JP7169550B2 - Light control cell, light control device, vehicle, method for manufacturing light control cell, and method for manufacturing light control device - Google Patents

Description

The present invention relates to a light control cell, a light control device including the light control cell, a vehicle including the light control device, a method for manufacturing the light control cell, and a method for manufacturing the light control device.

As a light control device capable of adaptively changing light transmittance, a light control device provided with a light control cell (liquid crystal cell) capable of freely controlling light transmittance according to an applied voltage has attracted attention. A light control device using liquid crystal orientation not only has excellent response performance, but also has a high degree of freedom in terms of installation, and can be installed in a desired space so as to form a flat surface or a curved surface. In addition, since the light-modulating cell can transmit light without changing the color, it is also excellent in color harmony with other members installed around it.

Such a light control device using a light control cell with excellent versatility is expected to be used in various fields. For example, like the light control film disclosed in Patent Document 1, it is possible to configure a light control device that can be used even in an external environment by attaching a light control cell to a translucent member such as plate glass. A light control device comprising a light control cell and a light transmitting member can protect the light control cell with the light transmitting member, so that it can be used even in an external environment, has a wide range of applications, and can, for example, freely control the amount of transmitted light. It can also be suitably used as a light control window.

Japanese Patent No. 6024844

In the light control device including the light control cell and the light transmission member described above, the light control cell needs to be bonded to the light transmission member in order to fix the light control cell to the light transmission member. However, it is not easy to properly bond the light-modulating cell, which needs to keep the thickness of the liquid crystal layer uniform, to the translucent member. In particular, when the light-modulating cell is joined to the translucent member, if uneven force is applied to the entire liquid crystal layer or if a large force is locally applied to the liquid crystal layer, the liquid crystal layer may be damaged. The thickness becomes non-uniform, and a "liquid crystal reservoir" that is extremely thicker than other parts may be locally generated.

The liquid crystal does not function normally in the liquid crystal pool portion, which is several times thicker than the normal portion of the liquid crystal layer, and the desired dimming performance cannot be obtained.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and provides a light control cell that effectively prevents the occurrence of liquid crystal pools and exhibits excellent light control performance, a light control device having such a light control cell, and a light control device having such a light control cell. It aims at providing the vehicle provided with such a light control apparatus, the manufacturing method of a light control cell, and the manufacturing method of a light control apparatus.

One aspect of the present invention is a light control cell in which light transmittance changes according to an applied voltage, and includes a first substrate including a first resin base material and a second substrate including a second resin base material. a liquid crystal layer disposed between the first substrate and the second substrate; a plurality of spacers disposed in the liquid crystal layer; and a plurality of seal columns disposed in the liquid crystal layer, each of which is a first and a plurality of sealing columns bonded to the first substrate and the second substrate, wherein the diameter of each of the plurality of sealing columns in the direction in which the liquid crystal layer extends is equal to that of each of the plurality of spacers. for a dimming cell larger than the diameter of the

Each of the plurality of spacers may be bonded to at least one of the first substrate and the second substrate, or may not be bonded to both the first substrate and the second substrate.

Each of the plurality of seal posts may be provided so as to contact or include at least one or more of the plurality of spacers. That is, all or some of the plurality of sealing posts can be provided in contact with or encompass one or more spacers.

The first substrate includes a first alignment layer, the second substrate includes a second alignment layer, the liquid crystal layer is adjacent to each of the first alignment layer and the second alignment layer, and each of the plurality of spacers comprises a first alignment layer. It may be bonded to the first substrate or the second substrate by an alignment layer or a second alignment layer.

A bonding force of the plurality of seal columns to each of the first substrate and the second substrate may be 25 mN/mm ² or more.

A diameter of each of the plurality of seal columns in the direction in which the liquid crystal layer extends may be 500 μm or less.

Regarding the direction in which the liquid crystal layer extends, the area where the plurality of seal columns are bonded to each of the first substrate and the second substrate may be 10% or less in the 1 mm square area where the liquid crystal layer exists.

Each of the plurality of seal posts may be colored.

Each of the plurality of sealing posts may be transparent.

The plurality of seal columns may be arranged at positions irregularly defined with respect to the direction in which the liquid crystal layer extends.

The plurality of seal columns may be arranged at regularly determined positions with respect to the direction in which the liquid crystal layer extends.

The material forming the plurality of seal posts may include epoxy resin or acrylic resin.

Another aspect of the present invention relates to a light control device including a pair of translucent members and the above-described light control cell arranged between the pair of translucent members.

Another aspect of the present invention relates to a vehicle including the light control device described above.

Another aspect of the present invention is a method for manufacturing a light control device including a pair of light-transmitting members and the above-described light control cell disposed between the pair of light-transmitting members, wherein the light control cell comprises a pair of The present invention relates to a method for manufacturing a light control device that is fixed to a pair of light-transmitting members while being at least partially pressed between the light-transmitting members.

Another aspect of the invention is
A light control cell having a variable transmittance,
a first substrate including a first resin base;
a second substrate including a second resin base;
a liquid crystal layer provided between the first substrate and the second substrate;
a plurality of spacers provided between the first substrate and the second substrate;
a plurality of sealing columns arranged in the liquid crystal layer, each of which is bonded to the first substrate and the second substrate;
a frame-shaped sealing material disposed between the first substrate and the second substrate so as to surround the liquid crystal layer and the plurality of sealing columns;
The spacer is a light control cell arranged in contact with the sealing column or the frame-shaped sealing material.

In the light control cell according to the present invention, each of the plurality of spacers may be arranged inside the sealing column or inside the frame-shaped sealing material.

In the light control cell according to the present invention, the sealing column, the frame-shaped sealing material and the spacer may be made of the same material.

In the dimming cell according to the invention, the spacer may have a spherical shape.

In the light control cell according to the present invention, the material forming the seal column may contain epoxy resin or acrylic resin.

Another aspect of the invention is
a pair of translucent members;
and a light control cell according to the present invention arranged between the pair of translucent members.

Another aspect of the invention is
1 is a vehicle equipped with a light control device according to the present invention;

Another aspect of the invention is
A first composition comprising an uncured first sealing material and first spacers dispersed in the first sealing material is applied to a circumferential region on one of the first substrate and the second substrate. process and
supplying a liquid crystal material to a region on the one of the first substrate and the second substrate surrounded by the first composition applied to the circumferential region;
A frame holding the first spacer by curing the first composition while the other of the first substrate and the second substrate is placed on the one of the first substrate and the second substrate. forming a frame-shaped sealing material, and bonding the first substrate and the second substrate via the frame-shaped sealing material.

In the method for manufacturing a light control cell according to the present invention, in the step of applying the first composition, a second composition comprising an uncured second sealing material and second spacers dispersed in the second sealing material. Coating the object dispersedly in the circumferential region,
In the step of bonding the first substrate and the second substrate, the second composition is cured to form a sealing column holding the second spacer in a region surrounded by the frame-shaped sealing material. may

In the method for manufacturing a light control cell according to the present invention, the first sealing material and the second sealing material may be made of the same material.

In the method for manufacturing a light control cell according to the present invention, the first spacer and the second spacer may be made of the same material.

Another aspect of the invention is
A method for manufacturing a light control device comprising a pair of light transmitting members and a light control cell according to the present invention arranged between the pair of light transmitting members,
In the method for manufacturing a light control device, the light control cell is fixed to the pair of light transmitting members while at least a portion of the light control cell is pressed between the pair of light transmitting members.

Another aspect of the present invention is a light control cell in which light transmittance changes in accordance with an applied voltage, and includes a first substrate including a first resin base material and a second substrate including a second resin base material. a substrate, a liquid crystal layer disposed between the first substrate and the second substrate, a plurality of spacers disposed in the liquid crystal layer, and a plurality of seal columns disposed in the liquid crystal layer, each and a plurality of sealing columns bonded to the first substrate and the second substrate, wherein the bonding force of the plurality of sealing columns to each of the first substrate and the second substrate is 25 mN/mm ² or more. Regarding cells.

Another aspect of the present invention is a light control cell in which light transmittance changes in accordance with an applied voltage, and includes a first substrate including a first resin base material and a second substrate including a second resin base material. a substrate, a liquid crystal layer disposed between the first substrate and the second substrate, a plurality of spacers disposed in the liquid crystal layer, and a plurality of seal columns disposed in the liquid crystal layer, each a plurality of sealing columns bonded to the first substrate and the second substrate; and a frame-like shape arranged between the first substrate and the second substrate so as to surround the liquid crystal layer, the plurality of spacers and the plurality of sealing columns. and a sealing material, wherein the frame-shaped sealing material and the plurality of sealing columns are made of the same material.

A diameter of each of the plurality of seal columns in the direction in which the liquid crystal layer extends may be 500 μm or less.

Regarding the direction in which the liquid crystal layer extends, the area where the plurality of seal columns are bonded to each of the first substrate and the second substrate may be 10% or less in the 1 mm square area where the liquid crystal layer exists.

Each of the plurality of seal posts may be colored.

Each of the plurality of sealing posts may be transparent.

The plurality of seal columns may be arranged at positions irregularly defined with respect to the direction in which the liquid crystal layer extends.

The plurality of seal columns may be arranged at regularly determined positions with respect to the direction in which the liquid crystal layer extends.

The material forming the plurality of seal posts may include epoxy resin or acrylic resin.

Each of the plurality of seal posts may be provided so as to contact or include at least one or more of the plurality of spacers.

Another aspect of the present invention relates to a light control device including a pair of translucent members and the above-described light control cell arranged between the pair of translucent members.

Another aspect of the present invention relates to a vehicle including the light control device described above.

Another aspect of the present invention is a method for manufacturing a light control device including a pair of light-transmitting members and the above-described light control cell disposed between the pair of light-transmitting members, wherein the light control cell comprises a pair of The present invention relates to a method for manufacturing a light control device that is fixed to a pair of light-transmitting members while being at least partially pressed between the light-transmitting members.

Another aspect of the present invention includes a first substrate including a first substrate and a first transparent electrode, a second substrate including a second substrate and a second transparent electrode, and a first substrate and a second substrate. and a liquid crystal layer disposed between the plurality of seal pillars between the first substrate and the second substrate, wherein the plurality of seal pillars are triangular or triangular in plan view. It is arranged at a position corresponding to each vertex of a figure filled with a plurality of pentagons, or corresponds to each vertex of a figure filled with at least two types of polygons out of triangles, quadrilaterals and hexagons in plan view. It relates to a dimming cell, each arranged in a position.

The plurality of seal columns may be arranged at positions corresponding to respective vertices of a figure filled with a plurality of equilateral triangles in plan view.

The plurality of seal columns may be arranged at positions corresponding to respective vertices of a figure filled with a plurality of pentagons in plan view.

The plurality of seal columns may be arranged at positions corresponding to respective vertices of a figure filled with a plurality of equilateral triangles, squares and regular hexagons in plan view.

The plurality of seal columns may be arranged at positions corresponding to respective vertices of a figure filled with a plurality of equilateral triangles and squares in plan view.

