for example, the temperature inside the heating device 53 may be raised from room temperature to the first temperature T1 over about 10 minutes. Next, while the temperature inside the heating device 53 is maintained at the first temperature T1, the laminate 30 may be heated for about 1 minute or more and 60 minutes or less, for example, 2 minutes. After that, the temperature in the heating device 53 may be lowered from the first temperature T1 to room temperature over about 60 minutes.

At this time, the air in the bag 51 is sucked by a pump (not shown) through the ventilation pipe 52 to degas the laminated body 30 at the first degree of vacuum. In this case, the first degree of vacuum may be -100 kPa or more and -10 kPa or less, and may be -100 kPa as an example. When the first vacuum degree is −100 kPa or more, it is possible to prevent the dimming cell 20 and the film 33 from being in close contact with each other too much. Further, when the first vacuum degree is −10 kPa or less, the air remaining between the members of the laminated body 30 is effectively sucked, and the crimping failure due to the air bubbles remaining inside the dimming device 10 is effective. Can be suppressed.

In this way, the laminate 30 in which the first glass plate 11, the first interlayer film 13, the frame interlayer film 16, the film 33, the dimming cell 20, the second intermediate film 14, and the second glass plate 12 are temporarily pressure-bonded is formed. can get.

Subsequently, the laminate 30 is placed in the bag 51, and the laminate 30 is heated and pressurized at a second temperature while being degassed at a second degree of vacuum. In this case, the second temperature T2 is higher than the first temperature T1. As a result, when the laminated body 30 is degassed and heated at the first temperature T1, the first intermediate film 13, the second intermediate film 14, and the frame intermediate film 16 of the laminated body 30 can be effectively cured. ..

When the laminate 30 is heated and pressurized at the second temperature, first, as shown in FIG. 22D, the laminate 30 is heated together with the bag 51 without removing the temporarily crimped laminate 30 from the bag 51. It is arranged in the pressurizing device 54.

Subsequently, the laminate 30 together with the bag 51 is heated at the second temperature T2 and a predetermined time. The time for heating the laminate 30 may be, for example, 120 minutes or more and 500 minutes or less. In this case, for example, the temperature inside the heating / pressurizing device 54 may be raised from room temperature to the second temperature T2 over about 80 minutes. Next, the laminate 30 may be heated for about 60 minutes or more and 70 minutes or less, for example, 50 minutes, while the temperature inside the heating / pressurizing device 54 is maintained at the second temperature T2. After that, the temperature inside the heating / pressurizing device 54 may be lowered from the second temperature T2 to room temperature over about 220 minutes.

Further, the laminated body 30 is pressurized in the heating / pressurizing device 54. At this time, the laminated body 30 may be pressurized at 0.1 MPa or more and 0.8 MPa or less, or as an example, may be pressurized at 0.2 MPa. In the present embodiment, unlike the first embodiment described above, when the laminated body 30 is pressurized in the heating / pressurizing device 54, the air in the bag 51 is sucked and the laminated body is sucked as described later. 30 is degassed at the second degree of vacuum. Therefore, by setting the upper limit of the pressure when pressurizing the laminated body 30 in the heating / pressurizing device 54 to 0.8 MPa, it is effective that the dimming cell 20 and the film 33 are in close contact with each other too much. Can be suppressed. Therefore, even when a plurality of spacers 34 (see FIG. 8) are provided in the gap layer G between the light control cell 20 and the film 33, the light control cell 20 has uneven skin-like texture. It is possible to suppress the storage.