Another aspect of the present invention includes a first substrate including a first substrate and a first transparent electrode, a second substrate including a second substrate and a second transparent electrode, and a first substrate and a second substrate. a plurality of seal columns arranged between the first substrate and the second substrate, and a liquid crystal layer arranged between the plurality of seal columns between the first substrate and the second substrate, wherein one side of the plurality of seal columns in plan view is The present invention relates to a light control cell arranged at a position corresponding to each vertex of a figure filled with squares of 408 μm or more and 2000 μm or less.

According to the present invention, a light control cell exhibiting excellent light control performance by effectively preventing the occurrence of a liquid crystal pool, a light control device comprising such a light control cell, a vehicle comprising such a light control device, A method for manufacturing a light control cell and a method for manufacturing a light control device can be provided.

FIG. 1A is a cross-sectional view showing an outline of a light control device, and is a diagram for explaining an example of a mechanism of generation of a liquid crystal pool. FIG. 1B is a cross-sectional view showing an outline of the light control device, and is a diagram for explaining an example of the mechanism of generation of liquid crystal pools. FIG. 2A is a cross-sectional view showing an outline of the light control device, and is a diagram for explaining another example of the generation mechanism of the liquid crystal pool. FIG. 2B is a schematic cross-sectional view of the light control device, and is a diagram for explaining another example of the mechanism of generation of liquid crystal pools. FIG. 3 is a cross-sectional view schematically showing the overall configuration of an example of the light control cell, and is a diagram mainly for explaining the layer configuration. FIG. 4 is a cross-sectional view showing an outline of the overall configuration of the light-modulating cell, and is a diagram mainly for explaining spacers, frame-shaped sealing materials, and sealing columns arranged together with the liquid crystal layer. FIG. 5 is a schematic cross-sectional view showing a modified example of the light control cell. FIG. 6 is a schematic cross-sectional view showing a modified example of the light control cell. FIG. 7 is a schematic cross-sectional view showing another modification of the light control cell. FIG. 8 is a cross-sectional view showing an outline of the overall configuration of the light-modulating cell, and is a diagram mainly for explaining spacers, frame-like sealing materials, and sealing columns arranged together with the liquid crystal layer. FIG. 9 is a plan view showing an outline of the overall configuration of the light control cell device. FIG. 10A is a diagram for explaining a method of manufacturing a light control cell. FIG. 10B is a diagram for explaining the method of manufacturing the light control cell. FIG. 10C is a diagram for explaining a method for manufacturing a light control cell. FIG. 10D is a diagram for explaining a method for manufacturing a light control cell. FIG. 11 is a cross-sectional view schematically showing a modified example of the light control cell. FIG. 12 is a cross-sectional view schematically showing a modified example of the light control cell. FIG. 13 is a schematic cross-sectional view showing another modification of the light control cell. FIG. 14 is a plan view showing the arrangement of seal columns. FIG. 15 is a plan view showing a modification of the arrangement of the seal columns. FIG. 16 is a plan view showing a modification of the arrangement of the seal columns. FIG. 17 is a plan view showing a modification of the arrangement of the seal columns. FIG. 18 is a plan view showing a modification of the arrangement of the seal columns. FIG. 19 is a schematic cross-sectional view showing the periphery of the external electrode substrate in the light control cell. FIG. 20 is a diagram showing an example of a vehicle to which the dimmer is applied.

An embodiment of the present invention will be described below with reference to the drawings.

For ease of illustration and understanding, the size of each element shown in the drawings and the size ratio between the elements do not necessarily match between the drawings. and size ratios can be easily understood. In the following description, when the term “light” is simply used, light in the visible light range is mainly intended, but the following embodiments can also be applied to light with wavelengths outside the visible light range. It is possible. The term “transparency” means a property of allowing light to pass therethrough, and although the specific transmittance of light for each wavelength does not matter, it can be generally said that the higher the transmittance, the higher the transparency. Therefore, so-called semi-transparency can also be included in the concept of transparency in a broad sense.

Also, in the description and specification of the present invention, the term "seal column" is used for convenience only, and the function, shape, and other characteristics of the seal column are not limited by the name alone. It may also be referred to as a "columnar spacer". That is, the characteristics of the seal column should be appropriately specified based on the description in this specification and the attached claims, drawings, and abstract. It should be noted that shape is not required.

[Generation Mechanism of Liquid Crystal Stagnant Part]
First, the mechanism of generation of liquid crystal pools will be described. In this specification, the term "liquid crystal reservoir" refers to a portion of the liquid crystal layer where the thickness of the liquid crystal layer becomes uneven and is extremely thicker than other portions. Various mechanisms for generating liquid crystal pools are conceivable, but a typical mechanism for generating them will be described below.

1A and 1B are cross-sectional views showing an outline of the light control device 10, and are diagrams for explaining an example of the generation mechanism of the liquid crystal pool portion 15. FIG.

The light control device 10 includes a pair of light transmitting members 12 and a light control cell 11 arranged between the pair of light transmitting members 12 . In the region between the pair of translucent members 12, the light control cell 11 is arranged and the intermediate support member 13 is filled. The light control cell 11 is arranged in an intermediate support member 13 and joined and fixed to each translucent member 12 via the intermediate support member 13 .

The light control cell 11 includes a liquid crystal layer (see reference numeral 21 in FIG. 3, which will be described later), and the light transmittance changes according to the applied voltage. A specific configuration example of the dimming cell 11 will be described later.

The translucent member 12 transmits light and protects the light control cell 11 from external forces. Therefore, the translucent member 12 has strength, rigidity, and elasticity to the extent that it can protect the light control cell 11 arranged inside from the force applied from the outside. Typically, the translucent member 12 can be made of glass or thermoplastic (for example, reinforced plastic), but various materials that can exhibit desired functions (for example, transparent glass fiber, ultraviolet absorber, etc.) can be used. may be included in the translucent member 12 . Also, the translucent member 12 is typically transparent, but may be made of a material that can transmit only light in a specific wavelength range. Further, the translucent members 12 may have the same composition, or may have different compositions.

The intermediate support member 13 adheres to each light-transmitting member 12 and the light-modulating cell 11 while allowing light to pass therethrough, holds the light-controlling cell 11 between the light-transmitting members 12 , and supports the light-modulating cell 11 with respect to each light-transmitting member 12 . protects the light control cell 11 from an external force while determining the relative position of the . The intermediate support 13 also seals the dimming cell 11 and isolates the dimming cell 11 from external influences (such as humidity). Therefore, the intermediate support member 13 is preferably made of a material (especially a resin adhesive) suitable for fulfilling these roles. For example, urethane resin (PU: Polyurethane), ionomer resin (IO: Ionomer), polyvinyl butyral resin (PVB: Polyvinyl butyral), ethylene-vinyl acetate copolymer (EVA: Ethylene-Vinyl Acetate polymer) and cycloolefin polymer (COP: Cyclo Olefin It is possible to configure the intermediate support 13 by any one or more materials of Polymer.

Although not shown, the light control cell 11 is attached with an FPC (Flexible Printed Circuits) as an electrode substrate. This FPC is connected to the electrodes of the light control cell 11 (see reference numerals "24" and "25" in FIG. 3 to be described later), penetrates the intermediate support member 13 and extends to the outside to serve as a light control controller (not shown). connected to

In the light control device 10 shown in FIGS. 1A and 1B described above, with respect to the direction D1 in which the light control cells 11 and the light-transmitting members 12 are stacked (that is, the stacking direction), the light-transmitting members 12 are arranged to approach each other under a heating environment. By applying force to the light-transmitting members 12 , the intermediate support members 13 are thermocompression bonded to the respective light-transmitting members 12 , and the light control cells 11 are thermocompression bonded to the intermediate support members 13 . Thereby, the light control cell 11 is fixed to each translucent member 12 via the intermediate support member 13 . In this thermocompression bonding process, if the pressing force F in the stacking direction D1 acts unevenly on the light control cell 11 with respect to the extending direction D2 of the light control cell 11 perpendicular to the stacking direction D1, the light control cell A liquid crystal reservoir 15 may occur in 11 . That is, since the liquid crystal has fluidity, the liquid crystal in the portion of the light control cell 11 that receives a relatively large pressing force F is pushed out toward other portions, and the liquid crystal in the portion that receives a relatively small pressing force F is pushed out. accumulates. As a result, as shown in FIG. 1B, a liquid crystal reservoir 15 having a relatively large thickness in the stacking direction D1 is generated.

2A and 2B are cross-sectional views schematically showing the dimming device 10 showing another example of the mechanism of generation of liquid crystal pools. The light control device 10 shown in FIGS. 2A and 2B has the same configuration as the light control device 10 shown in FIGS. 1A and 1B described above. However, in the light control device 10 shown in FIGS. 2A and 2B, the intermediate support member 13b (for example, the portion of the intermediate support member 13 that does not overlap the light control cell 11 in the stacking direction D1) in the heating vacuum environment is each It is preferentially thermocompression bonded to the translucent member 12 . As a result, the inner intermediate support member 13a (for example, the portion of the intermediate support member 13 that overlaps the light control cell 11 in the stacking direction D1) and the light control cell 11 are separated by the outer intermediate support member 13b and the translucent members 12. It is tightly enclosed and placed in an airtight state and has a pressure lower than atmospheric pressure. In this case, air bubbles 16 may be generated in the intermediate support member 13 if moisture contained in the intermediate support member 13 or the light control cell 11 evaporates or if the degree of vacuum in the vacuum environment is insufficient.

By placing the light control device 10 in a hot and pressurized environment using an autoclave or the like, the intermediate support member 13 (especially the inner intermediate support member 13a) is thermocompression bonded to each translucent member 12 and the light control cell 11. The light-modulating cell 11 is firmly fixed to each light-transmitting member 12 via the intermediate support member 13 . In this thermocompression bonding process, the bubble 16 is heated and expands in the intermediate support member 13. Due to the expansion of the bubble 16, the light control cell 11 is locally subjected to a large force, and as shown in FIG. may occur.

A specific method for manufacturing the light control device 10 shown in FIGS. 2A and 2B is not particularly limited. A plurality of pieces may be placed and then thermocompression bonded to the plurality of pieces. As an example, a frame-shaped first piece in which the light control cell 11 is arranged in the inner space, and a plate-shaped second piece arranged above and below the light control cell 11 so as to block the inner space of the first piece. The intermediate support member 13 may be configured by thermocompression bonding the piece and the third piece. In this case, the outer intermediate support 13b is constituted by the first piece and a portion of each of the second and third pieces, and the inner intermediate support 13a is constituted by the second and third pieces. Constructed by a third piece. In this case, by designing the frame-shaped first piece to be slightly larger than the light control cell 11 with respect to the stacking direction D1, the first piece is positioned relative to each of the second piece and the third piece. The inner space of the first piece, which is preferentially thermocompressed by the first piece and in which the light control cell 11 is arranged, can be made airtight relatively easily.

As described above, when uneven force is applied to the entire light control cell 11 or when a large force is applied locally to the light control cell 11, the liquid crystal pool 15 occurs (FIGS. 1B and 1B). See Figure 2B). Since the liquid crystal reservoir 15 may have a thickness several times greater than the original thickness in the lamination direction D1, the light transmittance cannot be appropriately changed according to the applied voltage, and the original dimming function is impaired. is

The mechanism by which the liquid crystal pooled portion 15 is generated is not limited to the above example, and the liquid crystal pooled portion 15 may be generated by, for example, a combination of the above mechanisms. For example, by applying a force to each light-transmitting member 12 so that the light-transmitting members 12 approach each other, mainly the intermediate support member 13b of the outer peripheral portion is thermocompression bonded to each light-transmitting member 12, so that the light-transmitting member 12 and the outer periphery After performing a temporary pressure bonding process to airtight the area surrounded by the intermediate support material 13b of the part, autoclave process is performed to firmly join the light control cell 11 to each light transmitting member 12 via the intermediate support material 13. A main crimping process may be performed. By dividing the bonding process into a plurality of stages (two stages in this example) in this way, the pressure bonding process can be performed accurately and reliably, and the generation of the liquid crystal pool 15 can be effectively prevented. However, even in this case, for example, if the pressing force F acts unevenly over the entire light control cell 11 in the temporary pressure bonding process, the liquid crystal reservoir 15 may occur (see FIGS. 1A and 1B). In addition, even if the intermediate support member 13 contains air bubbles 16 in the main pressure-bonding process, the liquid crystal pool 15 can occur (see FIGS. 2A and 2B).

The inventors of the present invention conducted intensive research based on the generation mechanism of the liquid crystal pool 15 described above, and as a result, as a result, the light control that exhibits excellent light control performance while effectively preventing the generation of the liquid crystal pool 15 as described below. A cell 11, a dimming device 10 comprising such a dimming cell 11, a vehicle comprising such a dimming device 10, a method for manufacturing such a dimming cell 11, and a method for manufacturing such a dimming device 10 newly found. It is considered that the above-described liquid crystal reservoir 15 is generated when a portion of the liquid crystal layer expands in the stacking direction D1 due to a local large force acting on the light control cell 11 . The inventors of the present invention have found a structure and method that can effectively prevent the generation of the liquid crystal reservoir 15 by providing the light control cell 11 with a structure that prevents such partial expansion of the liquid crystal layer. Specific examples of such new structures and methods are described below.

[Dimming cell]
FIG. 3 is a cross-sectional view showing an outline of the overall configuration of an example of the light control cell 11, and is a diagram mainly for explaining the layer configuration.

The light control cell 11 shown in FIG. 3 includes a first resin substrate 26 and a second resin substrate 27, and a first electrode layer 24 and a the second electrode layer 25, the first alignment layer 22 and the second alignment layer 23 provided between the first electrode layer 24 and the second electrode layer 25, and the first alignment layer 22 and the second alignment layer 23 and a liquid crystal layer 21 provided therebetween. These resin substrates 26, 27, electrode layers 24, 25, and alignment layers 22, 23 are made of a transparent material and have desired translucency. On the other hand, the liquid crystal layer 21 has a variable light transmittance depending on the liquid crystal alignment.

The resin substrates 26 and 27 contain a resin material and can be made thinner and lighter than a glass substrate. The resin substrates 26 and 27 may contain a single type of resin, or may contain a plurality of types of resin. Also, the resin base materials 26 and 27 may have a plurality of functions by using a plurality of kinds of resins. For example, the resin substrates 26 and 27 may have a pair of hard coat layers and a main resin layer arranged between the pair of hard coat layers. The pair of hard coat layers can be made of, for example, TAC (Triacetylcellulose) or acrylic, and may be attached to the main resin layer via a transparent adhesive layer. Alternatively, a cured film (for example, a film of a silicone-based ultraviolet curable resin containing fine particles such as titanium dioxide) may be formed on the surface of the main resin layer, and the cured film may be used as a hard coat layer. The resin base materials 26 and 27 may be made of the same material, or may be made of different materials.

The electrode layers 24 and 25 are made of a transparent conductive material such as ITO (Indium Tin Oxide) as transparent electrodes, and are connected to a dimming controller via an FPC (not shown). The arrangement of the electrode layers 24 and 25 is not particularly limited, and the electrode layers 24 and 25 may be formed only at predetermined locations by patterning, or the electrode layers 24 and 25 may be formed solidly. Also, the manner in which the electrode layers 24 and 25 are connected to the FPC is not particularly limited. The electric field formed between the first electrode layer 24 and the second electrode layer 25 changes according to the voltage applied to the electrode layers 24 and 25, and the liquid crystal orientation of the liquid crystal layer 21 changes according to the electric field. change. The voltage applied to the electrode layers 24 and 25 is controlled by a dimming controller.

The alignment layers 22 and 23 are provided adjacent to the liquid crystal layer 21, respectively, and have a liquid crystal alignment ability to determine the alignment of the liquid crystal in the liquid crystal layer 21 when no electric field is applied. The alignment layers 22 and 23 are typically formed by subjecting a resin layer such as polyimide to a rubbing treatment, or by irradiating a polymer film with linearly polarized ultraviolet rays to selectively react polymer chains in the polarization direction. Although the alignment layers 22, 23 may be made by any other technique.

The liquid crystal layer 21 is composed of liquid crystal (liquid crystal material), and transmits or blocks light according to the orientation of the liquid crystal. The orientation of the liquid crystal in the liquid crystal layer 21 changes according to the voltage applied to the first electrode layer 24 and the second electrode layer 25, and the light transmittance of the liquid crystal layer 21 changes according to the orientation of the liquid crystal. Therefore, by controlling the voltage applied to the first electrode layer 24 and the second electrode layer 25 by a light adjustment controller (not shown) to adjust the orientation of the liquid crystal, the light transmittance of the entire liquid crystal layer 21 can be set to a desired value. be changed.

FIG. 3 shows, as an example, a guest-host type light control cell 11 that does not have a polarizing element, and the liquid crystal layer 21 contains a dichroic dye and a liquid crystal. For example, when the voltage between the pair of electrode layers 24 and 25 is OFF, the dichroic dye and liquid crystal of the liquid crystal layer 21 are aligned in the extending direction D2. In particular, in the guest-host type light control cell 11 that does not have a polarizing element, the orientation of the dichroic dye and the liquid crystal is twisted by 180 degrees or more in the horizontal direction when no electric field is applied, and dichroic light is generated in any horizontal direction. Sex pigments are directed. On the other hand, when the voltage between the pair of electrode layers 24 and 25 is ON, the dichroic dye and the liquid crystal are oriented in the stacking direction D1. According to the light control cell 11 exhibiting such behavior, light is blocked by the light control cell 11 (especially dichroic dye) while the voltage between the pair of electrode layers 24 and 25 is OFF, and the pair of electrode layers Light can pass through the dimming cell 11 while the voltage between 24 and 25 is ON.

The guest-host type liquid crystal layer 21 is not limited to the structure shown in FIG. A polarizing element (not shown) may be provided on the second resin base material 27). In this case, when the voltage between the pair of electrode layers 24 and 25 is turned off, the dichroic dye and liquid crystal in the liquid crystal layer 21 move in the horizontal direction (especially in the direction perpendicular to the absorption axis direction of the polarizing element (that is, )) in the same direction as the polarization axis of On the other hand, when the voltage between the pair of electrode layers 24 and 25 is ON, the dichroic dye and the liquid crystal are vertically aligned. Even in the light control cell 11 that exhibits such behavior, light is blocked by the light control cell 11 (especially the dichroic dye and the polarizing element) while the voltage between the pair of electrode layers 24 and 25 is OFF. Light can pass through the dimming cell 11 while the voltage across the electrode layers 24 is ON. Such behavior of the dichroic dye and the liquid crystal in the liquid crystal layer 21 can be changed by adjusting the orientation imparted to the liquid crystal in the liquid crystal layer 21 by the orientation layers 22 and 23 .

Further, the driving method of the liquid crystal layer 21 is not limited to the guest-host type, and any method can be adopted. Typically, a VA (Vertical Alignment) type, TN (Twisted Nematic) type, IPS (In-Place-Switching) type, or FFS (Fringe Field Switching) type liquid crystal layer 21 can be used in the light control cell 11. can. Therefore, the configuration of the light control cell 11 is not limited to the configuration shown in FIG. For example, when the light control cell 11 employs a general VA type or TN type liquid crystal layer 21, the light control cell 11 includes a pair of polarizing elements, a pair of electrode layers arranged between the polarizing elements, It may comprise a pair of alignment layers disposed between the electrode layers and a liquid crystal layer disposed between the alignment layers. Further, when the light control cell 11 employs the IPS type liquid crystal layer 21, the electrode layers may be arranged only on one side of the liquid crystal layer without arranging the electrode layers on the positions sandwiching the liquid crystal layer.

Various embodiments are described below.

[First mode]
In the following description, a portion (in FIG. 3, the first alignment layer 22, the first electrode layer 24, and the first resin The base material 26) is collectively referred to as the “first substrate 28”, and the portions (the second alignment layer 23, the second electrode layer 25 and the The second resin base material 27) is collectively referred to as a "second substrate 29". Therefore, the liquid crystal layer 21 consists of a first substrate 28 including a first alignment layer 22 , a first electrode layer 24 and a first resin substrate 26 , a second alignment layer 23 , a second electrode layer 25 and a second resin substrate 27 . and a second substrate 29 including When the liquid crystal layer 21 adopts a driving method other than the guest-host type shown in FIG. 3, the components of the first substrate 28 and/or the second substrate 29 can be changed according to the driving method. Further, the first substrate 28 and/or the second substrate 29 may include elements other than the alignment layer, the electrode layer, and the resin base material.

FIG. 4 is a cross-sectional view showing an outline of the overall configuration of the light control cell 11, and is a diagram mainly for explaining the spacer 31, the frame-like sealing material 32, and the sealing column 33 arranged together with the liquid crystal layer 21. As shown in FIG.

Between the first substrate 28 and the second substrate 29, a plurality of spacers 31, a frame-shaped sealing member 32, and a plurality of sealing columns 33 are arranged. The plurality of spacers 31 and the plurality of seal columns 33 are fixedly arranged in the liquid crystal layer 21 and evenly distributed in the extending direction D2. The frame-shaped sealing material 32 is fixedly arranged so as to surround the liquid crystal layer 21 , the plurality of spacers 31 and the plurality of sealing columns 33 , prevents liquid crystal from leaking, and is bonded to the first substrate 28 and the second substrate 29 . to secure both substrates 28 and 29 to each other. Each spacer 31 is bonded to only one of the first substrate 28 and the second substrate 29 (the first substrate 28 in FIG. 4). Each spacer 31 may be bonded to at least one of the first substrate 28 and the second substrate 29 . Alternatively, all the spacers 31 may be bonded to only one of the first substrate 28 and the second substrate 29, or some of the spacers 31 may be bonded to the first substrate 28 while other spacers are bonded to the first substrate 28. 31 may be bonded to the second substrate 29 . Also, each spacer 31 may not be bonded to both the first substrate 28 and the second substrate 29 . On the other hand, each seal column 33 is desirably bonded to both the first substrate 28 and the second substrate 29 .