Here, in the present embodiment, the air in the bag 51 is sucked by a pump (not shown) through the ventilation pipe 52, and the laminated body 30 is degassed at the second vacuum degree. In this way, when the laminated body 30 is heated and pressurized at the second temperature, the laminated body 30 is degassed at the second vacuum degree to suck the air remaining between the members of the laminated body 30 and dimming. Crimping defects due to air bubbles or the like remaining inside the device 10 can be suppressed. Further, this second degree of vacuum is lower than that of the first degree of vacuum. That is, when the laminated body 30 is degassed at the second vacuum degree, the laminated body 30 is degassed at a higher pressure as compared with the case where the laminated body 30 is degassed at the first vacuum degree. As a result, it is possible to prevent the dimming cell 20 and the film 33 from being in close contact with each other. Therefore, even when the spacer 34 (FIG. 8) is provided between the light control cell 20 and the film 33 and the laminated body 30 is heated and pressurized at high temperature and high pressure, the laminate 30 is heated and pressurized. Due to the spacer 34, it is possible to prevent the uneven shape from being transferred to the surface of the dimming cell 20. Therefore, it is possible to prevent the dimming cell 20 from having a yuzu skin-like unevenness.

In this case, the second degree of vacuum may be −10 kPa or more and -1 kPa or less, and may be -1 kPa as an example. When the second vacuum degree is −10 kPa or more, it is possible to prevent the dimming cell 20 and the film 33 from being in close contact with each other too much. Further, when the second vacuum degree is -1 kPa or less, the air remaining between the members of the laminated body 30 can be sucked, and the crimping failure due to the remaining air bubbles or the like inside the dimming device 10 can be effectively suppressed. ..

In this way, the first intermediate film 13, the second intermediate film 14, and the frame intermediate film 16 are melted, and the first glass plate 11, the first intermediate film 13, the frame intermediate film 16, the film 33, and the adjustment of the laminate 30 are formed. The optical cell 20, the second interlayer film 14, and the second glass plate 12 are crimped (mainly crimped) and integrally joined to obtain a dimming device 10. At this time, the film 33 and the dimming cell 20 are not directly bonded to each other. Further, the laminated body 30 is provided with a communication hole 62 for communicating the space between the film 33 and the dimming cell 20 and the outside air. Therefore, even if the void g formed between the film 33 and the light control cell 20 is crushed after the temporary crimping, the void layer G is injected with a gas such as air or nitrogen from the communication hole 62. Can be restored. As a result, after the dimming device 10 is manufactured, the pressure applied to the liquid crystal layer 23 of the dimming cell 20 is released. Therefore, even if the liquid crystal layer 23 is unevenly distributed in the dimming cell 20, the liquid crystal layer 23 is released. The uneven distribution of 23 is naturally eliminated.

As described above, according to the present embodiment, the method of manufacturing the dimming device 10 is to arrange the laminated body 30 in the bag 51 and degas the laminated body 30 at the first vacuum degree to the first temperature. The second vacuum degree includes a step of heating at T1 and a step of arranging the laminate 30 in the bag 51 and heating and pressurizing the laminate 30 at the second temperature T2 while degassing at the second vacuum degree. However, it is lower than the first degree of vacuum. In this case, by heating the laminated body 30 at the first temperature T1 while degassing, the first glass plate 11, the first intermediate film 13, the frame intermediate film 16, the film 33, and the dimming cell 20 of the laminated body 30. The second interlayer film 14 and the second glass plate 12 can be temporarily crimped. Further, the laminated body 30 is provided with a communication hole 62 for communicating the space between the film 33 and the dimming cell 20 and the outside air. Therefore, even if the void g formed between the film 33 and the light control cell 20 is crushed after the temporary crimping, the void layer G is injected with a gas such as air or nitrogen from the communication hole 62. Can be restored. As a result, the liquid crystal pool of the dimming cell 20 is eliminated, the liquid crystal layer 23 of the dimming cell 20 can be uniformly distributed in the plane, and the quality and appearance of the dimming device 10 can be improved.

Further, by heating and pressurizing the laminated body 30 at the second temperature T2 while degassing the laminated body 30 at the second vacuum degree, the air remaining between the members of the laminated body 30 is sucked, and air bubbles and the like are inside the dimming device 10. It is possible to suppress crimping defects due to the remaining residue. Further, this second degree of vacuum is lower than that of the first degree of vacuum. As a result, it is possible to prevent the dimming cell 20 and the film 33 from being in close contact with each other. Therefore, even when the spacer 34 (FIG. 8) is provided between the light control cell 20 and the film 33 and the laminated body 30 is heated and pressurized at high temperature and high pressure, the laminate 30 is heated and pressurized. Due to the spacer 34, it is possible to prevent the uneven shape from being transferred to the surface of the dimming cell 20. Therefore, it is possible to prevent the dimming cell 20 from having a yuzu skin-like unevenness.