In this specification and the scope of the appended claims, bonding of a certain member (for example, each seal column 33) to another member (for example, the first substrate 28 and the second substrate 29) means, for example, the measurement method described later. It refers to joining members so that they have a joining force that can be confirmed by

The light control cell 11 shown in FIG. 4 can be manufactured, for example, by the following method. First, a first substrate 28 and a second substrate 29 are prepared. At this time, each spacer 31 is already provided on the first substrate 28 or the second substrate 29 . A plurality of sealing columns 33 and a frame-shaped sealing material 32 are formed on one of the first substrate 28 and the second substrate 29 by using a dispenser, a screen printer, or the like. At this time, the sealing column 33 and the frame-shaped sealing member 32 may be formed in separate steps, but from the viewpoint of productivity, the sealing column 33 and the frame-shaped sealing member 32 should be formed simultaneously in the same step. is preferred. In addition, the sealing column 33 and the frame-shaped sealing material 32 formed on one of the first substrate 28 and the second substrate 29 are larger than the spacer 31 in the stacking direction D1, and for example, the sealing column 33 has a hemispherical shape. can have

Then, the liquid crystal (that is, the liquid crystal layer 21) is provided on one of the first substrate 28 and the second substrate 29 on which the frame-shaped sealing material 32 is provided. Then, the first substrate 28 and the first substrate 28 are superimposed in a vacuum environment, and the plurality of sealing columns 33 and the frame-shaped sealing material 32 are pressure-bonded to the first substrate 28 and the second substrate 29 . As a result, the light control cell 11 shown in FIG. 4 can be manufactured, the sealing column 33 and the frame-shaped sealing material 32 have approximately the same size as the spacer 31 in the stacking direction D1, and the liquid crystal layer 21 has a uniform thickness. Become. The method of adhering the sealing columns 33 and the frame-shaped sealing material 32 to the first substrate 28 and the second substrate 29 is not particularly limited. Adhesion may be performed by irradiation (eg, ultraviolet irradiation) and/or electron beam irradiation.

Although the diameter of each sealing column 33 and the diameter of each spacer 31 are not particularly limited, the diameter of each sealing column 33 varies with respect to the extending direction D2 in the liquid crystal layer 21 (that is, the direction in which the liquid crystal layer 21 extends). It is larger than the diameter of spacer 31 . As an example, the diameter of each sealing column 33 in the extending direction D2 may be twice or more the diameter of each spacer 31. For example, the diameter of each spacer 31 in the extending direction D2 may be about several μm to 50 μm. On the other hand, it is also possible to set the diameter of each seal column 33 in the extending direction D2 to about several tens of μm to 500 μm (more preferably about several tens of μm to 100 μm).

Each spacer 31 shown in FIG. 4 and the like has a bead-like spherical shape and is provided so as to adhere to the first substrate 28 or the second substrate 29 from the outside. The mode is not particularly limited. For example, each spacer 31 may have a columnar shape (for example, a truncated cone shape such as a truncated cone or a truncated pyramid) having a planar portion. Also, part of the columnar member (especially the tip part) formed using a technique such as photolithography so as to be partially arranged inside the first substrate 28 and the second substrate 29 is used as the spacer 31. good too.

By providing the plurality of seal columns 33 separately from the plurality of spacers 31 in this manner, the spacing between the first substrate 28 and the second substrate 29 can be precisely regulated, and the thickness of the liquid crystal layer 21 in the stacking direction D1 can be reduced. (ie cell gap) uniformity can be improved. In particular, since each seal column 33 is bonded to both the first substrate 28 and the second substrate 29, it is difficult to regulate the gap between the first substrate 28 and the second substrate 29 in the stacking direction D1 with the spacer 31. The relative movement of the first substrate 28 and the second substrate 29 in the direction in which .theta.

As a result, even if a large force acts locally on the light control cell 11 (especially the liquid crystal layer 21) (see FIGS. 1A and 2B), the distance between the first substrate 28 and the second substrate 29 becomes small. Relative movement of the first substrate 28 and the second substrate 29 in the "direction" is suppressed by the spacers 31 and the seal columns 33, and movement in the "direction in which the distance between the first substrate 28 and the second substrate 29 increases" is suppressed. Relative movement of the first substrate 28 and the second substrate 29 is suppressed by each seal column 33 . Therefore, compared with the case where only a plurality of spacers 31 are provided, when the spacers 31 and the seal columns 33 are provided, the gap between the first substrate 28 and the second substrate 29 can be regulated with high accuracy, and the liquid crystal pool portion can be formed. The occurrence (see FIGS. 1B and 2B) can be effectively prevented, and the thickness uniformity of the liquid crystal layer 21 in the lamination direction D1 can be improved.

Each seal column 33 of the present embodiment has substantially the same size as each spacer 31 in the liquid crystal layer 21 with respect to the stacking direction D1 (that is, the direction in which the first substrate 28, the liquid crystal layer 21 and the second substrate 29 are stacked). have. As a result, for example, even if a large force acts on the liquid crystal layer 21 via the first substrate 28 and/or the second substrate 29, not only the spacers 31 but also the seal columns 33 bear such a large force. It will be. Therefore, the spacers 31 can be prevented from unintentionally biting into the first substrate 28 and/or the second substrate 29, effectively avoiding damage to the first substrate 28 and/or the second substrate 29, and achieving high reliability. Desired dimming performance of the dimming cell 11 can be maintained. In particular, the spacers 31 having a small contact area with the first substrate 28 and the second substrate 29 (for example, the bead-shaped spacers 31 and the spacers 31 with a small diameter) locally exert a large force on the first substrate 28 and the second substrate 29. However, by providing a plurality of sealing columns 33 together with a plurality of spacers 31 as described above and making the diameter of each sealing column 33 larger than the diameter of each spacer 31 in the extending direction D2, Such biting of the spacer 31 can be effectively prevented. Also, the seal column 33 may be made of a material having excellent elasticity (for example, a material having a lower elastic modulus than the spacer 31). In this case, it is possible to more effectively prevent the spacers 31 from biting into the first substrate 28 and the second substrate 29 .

Thus, by providing a plurality of types of regulating members (two types of regulating members (that is, the spacer 31 and the seal column 33) in this embodiment) and giving each of the regulating members a specific function, the cell gap can be maintained. Therefore, it is possible to prevent damage to the first substrate 28 and the second substrate 29 while preventing the formation of liquid crystal pools.

It is preferable that the frame-shaped sealing member 32 and the plurality of sealing columns 33 are made of the same material. In this case, the formation of the frame-shaped sealing material 32 and the respective sealing columns 33 is facilitated. For example, using the same forming apparatus, the frame-shaped sealing material 32 and each sealing post 33 are simultaneously formed on the first substrate 28 (for example, the first alignment layer 22) or the second substrate 29 (for example, the second alignment layer). 23 above). As such a forming device, a dispenser or a screen printing device can typically be used. is preferred.

Also, the bonding force of the plurality of seal columns 33 to each of the first substrate 28 and the second substrate 29 is preferably 25 mN/mm ² or more, more preferably 75 mN/mm ² or more. In this embodiment, the bonding force of the plurality of sealing posts 33 to each of the first substrate 28 and the second substrate 29 is the bonding force between each of the alignment layers 22 , 23 and the sealing posts 33 . When another layer exists between the alignment layers 22 and 23 and the liquid crystal layer 21, the bonding force of the plurality of seal columns 33 to each of the first substrate 28 and the second substrate 29 is the closest to the liquid crystal layer 21. It is the bonding force between the layer that contacts the sealing post 33 and the sealing post 33 and the bonding force between the layer that the sealing post 33 contacts and the sealing post 33 . From the viewpoint of preventing relative movement of the first substrate 28 and the second substrate 29 in "the direction in which the distance between the first substrate 28 and the second substrate 29 increases," It is preferable to increase the bonding force to the second substrate 29 so that each seal column 33 is not separated from the first substrate 28 and the second substrate 29 . As a result of repeated trial and error and consideration of the light control cell 11 and the light control device 10 under various conditions, the inventors of the present invention have found that, in order to prevent the generation of the liquid crystal pool 15, a bonding force of 25 mN/ ^mm It has been found that it is preferable that the seal column 33 is bonded to each of the first substrate 28 and the second substrate 29 .

The bonding force referred to here can be measured by any method. It is possible to measure the bond strength by measuring the force required to pull the two apart from each other. Specifically, for example, a portion having a planar shape of 1 cm square including the seal column 33 is cut out of the light control cell 11, and both surfaces of the cut portion (that is, the outer surfaces of the first substrate 28 and the second substrate 29) are cut out. The first substrate 28 and the second substrate 29 are separated from each other by affixing each of the side surfaces to a supporting member such as glass via double-sided tape or the like, and pulling the supporting members away from each other in a direction perpendicular to both surfaces. The bonding force (N/mm ² ) can be measured by measuring the force required for . The above-described bonding force can also be measured in the form of a light control device 10 that includes a light control cell 11 and a translucent member 12 fixedly attached to the light control cell 11 (see FIGS. 1A to 2B). In this case, for example, in a portion cut out to a predetermined size from the light control device 10, the light transmitting members 12 arranged on opposite sides of the light control cell 11 are separated in the stacking direction D1, and the first substrate is separated. The bonding force may be measured by measuring the force required for 28 and second substrate 29 to separate from each other. In the measurement of these bonding strengths, the peeling speed (that is, the peeling speed in the stacking direction D1) when separating the first substrate 28 and the second substrate 29 is set to 5 mm/min, for example.

Moreover, it is preferable that the diameter of each of the plurality of seal columns 33 in the direction in which the liquid crystal layer 21 extends (that is, the extending direction D2) is 500 μm or less. In addition, regarding the direction in which the liquid crystal layer 21 extends (that is, the extending direction D2), a 1 mm square area where the liquid crystal layer 21 exists (that is, an area having a planar size of 1 mm (vertical)×1 mm (horizontal)=1 mm ² ) ), the area where the plurality of seal columns 33 are bonded to each of the first substrate 28 and the second substrate 29 is preferably 10% or less, more preferably 2% or less.

It should be noted that each seal column 33 does not necessarily have to have a substantially constant diameter in the extending direction D2. good. For example, each seal column 33 may increase in diameter continuously or discontinuously from one end to the other end in the stacking direction D1, and may have a truncated cone shape. If one end of each seal column 33 in the stacking direction D1 has a larger diameter than the other end, the diameter of the end of each seal column 33 on the first substrate 28 side is larger than the diameter of the end on the second substrate 29 side. Alternatively, the diameter of the end of each seal column 33 on the second substrate 29 side may be larger than the diameter of the end on the first substrate 28 side. Further, each seal column 33 may include a portion having a diameter larger than that of both ends in an intermediate portion (for example, a central portion) between both ends in the stacking direction D1. You may have the shape which swelled about the extension direction D2 rather than both ends. Also, the cross-sectional shape of each seal column 33 and each spacer 31 in the extending direction D2 does not necessarily have to be a perfect circle, and may be, for example, a polygonal shape such as a rectangle, an elliptical shape, or another shape. If the cross-sectional shape of each sealing column 33 and each spacer 31 in the extending direction D2 is not a perfect circle, the minimum diameter of each sealing column 33 and each spacer 31 is equal to each sealing column 33 and each spacer. 31 diameter.