In the above-described embodiment, the method of manufacturing the dimming device 10 is a step of arranging the laminated body 30 in the bag 51 and heating the laminated body 30 at the first temperature T1 while degassing at the first vacuum degree. An example of arranging the laminate 30 in the bag 51 and heating and pressurizing the laminate 30 at the second temperature T2 while degassing at the second vacuum degree has been described. Not limited. For example, the method for manufacturing the dimmer 10 does not have to include a step of arranging the laminate 30 in the bag 51 and heating the laminate 30 at the first temperature T1 while degassing the laminate 30 at the first degree of vacuum. ..

Further, in the above-described embodiment, an example in which the laminated body 30 is provided with the communication holes 62 has been described, but the present invention is not limited to this. For example, although not shown, the laminated body 30 may be provided with communication holes 62A to 62H (FIGS. 13 to 17 and 21).

(Modification example)
Next, various modifications of the present embodiment will be described with reference to FIGS. 23 and 24. 23 and 24 are diagrams showing a dimming device according to a modified example of the present embodiment, respectively. In FIGS. 23 and 24, the same reference numerals are given to the same parts as those of the first embodiment shown in FIGS. 1 to 7, the modified examples shown in FIGS. 8 to 21, and the second embodiment shown in FIG. A detailed description will be omitted.

(First modification)
FIG. 23 shows the dimming device 10M according to the first modification. In the dimming device 10M shown in FIG. 23, a fluid resin layer L is provided between the dimming cell 20 and the film 33. The fluid resin layer L is enclosed in the space between the light control cell 20 and the film 33. The fluid resin layer L is, for example, a transparent resin that softens at a temperature lower than that of the first intermediate film 13 and the second intermediate film 14, and may be an uncured liquid or a gel. Further, it is preferable that the refractive index of the fluid resin layer L is adjusted to that of the film 33. As such a fluid resin layer L, for example, glycerin or the like can be used. Further, the fluid resin layer L may be a fluid liquid layer. The thickness of the fluid resin layer L may be larger than 0 μm and less than 10000 μm. By providing the fluidized resin layer L between the light control cell 20 and the film 33 in this way, the fluidized resin layer L can be made to flow after the laminated glass processing. As a result, the thickness of the liquid crystal layer 23 of the dimming cell 20 can be made uniform, and the occurrence of liquid crystal pools can be suppressed.

When the fluidized resin layer L is sealed between the light control cell 20 and the film 33, the fluidized resin layer L is formed from the communication holes 62 to 62H shown in FIGS. 10 to 17 and 19 to 21 described above. You may inject. In particular, in an example in which the laminated body 30 is provided with two communication holes (vent holes) 62B and 62C (FIG. 15), flow flows from one communication hole 62A (62B) between the dimming cell 20 and the film 33. When the sex resin layer L is sealed, it can be evacuated from the other communication hole 62B (62A), and the fluid resin layer L can be smoothly sealed. Further, after the fluid resin layer L is sealed, the communication holes 62 to 62H may be sealed with an adhesive, a liquid interlayer film, or the like. In this case, the communication holes 62 to 62H are preferably closed with the material of the frame interlayer film 16 or the sealing material.

Further, in the case of the example shown in FIG. 19 described above, when the fluidized resin layer L is sealed in the space between the extension portion 61 and the dimming cell 20 and the film 33, the space is set to a negative pressure. By immersing the tip of the extension portion 61 in a container containing the fluid resin layer L, the fluid resin layer L can be smoothly sealed in the space. Therefore, it is not necessary to immerse the entire side of the light control cell 20 in the container containing the fluid resin layer L. Of the four sides constituting the light control cell 20 and the film 33, the sealing material 64 may be formed in a U-shape in a plan view along three sides where the extension portion 61 does not exist. In this case, the entire side where the light control cell 20 and the extension portion 61 of the film 33 exist is immersed in the container containing the fluid resin layer L, and the fluid resin layer is formed in the space between the light control cell 20 and the film 33. L may be enclosed.

(Second modification)
FIG. 24 shows the dimming device 10N according to the second modification. In the dimming device 10N shown in FIG. 24, a transparent curable resin layer 38 is provided between the dimming cell 20 and the film 33. The curable resin layer 38 is cured after being filled in the space between the light control cell 20 and the film 33. As such a curable resin layer 38, for example, a thermosetting resin, an ultraviolet curable resin, or the like can be used. The thickness of the curable resin layer 38 may be larger than 0 μm and 10000 μm or less. The curable resin layer 38 is filled between the light control cell 20 and the film 33 after the laminated glass processing, and is then cured by heat, ultraviolet rays, or the like. By providing the curable resin layer 38 between the light control cell 20 and the film 33 in this way, the uncured curable resin layer 38 can be flowed immediately after the laminated glass processing. As a result, the thickness of the liquid crystal layer 23 of the dimming cell 20 can be made uniform, and the occurrence of liquid crystal pools can be suppressed. After that, by curing the curable resin layer 38, the liquid crystal layer 23 of the dimming cell 20 can be held on the second glass plate 12 side by the rigidity of the curable resin layer 38. As a result, when the dimming device 10B is placed vertically, it is possible to prevent a part of the liquid crystal layer 23 from falling downward in the vertical direction due to gravity.

When the curable resin layer 38 is sealed between the light control cell 20 and the film 33, the curable resin layer 38 is formed from the communication holes 62 to 62H shown in FIGS. 10 to 17 and 19 to 21 described above. You may inject. In particular, in the example in which the laminated body 30 is provided with two communication holes (vent holes) 62B and 62C (FIG. 15), the one communication hole 62A (62B) is cured between the dimming cell 20 and the film 33. When the sex resin layer 38 is sealed, it can be evacuated from the other communication hole 62B (62A), and the curable resin layer 38 can be smoothly sealed. Further, after the curable resin layer 38 is sealed, the communication holes 62 to 62H may be sealed with an adhesive, a liquid interlayer film, or the like. In this case, the communication holes 62 to 62H are preferably closed with the material of the frame interlayer film 16 or the sealing material.

Further, in the case of the example shown in FIG. 19 described above, when the curable resin layer 38 is sealed in the space between the extension portion 61 and the dimming cell 20 and the film 33, the space is set to a negative pressure. By immersing the tip of the extension portion 61 in a container containing the curable resin layer 38, the curable resin layer 38 can be smoothly sealed in the space. Therefore, it is not necessary to immerse the entire side of the light control cell 20 in the container containing the curable resin layer 38. Of the four sides constituting the light control cell 20 and the film 33, the sealing material 64 may be formed in a U-shape in a plan view along three sides where the extension portion 61 does not exist. In this case, the entire side of the light control cell 20 and the extension portion 61 of the film 33 is immersed in the container containing the curable resin layer 38, and the curable resin layer is formed in the space between the light control cell 20 and the film 33. 38 may be enclosed.

(Third Embodiment)
Next, a third embodiment will be described with reference to FIG. In the third embodiment shown in FIG. 25, the laminate 30 is mainly arranged in the bag 51 with the communication holes 62 communicating with the outside of the bag 51, and the laminate 30 is heated while being degassed. The point of pressurization is different from that of the first embodiment. In FIG. 25, the same parts as those of the first embodiment or the second embodiment are designated by the same reference numerals, and detailed description thereof will be omitted.

In the present embodiment, first, as shown in FIG. 25A, the first glass plate 11, the first interlayer film 13, the film 33, the dimming cell 20, the second interlayer film 14, and the second A laminated body 30 is produced which has two glass plates 12 and is provided with a communication hole 62 for communicating the space between the film 33 and the dimming cell 20 and the outside air. In this case, in the laminated body 30, similarly to the dimming device 10J shown in FIG. 19, the peripheral edge of the dimming cell 20 and the peripheral edge of the film 33 are adhered to each other by the sealing material 64, and the sealing material 64 is bonded to each other. It is preferable that the extension portion 61 is also formed at both end edges in the width direction. As a result, as will be described later, even when the laminate 30 is arranged in the bag 51 with the communication holes 62 communicating with the outside of the bag (vacuum bag) 51, the laminate 30 is degassed. be able to.