From the viewpoint of ensuring the dimming performance, in the area where the liquid crystal layer 21 is arranged (that is, the active area surrounded by the frame-shaped sealing material 32), the occupancy rate of the seal column 33 is made as small as possible so that the liquid crystal can be adjusted. It is preferable to make the region capable of exhibiting optical performance as large as possible. In general, as the diameter of each seal column 33 increases, the bonding area between each seal column 33 and each of the first substrate 28 and the second substrate 29 increases, and the bonding strength can be increased. On the other hand, when the light control device 10 is used in a window (for example, a sunroof, etc.) that people are expected to look into, it is preferable that each seal column 33 is not visually recognized by the observer.

As a result of diligent research, the inventors of the present invention have found that the diameter of each seal column 33 has a very large effect on visibility. On the other hand, the inventor of the present invention comprehensively considers the above-described light control performance, bonding strength, and visibility of each seal pillar 33, and finds that each seal pillar 33 is visually inconspicuous and the light control cell 11 is excellent. In order to secure a bonding force effective for preventing the occurrence of the liquid crystal pool 15 while realizing good dimming performance, the diameter of each seal column 33 is preferably 500 μm or less, more preferably 100 μm or less. is more preferable. Also, based on the same reason, in the 1 mm square area where the liquid crystal layer 21 exists, the ratio of the area where the seal column 33 is in contact with each of the first substrate 28 and the second substrate 29 (that is, the occupation ratio) is 10% or less. It came to acquire the knowledge that it is preferable to be. The occupation rate referred to here is determined based on the size of the diameter of each seal column 33 and the number (number density) of the seal columns 33 in the 1 mm square area where the liquid crystal layer 21 is present.

The number (number density) of the seal pillars 33 is not particularly limited, and is preferably as small as possible from the viewpoint of ensuring the dimming performance and from the viewpoint of preventing the seal pillars 33 from being visually recognized, but from the viewpoint of ensuring the bonding strength. is preferably larger. However, the number density of the sealing columns 33 is smaller than the number density of the spacers 31. As an example, about 100 to 200 spacers 31 are provided per 1 mm square, and about 10 sealing columns 33 are provided per 1 mm square. It should be noted that the number (number density) of the seal columns 33 is preferably small from the viewpoint of ensuring the dimming performance, and is evenly arranged in the extending direction D2 in the liquid crystal layer 21 from the viewpoint of ensuring a uniform cell gap. preferably.

From the viewpoint of making each seal column 33 visually inconspicuous, each of the plurality of seal columns 33 is preferably colored (for example, black) or transparent. For example, each seal pillar 33 preferably has a black color in order to make each seal pillar 33 inconspicuous when the light control cell 11 blocks light. On the other hand, each seal pillar 33 is preferably transparent in order to make each seal pillar 33 inconspicuous when the light control cell 11 transmits light. The light control cell 11 in which the seal columns 33 are black has excellent black reproducibility, and when the incident light is blocked by the liquid crystal of the liquid crystal layer 21, the incident light is also blocked by the black seal columns 33. be. On the other hand, the light control cell 11 in which each seal column 33 is transparent (colorless) has excellent transparency. To Penetrate.

Also, from the viewpoint of making the plurality of seal columns 33 inconspicuous visually, the plurality of seal columns 33 are arranged at positions irregularly determined with respect to the direction in which the liquid crystal layer 21 extends (that is, the extension direction D2). is preferred. On the other hand, from the viewpoint of keeping the thickness of the entire liquid crystal layer 21 uniform, the plurality of seal columns 33 are arranged at regularly determined positions with respect to the direction in which the liquid crystal layer 21 extends (that is, the extending direction D2). is preferred. In this case, the bonding strength of the plurality of seal columns 33 to the first substrate 28 and the second substrate 29 can be uniformly exerted over the entire liquid crystal layer 21 .

It should be noted that the "regularly determined position" referred to here corresponds to, for example, the case where the interval between adjacent positions is regularly determined, and typically the interval between adjacent positions is a predetermined distance. is applicable. On the other hand, "positions determined irregularly" correspond to, for example, the case where the intervals between adjacent positions are determined irregularly, typically the intervals between adjacent positions are random. case applies. It should be noted that the positions of the plurality of seal columns 33 arranged at irregularly determined positions do not necessarily have to be determined irregularly, and only some of the plurality of seal columns 33 are arranged at irregularly defined positions, it can be said that the plurality of seal columns 33 are arranged at irregularly defined positions as a whole. Therefore, for example, the plurality of seal columns 33 are classified into a plurality of groups for each predetermined plane area, and one or more seal columns 33 among the two or more seal columns 33 included in each group are determined irregularly. Even when the other seal pillars 33 are arranged at regularly determined positions while arranging them in position, it can be said that the plurality of seal pillars 33 are arranged at irregularly determined positions as a whole. Note that, for example, a position randomly determined within a predetermined distance from a regularly determined predetermined position corresponds to the "irregularly determined position."

In order to satisfactorily satisfy the various conditions described above, the material forming the plurality of sealing posts 33 can include, for example, epoxy resin or acrylic resin. In particular, from the viewpoint of preventing damage to the first substrate 28 and the second substrate 29 as described above, the hardness of each seal column 33 may be made smaller than the hardness of each spacer 31 . Also, the elastic modulus (for example, bulk elastic modulus) of each seal column 33 may be smaller than the elastic modulus of each spacer 31 .

As described above, according to this embodiment, by providing the seal column 33, it is possible to prevent the liquid crystal layer 21 from becoming unnecessarily thick, and the spacer 31 prevents the liquid crystal layer 21 from becoming unnecessarily thin. can be prevented with As a result, the light control cell 11 can effectively prevent the generation of the liquid crystal pool 15 and exhibit excellent light control performance, and the light control cell 11 arranged between the pair of light transmitting members 12 is provided. An optical device 10 can be provided. Further, by using the light control cell 11 described above, it is possible to fix the light control cell 11 to the pair of light transmitting members 12 while at least part of the light control cell 11 is pressed between the pair of light transmitting members 12. Based on the "manufacturing method", it is possible to manufacture the light control device 10 with high accuracy while preventing the occurrence of the liquid crystal pool 15.

In particular, by making the diameter of each seal column 33 larger than the diameter of each spacer 31 in the liquid crystal layer 21 in the extending direction D2 of the liquid crystal layer 21, each spacer 31 bites into the first substrate 28 and the second substrate 29. can be prevented, and the dimming performance of the dimming cell 11 can be maintained satisfactorily. Further, by making the diameter of each seal column 33 larger than the diameter of each spacer 31 in the extending direction D2, the bonding force of the seal column 33 to the first substrate 28 and the second substrate 29 can be increased. By providing the seal column 33 so as to contact or include the spacer 31 as described above, such bonding force can be increased more effectively.

[Modification]
5 and 6 are schematic cross-sectional views showing a modified example of the light control cell 11. FIG. In the light control cell 11 shown in FIGS. 3 and 4 described above, the first substrate 28 and the second substrate 29 have a flat plate shape, but the first substrate 28 and/or the second substrate 29 are bent at least in part. For example, various curved surfaces such as a two-dimensional curved surface and a three-dimensional curved surface may be formed. The two-dimensional curved surface referred to here is a curved surface that is two-dimensionally curved around a single axis, or a curved surface that is two-dimensionally curved around multiple axes parallel to each other with the same or different curvatures. be. On the other hand, a three-dimensional curved surface means a surface partially or entirely curved around each of a plurality of non-parallel axes.

When the liquid crystal layer 21 is arranged between the curved surface of the first substrate 28 and the curved surface of the second substrate 29 as shown in FIG. A space (bubble) S may be formed at the location of . On the other hand, as shown in FIG. 6, by providing a plurality of seal columns 33 bonded to each of the first substrate 28 and the second substrate 29, the distance between the first substrate 28 and the second substrate 29 can be adjusted to a desired size. It is possible to keep the liquid crystal layer 21 at a desired thickness while preventing the formation of spaces (bubbles) S in the liquid crystal layer 21 .

1A to 2B, both the front surface and the back surface of each light-transmitting member 12 have a planar shape. At least part of the surface to which the light control cell 11 is fixed via 13 may form a curved surface. Even when the light control cell 11 is fixed to the curved surface of the translucent member 12, the light control cell 11 can be fixed by interposing the intermediate support member 13 between the curved surface and the light control cell 11. can be appropriately fixed to the curved surface of the translucent member 12 . In this manner, the light control cell 11 can be fixed with high reliability to any of the curved surface, the flat surface, or the combination of the curved surface and the flat surface of the translucent member 12 .

Also, each of the plurality of seal columns 33 may be provided so as to contact at least one or more of the plurality of spacers 31 or include at least one or more of the plurality of spacers 31 . That is, all or part of the plurality of seal posts 33 can be provided so as to contact or include one or more spacers 31 .

FIG. 7 is a schematic cross-sectional view showing another modification of the light control cell 11. As shown in FIG. Each seal column 33 shown in FIG. 7 is arranged on the spacer 31 , and the spacer 31 in contact with the seal column 33 is provided so as to bite into the seal column 33 . This makes it possible to increase the area of the portion of each seal column 33 that contributes to bonding to each of the first substrate 28 and the second substrate 29 . Also, each seal column 33 can be fixed by hooking on a spacer 31 fixed to the first substrate 28 or the second substrate 29 . Also, the spacer 31 can be effectively utilized as a trigger for bonding each seal column 33 to each of the first substrate 28 and the second substrate 29 . Therefore, according to this modification, the bonding force of the seal column 33 to each of the first substrate 28 and the second substrate 29 can be effectively increased. Furthermore, when manufacturing the light control cell 11, it is possible to prevent the height of each seal column 33 from becoming lower than the height of each spacer 31 in the stacking direction D1. In this modified example, all the spacers 31 may be fixed to only one of the first substrate 28 and the second substrate 29, but some spacers 31 may be fixed to the first substrate 28. Another spacer 31 may be fixed to the second substrate 29 . In this case, the plurality of seal columns 33 can be firmly fixed to both the first substrate 28 and the second substrate 29, and the bonding force of the seal columns 33 to each of the first substrate 28 and the second substrate 29 can be increased. It can be increased more effectively.