Next, the laminate 30 is placed in the bag 51 with the communication holes 62 communicating with the outside of the bag (vacuum bag) 51, and the laminate 30 is heated and pressurized while being degassed.

At this time, first, as shown in FIG. 25 (b), the laminated body 30 is enclosed in the bag 51. At this time, the laminate 30 is sealed in the bag 51 so that the communication hole 62 of the laminate 30 communicates with the outside of the bag 51.

Next, as shown in FIG. 25 (c), after the laminated body 30 is sealed in the bag 51, the laminated body 30 is arranged together with the bag 51 in the heating device 53.

Subsequently, the laminate 30 together with the bag 51 is heated at a predetermined temperature and time. The heating temperature of the laminate 30 is equal to or higher than the softening temperature of the first intermediate film 13, the second intermediate film 14, and the frame intermediate film 16. In this case, the laminate 30 may be heated to 90 ° C. or higher and 140 ° C. or lower, and as an example, it may be heated to 130 ° C. or higher. When the heating temperature is 90 ° C. or higher, the first intermediate film 13, the second intermediate film 14, and the frame intermediate film 16 of the laminated body 30 can be effectively cured. Further, when the heating temperature is 140 ° C. or lower, it is possible to prevent the first intermediate film 13, the second intermediate film 14, the frame intermediate film 16 and the like of the laminated body 30 from being damaged by heat. .. When the first interlayer film 13 contains PVB (polyvinyl butyral), the heating temperature may be 120 ° C. or higher and 140 ° C. or lower.

Further, the time for heating the laminated body 30 may be, for example, 120 minutes or more and 500 minutes or less. In this case, for example, the temperature inside the heating / pressurizing device 54 may be raised from room temperature to the above-mentioned heating temperature over about 80 minutes. Next, the laminate 30 may be heated for about 60 minutes or more and 70 minutes or less, for example, 50 minutes, while the temperature inside the heating / pressurizing device 54 is maintained at the above-mentioned heating temperature. After that, the temperature inside the heating / pressurizing device 54 may be lowered from the above-mentioned heating temperature to room temperature over about 220 minutes.

Further, the laminated body 30 is pressurized in the heating / pressurizing device 54. At this time, the laminate 30 may be pressurized at 0.1 MPa or more and 1.3 MPa or less, preferably 0.8 MPa or more and 1.3 MPa or less, or may be heated at 0.8 MPa or less as an example. By pressurizing the laminated body 30 at 0.1 MPa or more, the first intermediate film 13, the second intermediate film 14 and the frame intermediate film 16 of the laminated body 30 can be effectively cured. Further, when the laminated body 30 is pressurized at 1.3 MPa or less, it is possible to prevent the light control cell 20 and the film 33 from being in close contact with each other too much.

Further, at this time, the air in the bag 51 is sucked by a pump (not shown) through the ventilation pipe 52 to degas the laminated body 30. In this way, when the laminated body 30 is heated and pressurized, the air remaining between the members of the laminated body 30 is sucked by degassing the laminated body 30, and air bubbles or the like remain inside the dimming device 10. It is possible to suppress crimping defects due to this. At this time, the laminated body 30 is arranged in the bag 51 with the communication holes 62 communicating with the outside of the bag (vacuum bag) 51. Therefore, even when the laminated body 30 is degassed, it is possible to prevent the dimming cell 20 and the film 33 from being in close contact with each other. Therefore, even when the spacer 34 (FIG. 8) is provided between the light control cell 20 and the film 33 and the laminated body 30 is heated and pressurized at high temperature and high pressure, the laminate 30 is heated and pressurized. Due to the spacer 34, it is possible to prevent the uneven shape from being transferred to the surface of the dimming cell 20. Therefore, it is possible to prevent the dimming cell 20 from having a yuzu skin-like unevenness.

In this case, the laminated body 30 may be degassed at −100 kPa or more and −10 kPa or less, for example, −100 kPa. By degassing the laminated body 30 at -10 kPa or less, the air remaining between the members of the laminated body 30 is effectively sucked, and the crimping failure due to the air bubbles remaining inside the dimming device 10 is effective. Can be suppressed.

In this way, the first intermediate film 13, the second intermediate film 14, and the frame intermediate film 16 are melted, and the first glass plate 11, the first intermediate film 13, the frame intermediate film 16, the film 33, and the adjustment of the laminate 30 are formed. The optical cell 20, the second interlayer film 14, and the second glass plate 12 are crimped and integrally joined to obtain a dimming device 10. At this time, the film 33 and the dimming cell 20 are not directly bonded to each other. Further, the laminated body 30 is provided with a communication hole 62 for communicating the space between the film 33 and the dimming cell 20 and the outside air. Therefore, even when the gap g formed between the film 33 and the light control cell 20 is crushed, the first glass plate 11, the first intermediate film 13, and the frame intermediate film 16 of the laminated body 30 are crushed. , Film 33, dimming cell 20, second interlayer film 14, and second glass plate 12 are crimped (main crimped), and then a gas such as air or nitrogen is injected from the communication hole 62 to restore the void layer G. Can be done. As a result, after the dimming device 10 is manufactured, the pressure applied to the liquid crystal layer 23 of the dimming cell 20 is released. Therefore, even if the liquid crystal layer 23 is unevenly distributed in the dimming cell 20, the liquid crystal layer 23 is released. The uneven distribution of 23 is naturally eliminated.

As described above, according to the present embodiment, in the method of manufacturing the dimming device 10, the laminated body 30 is arranged in the bag 51 with the communication holes 62 communicating with the outside of the bag 51, and the laminated body 30 is laminated. The body 30 is provided with a step of heating and pressurizing while degassing. As a result, even when the laminated body 30 is heated and pressurized while being degassed, it is possible to prevent the dimming cell 20 and the film 33 from being in close contact with each other. Therefore, even when the spacer 34 (FIG. 8) is provided between the light control cell 20 and the film 33 and the laminated body 30 is heated and pressurized at high temperature and high pressure, the laminate 30 is heated and pressurized. Due to the spacer 34, it is possible to prevent the uneven shape from being transferred to the surface of the dimming cell 20. Therefore, it is possible to prevent the dimming cell 20 from having a yuzu skin-like unevenness. Further, since the laminated body 30 is degassed when the laminated body 30 is heated and pressurized, the air remaining between the members of the laminated body 30 is sucked, and air bubbles or the like remain inside the dimming device 10. It is possible to suppress crimping defects due to.

Further, since the laminated body 30 is provided with a communication hole 62 for communicating the space between the film 33 and the dimming cell 20 and the outside air, it is formed between the film 33 and the dimming cell 20 after crimping. Even when the void g is crushed, the void layer G can be restored by injecting a gas such as air or nitrogen through the communication hole 62. As a result, the liquid crystal pool of the dimming cell 20 is eliminated, the liquid crystal layer 23 of the dimming cell 20 can be uniformly distributed in the plane, and the quality and appearance of the dimming device 10 can be improved.

It is also possible to appropriately combine a plurality of components disclosed in each of the above-described embodiments and modifications. Alternatively, some components may be deleted from all the components shown in each of the above-described embodiments and modifications.