Moreover, the method and manner of providing the spacer 31 are not limited to the above-described contents. For example, a plurality of spacers 31 are mixed in advance with the alignment material constituting the first alignment layer 22 and the second alignment layer 23, and when the alignment layers 22 and 23 are formed, the alignment material is added together with the spacers 31 to the first alignment material. A plurality of spacers 31 may be provided on the first substrate 28 and the second substrate 29 by applying on the electrode layer 24 and the second electrode layer 25 . In this case, not only can the plurality of spacers 31 be evenly distributed on the first substrate 28 and the second substrate 29, but also each spacer 31 can be disposed on either the first alignment layer 22 or the second alignment layer 23. can be fixed by Thus, each spacer 31 is compared by first alignment layer 22 or second alignment layer 23 to first substrate 28 (especially first electrode layer 24) or second substrate 29 (especially second electrode layer 25). can be strongly bonded. Also, the plurality of spacers 31 may be mixed with the material forming the seal pillars 33 and may be applied to the first substrate 28 and the second substrate 29 together with the seal pillars 33 .

[Second mode]
In the following description, a portion (in FIG. 3, the first alignment layer 22, the first electrode layer 24, and the first resin The base material 26) is collectively referred to as the “first substrate 28”, and the portions (the second alignment layer 23, the second electrode layer 25 and the The second resin base material 27) is collectively referred to as a "second substrate 29". Therefore, the liquid crystal layer 21 is arranged between the first substrate 28 including the first resin base material 26 and the second substrate 29 including the second resin base material 27 . When the liquid crystal layer 21 adopts a driving method other than the guest-host type shown in FIG. 3, the components of the first substrate 28 and/or the second substrate 29 can be changed according to the driving method. Further, the first substrate 28 and/or the second substrate 29 may include elements other than the alignment layer, the electrode layer, and the resin base material.

FIG. 8 is a cross-sectional view showing an outline of the overall configuration of the light control cell 11, and is a diagram mainly for explaining the spacers 31 and the frame-shaped sealing material 32 arranged together with the liquid crystal layer 21. As shown in FIG. Also, FIG. 9 is a plan view showing an outline of the overall configuration of the light control cell 11. As shown in FIG.

Between the first substrate 28 and the second substrate 29, a plurality of spacers 31, a frame-shaped sealing member 32, and a plurality of sealing columns 33 are arranged. The plurality of spacers 31 and the plurality of seal columns 33 are fixedly arranged in the liquid crystal layer 21 and evenly distributed in the extending direction D2. Among them, the spacer 31 is arranged in contact with the frame-shaped sealing member 32 or the sealing column 33 . In the examples shown in FIGS. 8 and 9 , each of the plurality of spacers 31 is arranged inside the frame-shaped sealing member 32 or inside the sealing column 33 . In this case, the spacer 31 is held by the frame-shaped sealing member 32 or the sealing column 33 so as to be embedded in the frame-shaped sealing member 32 or the sealing column 33 . Further, the frame-shaped sealing material 32 is fixedly arranged so as to surround the liquid crystal layer 21, the plurality of spacers 31 and the plurality of sealing columns 33 in a circumferential shape, and as shown in FIG. It is provided in a frame shape along the outer circumference of the substrate 29 . Such a frame-shaped sealing member 32 prevents the liquid crystal from leaking, and is bonded to the first substrate 28 and the second substrate 29 to fix the substrates 28 and 29 to each other. Also, as shown in FIG. 8, each spacer 31 is preferably in contact with the first substrate 28 or the second substrate 29 . On the other hand, each seal column 33 is desirably bonded to both the first substrate 28 and the second substrate 29 . Such spacers 31 regulate the distance between the first substrate 28 and the second substrate 29, and improve the uniformity of the thickness (that is, the cell gap) of the liquid crystal layer 21 in the stacking direction D1. Therefore, it is possible to suppress the expansion of a portion of the liquid crystal layer 21 and suppress the occurrence of liquid crystal pools. Some spacers 31 among the plurality of spacers 31 may be arranged inside the liquid crystal layer 21 , and a part of each spacer 31 may be located inside the liquid crystal layer 21 .

In this specification and the scope of the appended claims, bonding a certain member (for example, each seal column 33) to another member (for example, the first substrate 28 and the second substrate 29) means, for example, measurement It refers to joining members so that they have a joining force that can be confirmed by a method.

The spacer 31 described above can be made of various resin materials, and may have a shape such as a spherical bead shape or a truncated cone shape (for example, a truncated cone or a truncated pyramid). The frame-shaped sealing material 32 described above is made of a first sealing material 41 (see FIGS. 10B and 10C), and the sealing column 33 is made of a second sealing material 44 (see FIGS. 10B and 10C). It is These first sealing material 41 and second sealing material 44 are preferably adhesive or tacky materials, and preferably contain epoxy resin or acrylic resin, for example.

The light control cell 11 shown in FIGS. 8 and 9 can be manufactured, for example, by the following method.

First, as shown in FIG. 10A, one of the first substrate 28 and the second substrate 29, for example, the second substrate 29 is prepared.

In parallel with preparing the second substrate 29, a first composition 43 including an uncured first sealing material 41 and first spacers 42 dispersed in the first sealing material 41 is prepared. A second composition 46 is provided which includes a second sealing material 44 in an uncured state and second spacers 45 dispersed in the second sealing material 44 . Among them, the first sealing material 41 and the second sealing material 44 are adhesive or tacky materials, and may contain, for example, epoxy resin or acrylic resin. The first sealing material 41 and the second sealing material 44 may be made of the same material, and the first spacer 42 and the second spacer 45 may be made of the same material. In this case, preparation of the first composition 43 and the second composition 46 is facilitated.

Next, as shown in FIG. 10B, the first composition 43 is applied to the circumferential region on the second substrate 29 . At this time, the second composition 46 is dispersed and applied within the circumferential region. In this case, the first composition 43 and the second composition 46 are applied onto the second substrate 29 using a dispenser, a screen printer, or the like. Although the first composition 43 and the second composition 46 may be applied in separate steps, from the viewpoint of productivity, the first composition 43 and the second composition 46 are simultaneously applied in the same step. Coating is preferred.

Next, a liquid crystal material 47 is supplied to the area on the second substrate 29 surrounded by the first composition 43 applied to the circumferential area.

Next, the first substrate 28 and the second substrate 29 are overlaid under a vacuum environment. In this case, a roller or the like (not shown) may be used to squeeze.

After that, in a state in which the first substrate 28 is placed on the second substrate 29, the first composition 43 is cured to form a frame-shaped sealing material 32 holding the spacers 31 (first spacers) composed of the first spacers 42. is formed, and the first substrate 28 and the second substrate 29 are bonded via this frame-shaped sealing material 32 . At this time, by curing the second composition 46 , the sealing column 33 holding the spacer 31 (second spacer) composed of the second spacer 45 is formed in the region surrounded by the frame-shaped sealing material 32 . In this way, the frame-shaped sealing material 32 and the sealing columns 33 are crimped to the first substrate 28 and the second substrate 29, respectively. Thereby, the light control cell 11 shown in FIGS. 8 and 9 can be manufactured. The method of adhering the frame-shaped sealing material 32 and each sealing column 33 to the first substrate 28 and the second substrate 29 is not particularly limited. Adhesion may be performed by irradiation (eg, ultraviolet irradiation) and/or electron beam irradiation.

Although the example in which the first composition 43 and the second composition 46 are applied on the second substrate 29 has been described here, the first composition 43 and the second composition 46 are applied to the first substrate 28 . may be coated over the

Each spacer 31 shown in FIGS. 8 and 9 has a spherical shape. The shape and arrangement of each spacer 31 are not particularly limited. For example, each spacer 31 may have a columnar shape (for example, a truncated cone shape such as a truncated cone or a truncated pyramid) having a planar portion. Alternatively, a columnar member may be formed on the first substrate 28 and the second substrate 29 using a technique such as photolithography and used as the spacer 31 . In this case, by providing the first composition 43 and the second composition 46 at positions corresponding to the spacers 31, the plurality of spacers 31 are arranged so as to contact the frame-shaped sealing material 32 or the sealing column 33. be able to.

Although the diameter of each sealing column 33 and the diameter of each spacer 31 are not particularly limited, each sealing column 33 usually has a larger diameter than each spacer 31 in the extending direction D2. As an example, the diameter of each seal column 33 can be about ten times the diameter of each spacer 31 or more, and the diameter of each spacer 31 is about several μm to 50 μm, while each seal It is also possible to set the diameter of the column 33 to about several tens of μm to 150 μm. Also, the width of the frame-shaped sealing material 32 is not particularly specified, but is usually about 1 mm to 5 mm.

By providing the plurality of sealing columns 33 separately from the plurality of spacers 31 in this way, the spacing between the first substrate 28 and the second substrate 29 can be regulated with high precision, and the liquid crystal layer 21 can be stacked in the direction D1. Thickness (ie, cell gap) uniformity can be improved. In particular, since each seal column 33 is bonded to both the first substrate 28 and the second substrate 29, the spacer 31 was difficult to regulate, "the first substrate 28 and the second substrate 29 in the lamination direction D1 The relative movement of the first substrate and the second substrate 29 in the direction in which the distance is increased can be restricted by each seal column 33 .

As a result, even if a large force acts locally on the light control cell 11 (especially the liquid crystal layer 21) (see FIGS. 1A to 2B), the distance between the first substrate 28 and the second substrate 29 becomes small. Relative movement of the first substrate 28 and the second substrate 29 in the "direction" is suppressed by the spacers 31 and the seal columns 33, and the distance between the first substrate 28 and the second substrate 29 increases. Relative movement of the first substrate 28 and the second substrate 29 is suppressed by each seal column 33 . Therefore, when the seal columns 33 are provided together with the spacers 31, the gap between the first substrate 28 and the second substrate 29 can be regulated with high accuracy as compared with the case where only the plurality of spacers 31 are provided. It is possible to effectively prevent the generation of the portion 15 (see FIGS. 1B and 2B) and improve the thickness uniformity of the liquid crystal layer 21 in the stacking direction D1.

It should be noted that the plurality of spacers 31, the frame-shaped sealing material 32, and the plurality of sealing columns 33 are preferably made of the same material. That is, the first sealing material 41, first spacer 42, second sealing material 44 and second spacer 45 described above are preferably made of the same material. In this case, the production of the first composition 43 and the second composition 46 becomes easy, and the formation of the plurality of spacers 31, the frame-shaped sealing material 32, and the respective sealing columns 33 becomes easy. For example, using the same forming apparatus, a plurality of spacers 31, frame-shaped sealing materials 32, and respective sealing pillars 33 can be simultaneously formed on the first substrate 28 (for example, the first alignment layer 22) or the second substrate 29 ( for example on the second alignment layer 23). As such a forming device, a dispenser or a screen printing device can typically be used. , screen printers are preferred.