10, 10A-10N Dimming device 11 1st glass plate 12 2nd glass plate 13 1st intermediate film 14 2nd intermediate film 20 Dimming cell 30 Laminated body 33 Film 34 Spacer 51 Bag 61, 61A to 61E Extension 62, 62A-61H Communication hole 63 Communication pipe

Claims (16)

A step of producing a laminate having a first transparent substrate, a first intermediate, a film, a dimming cell, a second intermediate, and a second transparent substrate.
A step of arranging the laminate in a vacuum bag and heating the laminate at a first temperature while degassing.
A step of taking out the laminate from the vacuum bag and heating the laminate at a second temperature while pressurizing the laminate is provided.
A method for manufacturing a dimmer, wherein the first temperature is lower than the second temperature. In the step of heating the laminate at the first temperature while degassing, the laminate is degassed at a degree of vacuum of −100 kPa or more and −10 kPa or less, and the first temperature is 50 ° C. or higher and 90 ° C. or lower. , The method for manufacturing a dimmer according to claim 1. In the step of heating the laminate at a second temperature while pressurizing the laminate, the laminate is pressurized at 0.1 MPa or more and 1.3 MPa or less, and the second temperature is 90 ° C. or more and 140 ° C. or less. Item 3. The method for manufacturing a dimmer according to Item 1 or 2. It has a first transparent substrate, a first intermediate, a film, a dimming cell, a second intermediate, and a second transparent substrate, and also has a space between the film and the dimming cell and outside air. And the process of producing a laminated body, which is provided with a communication hole for communicating with
A step of arranging the laminate in a vacuum bag and heating the laminate at a first temperature while degassing at a first degree of vacuum.
A step of arranging the laminate in the vacuum bag and heating and pressurizing the laminate at a second temperature while degassing at a second degree of vacuum is provided.
The method for manufacturing a dimmer, wherein the second degree of vacuum is lower than the degree of first degree of vacuum. The method for manufacturing a dimmer according to claim 4, wherein the first degree of vacuum is -100 kPa or more and -10 kPa or less. The method for manufacturing a dimmer according to claim 4 or 5, wherein the second degree of vacuum is -10 kPa or more and -1 kPa or less. The method for manufacturing a dimmer according to any one of claims 4 to 6, wherein the second temperature is higher than the first temperature. The method for manufacturing a dimmer according to any one of claims 4 to 7, wherein the first temperature is 50 ° C. or higher and 90 ° C. or lower. It has a first transparent substrate, a first intermediate, a film, a dimming cell, a second intermediate, and a second transparent substrate, and also has a space between the film and the dimming cell and outside air. And the process of producing a laminated body, which is provided with a communication hole for communicating with
A step of arranging the laminate in a vacuum bag and heating and pressurizing the laminate at a second temperature while degassing at a second degree of vacuum is provided.
A method for manufacturing a dimmer, wherein the second degree of vacuum is -10 kPa or more and -1 kPa or less. In the step of heating and pressurizing the laminate at the second temperature while degassing the laminate at the second vacuum degree, the laminate is pressurized at 0.1 MPa or more and 0.8 MPa or less, and the second temperature is 90 ° C. The method for manufacturing a dimmer according to any one of claims 4 to 9, wherein the temperature is 140 ° C. or lower. It has a first transparent substrate, a first intermediate, a film, a dimming cell, a second intermediate, and a second transparent substrate, and also has a space between the film and the dimming cell and outside air. And the process of producing a laminated body, which is provided with a communication hole for communicating with
A dimming device comprising a step of arranging the laminate in the vacuum bag with the communication holes communicating with the outside of the vacuum bag, and heating and pressurizing the laminate while degassing the laminate. Production method. In the step of heating and pressurizing the laminate while degassing, the laminate is degassed at a degree of vacuum of -100 kPa or more and -10 kPa or less, and the laminate is heated to 90 ° C or more and 140 ° C or less. The method for manufacturing a dimmer according to claim 11, wherein the pressure is increased at 0.1 MPa or more and 1.3 MPa or less. An extension portion is formed by a part of the dimming cell and a part of the film, and the extension portion extends outward from the first transparent substrate and the second transparent substrate in a plan view, and the communication hole is formed. The method for manufacturing a dimmer according to any one of claims 4 to 11, which is formed on the extension portion. The method for manufacturing a dimming device according to any one of claims 4 to 13, further comprising a step of sealing the communication holes. The method for manufacturing a dimmer according to any one of claims 1 to 14, wherein the first intermediate contains polyvinyl butyral. The method for manufacturing a dimming device according to any one of claims 1 to 15, wherein a spacer is arranged between the dimming cell and the film.

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