Also, the bonding force of the plurality of seal columns 33 to each of the first substrate 28 and the second substrate 29 is preferably 25 mN/mm ² or more, more preferably 75 mN/mm ² or more. In this embodiment, the bonding force of the plurality of sealing posts 33 to each of the first substrate 28 and the second substrate 29 is the bonding force between each of the alignment layers 22 , 23 and the sealing posts 33 . When another layer exists between the alignment layers 22 and 23 and the liquid crystal layer 21, the bonding force of the plurality of seal columns 33 to each of the first substrate 28 and the second substrate 29 is the closest to the liquid crystal layer 21. It is the bonding force between the layer that contacts the sealing post 33 and the sealing post 33 and the bonding force between the layer that the sealing post 33 contacts and the sealing post 33 . From the viewpoint of preventing relative movement of the first substrate 28 and the second substrate 29 in "the direction in which the distance between the first substrate 28 and the second substrate 29 increases," It is preferable to increase the bonding force to the second substrate 29 so that each seal column 33 is not separated from the first substrate 28 and the second substrate 29 . As a result of repeated trial and error and consideration of the light control cell 11 and the light control device 10 under various conditions, the inventors of the present invention have found that, in order to prevent the generation of the liquid crystal pool 15, a bonding force of 25 mN/ ^mm It has been found that it is preferable that the seal column 33 is bonded to each of the first substrate 28 and the second substrate 29 .

The bonding force referred to here can be measured by any method. It is possible to measure the bond strength by measuring the force required to pull the two apart from each other. Specifically, for example, a portion having a planar shape of 1 cm square including the seal column 33 is cut out of the light control cell 11, and both surfaces of the cut portion (that is, the outer surfaces of the first substrate 28 and the second substrate 29) are cut out. The first substrate 28 and the second substrate 29 are separated from each other by affixing each of the side surfaces to a supporting member such as glass via double-sided tape or the like, and pulling the supporting members away from each other in a direction perpendicular to both surfaces. The bonding force (N/mm ² ) can be measured by measuring the force required for . The above-described bonding force can also be measured in the form of a light control device 10 that includes a light control cell 11 and a translucent member 12 fixedly attached to the light control cell 11 (see FIGS. 1A to 2B). In this case, for example, in a portion cut out to a predetermined size from the light control device 10, the light transmitting members 12 arranged on opposite sides of the light control cell 11 are separated in the stacking direction D1, and the first substrate is separated. The bonding force may be measured by measuring the force required for 28 and second substrate 29 to separate from each other. In the measurement of these bonding strengths, the peeling speed (that is, the peeling speed in the stacking direction D1) when separating the first substrate 28 and the second substrate 29 is set to 5 mm/min, for example.

Moreover, it is preferable that the diameter of each of the plurality of seal columns 33 in the direction in which the liquid crystal layer 21 extends (that is, the extending direction D2) is 500 μm or less. In addition, regarding the direction in which the liquid crystal layer 21 extends (that is, the extending direction D2), a 1 mm square area where the liquid crystal layer 21 exists (that is, an area having a planar size of 1 mm (vertical)×1 mm (horizontal)=1 mm 2 ) , the area where the plurality of seal columns 33 are bonded to each of the first substrate 28 and the second substrate 29 is preferably 10% or less, more preferably 2% or less.

It should be noted that each seal column 33 does not necessarily have to have a substantially constant diameter in the extending direction D2. good. For example, each seal column 33 may increase in diameter continuously or discontinuously from one end to the other end in the stacking direction D1, and may have a truncated cone shape. If one end of each seal column 33 in the stacking direction D1 has a larger diameter than the other end, the diameter of the end of each seal column 33 on the first substrate 28 side is larger than the diameter of the end on the second substrate 29 side. Alternatively, the diameter of the end of each seal column 33 on the second substrate 29 side may be larger than the diameter of the end on the first substrate 28 side. Further, each seal column 33 may include a portion having a diameter larger than that of both ends in an intermediate portion (for example, a central portion) between both ends in the stacking direction D1. You may have the shape which swelled about the extension direction D2 rather than both ends. Also, the cross-sectional shape of each seal column 33 and each spacer 31 in the extending direction D2 does not necessarily have to be a perfect circle, and may be, for example, a polygonal shape such as a rectangle, an elliptical shape, or another shape. If the cross-sectional shape of each sealing column 33 and each spacer 31 in the extending direction D2 is not a perfect circle, the minimum diameter of each sealing column 33 and each spacer 31 is equal to each sealing column 33 and each spacer. 31 diameter.

From the viewpoint of ensuring dimming performance, in the area where the liquid crystal layer 21 is arranged (that is, the active area surrounded by the frame-shaped sealing material 32), the occupancy rate of the seal pillars 33 is made as small as possible so that the liquid crystal It is preferable that the area in which the dimming performance can be exhibited is made as large as possible. In general, as the diameter of each seal column 33 increases, the bonding area between each seal column 33 and each of the first substrate 28 and the second substrate 29 increases. 29 can be increased. On the other hand, when the light control device 10 is used in a window (for example, a sunroof, etc.) that people are expected to look into, it is preferable that each seal column 33 is not visually recognized by the observer.

The number (number density) of the seal pillars 33 is not particularly limited, and is preferably as small as possible from the viewpoint of ensuring the dimming performance and from the viewpoint of preventing the seal pillars 33 from being visually recognized, but from the viewpoint of ensuring the bonding strength. is preferably larger. However, the number density of the sealing columns 33 is smaller than the number density of the spacers 31. As an example, about 100 to 200 spacers 31 are provided per 1 mm square, and about 10 sealing columns 33 are provided per 1 mm square.

From the viewpoint of making each seal column 33 visually inconspicuous, each of the plurality of seal columns 33 is preferably colored (for example, black) or transparent. For example, each seal pillar 33 preferably has a black color in order to make each seal pillar 33 inconspicuous when the light control cell 11 blocks light. On the other hand, each seal pillar 33 is preferably transparent in order to make each seal pillar 33 inconspicuous when the light control cell 11 transmits light. The light control cell 11 in which the seal columns 33 are black has excellent black reproducibility, and when the incident light is blocked by the liquid crystal of the liquid crystal layer 21, the incident light is also blocked by the black seal columns 33. be. On the other hand, the light control cell 11 in which each seal column 33 is transparent (colorless) has excellent transparency. To Penetrate.

Also, from the viewpoint of making the plurality of seal columns 33 inconspicuous visually, the plurality of seal columns 33 are arranged at positions irregularly determined with respect to the direction in which the liquid crystal layer 21 extends (that is, the extension direction D2). is preferred. On the other hand, from the viewpoint of keeping the thickness of the entire liquid crystal layer 21 uniform, the plurality of seal columns 33 are arranged at regularly determined positions with respect to the direction in which the liquid crystal layer 21 extends (that is, the extending direction D2). is preferred. In this case, the bonding strength of the plurality of seal columns 33 to the first substrate 28 and the second substrate 29 can be uniformly exerted over the entire liquid crystal layer 21 .

It should be noted that the "regularly determined position" referred to here corresponds to, for example, the case where the interval between adjacent positions is regularly determined, and typically the interval between adjacent positions is a predetermined distance. is applicable. On the other hand, "positions determined irregularly" correspond to, for example, the case where the intervals between adjacent positions are determined irregularly, typically the intervals between adjacent positions are random. case applies. It should be noted that the positions of the plurality of seal columns 33 arranged at irregularly determined positions do not necessarily have to be determined irregularly, and only some of the plurality of seal columns 33 are arranged at irregularly defined positions, it can be said that the plurality of seal columns 33 are arranged at irregularly defined positions as a whole. Therefore, for example, the plurality of seal columns 33 are classified into a plurality of groups for each predetermined plane area, and one or more seal columns 33 among the two or more seal columns 33 included in each group are determined irregularly. Even when the other seal pillars 33 are arranged at regularly determined positions while arranging them in position, it can be said that the plurality of seal pillars 33 are arranged at irregularly determined positions as a whole. Note that, for example, a position randomly determined within a predetermined distance from a regularly determined predetermined position corresponds to the "irregularly determined position."

Further, when the spacers 31 are arranged in the liquid crystal layer 21 in the region surrounded by the first substrate 28, the second substrate 29, and the frame-shaped sealing material 32, the liquid crystal has fluidity. As a result, the spacers 31 may be densely packed at predetermined locations in the liquid crystal layer 21 . In this case, each spacer 31 may be visually recognized by an observer. In this embodiment, the plurality of spacers 31 are arranged in contact with the frame-shaped sealing member 32 or the sealing column 33 . Accordingly, it is possible to prevent the spacers 31 from crowding in a predetermined place in the region surrounded by the first substrate 28 , the second substrate 29 and the frame-shaped sealing material 32 . Therefore, the spacers 31 are visually inconspicuous and the light control cell 11 can achieve good light control performance.

The color of each spacer 31 is arbitrary, and each of the plurality of spacers 31 may be colored. Further, each of the plurality of spacers 31 may be transparent or opaque, but from the viewpoint of visually inconspicuous each of the plurality of spacers 31, it is desirable to use the same color as the seal column 33. .

In order to satisfactorily satisfy the various conditions described above, the material forming the plurality of spacers 31, the frame-shaped sealing material 32, and the plurality of sealing columns 33 can contain, for example, epoxy resin or acrylic resin.

As described above, according to this embodiment, by providing the seal column 33, it is possible to prevent the liquid crystal layer 21 from becoming unnecessarily thick, and the spacer 31 prevents the liquid crystal layer 21 from becoming unnecessarily thin. can be prevented with As a result, the light control cell 11 can effectively prevent the generation of the liquid crystal pool 15 and exhibit excellent light control performance, and the light control cell 11 arranged between the pair of light transmitting members 12 is provided. An optical device 10 can be provided. Further, by using the light control cell 11 described above, it is possible to fix the light control cell 11 to the pair of light transmitting members 12 while at least part of the light control cell 11 is pressed between the pair of light transmitting members 12. Based on the "manufacturing method", it is possible to manufacture the light control device 10 with high accuracy while preventing the occurrence of the liquid crystal pool 15.

Further, by forming the frame-shaped sealing member 32 and the plurality of sealing columns 33 from the same material, the frame-shaped sealing member 32 and the plurality of sealing columns 33 can be formed easily and quickly.

Further, according to the present embodiment, by providing each spacer 31 so that at least a part thereof contacts the frame-shaped sealing member 32 or the sealing column 33, the first substrate 28, the second substrate 29, and the frame-shaped seal can be separated. In the area surrounded by the material 32, it is possible to suppress the spacers 31 from crowding in a predetermined place. This makes it possible to exhibit excellent dimming performance.

[Modification]
11 and 12 are schematic cross-sectional views showing a modified example of the light control cell 11. FIG. Although the first substrate 28 and the second substrate 29 have a flat shape in the light control cell 11 shown in FIGS. 3 to 10D, the first substrate 28 and/or the second substrate 29 are bent at least in part. For example, various curved surfaces such as a two-dimensional curved surface and a three-dimensional curved surface may be formed. The two-dimensional curved surface referred to here is a curved surface that is two-dimensionally curved around a single axis, or a curved surface that is two-dimensionally curved around multiple axes parallel to each other with the same or different curvatures. be. On the other hand, a three-dimensional curved surface means a surface partially or entirely curved around each of a plurality of non-parallel axes.

When the liquid crystal layer 21 is arranged between the curved surface of the first substrate 28 and the curved surface of the second substrate 29 as shown in FIG. A space (bubble) S may be formed at the location of . On the other hand, as shown in FIG. 12, by providing a plurality of seal columns 33 bonded to each of the first substrate 28 and the second substrate 29, the distance between the first substrate 28 and the second substrate 29 can be adjusted to a desired size. It is possible to keep the liquid crystal layer 21 at a desired thickness while preventing the formation of spaces (bubbles) S in the liquid crystal layer 21 .

1A to 2B, both the front surface and the back surface of each light-transmitting member 12 have a planar shape. At least part of the surface to which the light control cell 11 is fixed via 13 may form a curved surface. Even when the light control cell 11 is fixed to the curved surface of the translucent member 12, the light control cell 11 can be fixed by interposing the intermediate support member 13 between the curved surface and the light control cell 11. can be appropriately fixed to the curved surface of the translucent member 12 . In this manner, the light control cell 11 can be fixed with high reliability to any of the curved surface, the flat surface, or the combination of the curved surface and the flat surface of the translucent member 12 .

[Third mode]
In the following description, a portion (in FIG. 3, the first alignment layer 22, the first electrode layer 24, and the first resin The base material 26) is collectively referred to as the “first substrate 28”, and the portions (the second alignment layer 23, the second electrode layer 25 and the The second resin base material 27) is collectively referred to as a "second substrate 29". Therefore, the liquid crystal layer 21 is arranged between the first substrate 28 including the first resin base material 26 and the second substrate 29 including the second resin base material 27 . When the liquid crystal layer 21 adopts a driving method other than the guest-host type shown in FIG. 3, the components of the first substrate 28 and/or the second substrate 29 can be changed according to the driving method. Further, the first substrate 28 and/or the second substrate 29 may include elements other than the alignment layer, the electrode layer, and the resin base material.

FIG. 4 is a cross-sectional view showing an outline of the overall configuration of the light control cell 11, and is a diagram mainly for explaining the spacer 31, the frame-like sealing material 32, and the sealing column 33 arranged together with the liquid crystal layer 21. As shown in FIG.

Between the first substrate 28 and the second substrate 29, a plurality of spacers 31, a frame-shaped sealing member 32, and a plurality of sealing columns 33 are arranged. The plurality of spacers 31 and the plurality of seal columns 33 are fixedly arranged in the liquid crystal layer 21 and evenly distributed in the extending direction D2. The frame-shaped sealing material 32 is fixedly arranged so as to surround the liquid crystal layer 21 , the plurality of spacers 31 and the plurality of sealing columns 33 , prevents liquid crystal from leaking, and is bonded to the first substrate 28 and the second substrate 29 . to secure both substrates 28 and 29 to each other. Each spacer 31 is bonded to the first substrate 28 or the second substrate 29 (the first substrate 28 in FIG. 4). Note that all the spacers 31 may be fixed to only one of the first substrate 28 and the second substrate 29, or some of the spacers 31 may be fixed to the first substrate 28 while others are fixed to the first substrate 28. A spacer 31 may be fixed to the second substrate 29 . On the other hand, each seal column 33 is desirably bonded to both the first substrate 28 and the second substrate 29 .

The light control cell 11 shown in FIG. 4 can be manufactured, for example, by the following method. First, a first substrate 28 and a second substrate 29 are prepared. At this time, each spacer 31 is already provided on the first substrate 28 or the second substrate 29 . A plurality of sealing columns 33 and a frame-shaped sealing material 32 are formed on one of the first substrate 28 and the second substrate 29 by using a dispenser, a screen printer, or the like. At this time, the sealing column 33 and the frame-shaped sealing member 32 may be formed in separate steps, but from the viewpoint of productivity, the sealing column 33 and the frame-shaped sealing member 32 should be formed simultaneously in the same step. is preferred.

Then, the liquid crystal (that is, the liquid crystal layer 21) is provided on one of the first substrate 28 and the second substrate 29 on which the frame-shaped sealing material 32 is provided. Then, the first substrate 28 and the first substrate 28 are superimposed in a vacuum environment, and the plurality of sealing columns 33 and the frame-shaped sealing material 32 are pressure-bonded to the first substrate 28 and the second substrate 29 . Thereby, the light control cell 11 shown in FIG. 4 can be manufactured. The method of adhering the sealing columns 33 and the frame-shaped sealing material 32 to the first substrate 28 and the second substrate 29 is not particularly limited. Adhesion may be performed by irradiation (eg, ultraviolet irradiation) and/or electron beam irradiation.

Although the diameter of each sealing column 33 and the diameter of each spacer 31 are not particularly limited, each sealing column 33 is normally aligned in the liquid crystal layer 21 with respect to the extending direction D2 (that is, the direction in which the liquid crystal layer 21 extends). 31 with a larger diameter. As an example, the diameter of each sealing column 33 may be about ten times the diameter of each spacer 31 or more. It is also possible to set the diameter of 33 to several tens of μm to 150 μm.

Each spacer 31 shown in FIG. 4 and the like has a bead-like spherical shape and is provided so as to adhere to the first substrate 28 or the second substrate 29 from the outside. The aspect is not particularly limited. For example, each spacer 31 may have a columnar shape (for example, a truncated cone shape such as a truncated cone or a truncated pyramid) having a planar portion. Also, a columnar member that is partially arranged inside the first substrate 28 and the second substrate 29 using a technique such as photolithography may be used as the spacer 31 .

By providing the plurality of seal columns 33 separately from the plurality of spacers 31 in this manner, the spacing between the first substrate 28 and the second substrate 29 can be precisely regulated, and the thickness of the liquid crystal layer 21 in the stacking direction D1 can be reduced. (ie cell gap) uniformity can be improved. In particular, since each seal column 33 is bonded to both the first substrate 28 and the second substrate 29, it is difficult to regulate the gap between the first substrate 28 and the second substrate 29 in the stacking direction D1 with the spacer 31. The relative movement of the first substrate 28 and the second substrate 29 in the direction in which .theta.

As a result, even if a large force acts locally on the light control cell 11 (especially the liquid crystal layer 21) (see FIGS. 1A and 2B), the distance between the first substrate 28 and the second substrate 29 becomes small. Relative movement of the first substrate 28 and the second substrate 29 in the "direction" is suppressed by the spacers 31 and the seal columns 33, and movement in the "direction in which the distance between the first substrate 28 and the second substrate 29 increases" is suppressed. Relative movement of the first substrate 28 and the second substrate 29 is suppressed by each seal column 33 . Therefore, compared with the case where only a plurality of spacers 31 are provided, when the spacers 31 and the seal columns 33 are provided, the gap between the first substrate 28 and the second substrate 29 can be regulated with high accuracy, and the liquid crystal pool portion can be formed. The occurrence (see FIGS. 1B and 2B) can be effectively prevented, and the thickness uniformity of the liquid crystal layer 21 in the lamination direction D1 can be improved.

It is preferable that the frame-shaped sealing member 32 and the plurality of sealing columns 33 are made of the same material. In this case, the formation of the frame-shaped sealing material 32 and the respective sealing columns 33 is facilitated. For example, using the same forming apparatus, the frame-shaped sealing material 32 and each sealing post 33 are simultaneously formed on the first substrate 28 (for example, the first alignment layer 22) or the second substrate 29 (for example, the second alignment layer). 23 above). As such a forming device, a dispenser or a screen printing device can typically be used. is preferred.

Moreover, the bonding force of the plurality of seal columns 33 to each of the first substrate 28 and the second substrate 29 is preferably 25 mN/mm ² or more. From the viewpoint of preventing relative movement of the first substrate 28 and the second substrate 29 in "the direction in which the distance between the first substrate 28 and the second substrate 29 increases," It is preferable to increase the bonding force to the second substrate 29 so that each seal column 33 is not separated from the first substrate 28 and the second substrate 29 . As a result of repeated trial and error and consideration of the light control cell 11 and the light control device 10 under various conditions, the inventors of the present invention have found that, in order to prevent the generation of the liquid crystal pool 15, a bonding force of 25 mN/ ^mm It has been found that it is preferable that the seal column 33 is bonded to each of the first substrate 28 and the second substrate 29 .

The bonding force referred to here can be measured by any method. It is possible to measure the bond strength by measuring the force required to pull the two apart from each other. Specifically, for example, a portion having a planar shape of 1 cm square including the seal column 33 is cut out of the light control cell 11, and both surfaces of the cut portion (that is, the outer surfaces of the first substrate 28 and the second substrate 29) are cut out. The first substrate 28 and the second substrate 29 are separated from each other by attaching the support members such as glass to the support members such as glass via double-sided tape or the like, and pulling the support members away from each other in the direction perpendicular to the both surfaces. The bonding force (N/mm ² ) can be measured by measuring the force required for .

Moreover, it is preferable that the diameter of each of the plurality of seal columns 33 in the direction in which the liquid crystal layer 21 extends (that is, the extending direction D2) is 500 μm or less. In addition, regarding the direction in which the liquid crystal layer 21 extends (that is, the extending direction D2), a 1 mm square area where the liquid crystal layer 21 exists (that is, an area having a planar size of 1 mm (vertical)×1 mm (horizontal)=1 mm ² ) ), the area where the plurality of seal columns 33 are bonded to each of the first substrate 28 and the second substrate 29 is preferably 10% or less.

From the viewpoint of ensuring the dimming performance, in the area where the liquid crystal layer 21 is arranged (that is, the active area surrounded by the frame-shaped sealing material 32), the occupancy rate of the seal column 33 is made as small as possible so that the liquid crystal can be adjusted. It is preferable to make the region capable of exhibiting optical performance as large as possible. In general, as the diameter of each seal column 33 increases, the bonding area between each seal column 33 and each of the first substrate 28 and the second substrate 29 increases, and the bonding strength can be increased. On the other hand, when the light control device 10 is used in a window (for example, a sunroof, etc.) that people are expected to look into, it is preferable that each seal column 33 is not visually recognized by the observer.

As a result of diligent research, the inventors of the present invention have found that the diameter of each seal column 33 has a very large effect on visibility. On the other hand, the inventor of the present invention comprehensively considers the above-described light control performance, bonding strength, and visibility of each seal pillar 33, and finds that each seal pillar 33 is visually inconspicuous and the light control cell 11 is excellent. It has been found that the diameter of each seal column 33 is preferably 500 μm or less in order to secure a bonding force effective for preventing the generation of the liquid crystal pool 15 while realizing a good dimming performance. rice field. Also, based on the same reason, in the 1 mm square area where the liquid crystal layer 21 exists, the ratio of the area where the seal column 33 is in contact with each of the first substrate 28 and the second substrate 29 (that is, the occupation ratio) is 10% or less. It came to acquire the knowledge that it is preferable to be. The occupation rate referred to here is determined based on the size of the diameter of each seal column 33 and the number (number density) of the seal columns 33 in the 1 mm square area where the liquid crystal layer 21 is present.

The number (number density) of the seal pillars 33 is not particularly limited, and is preferably as small as possible from the viewpoint of ensuring the dimming performance and from the viewpoint of preventing the seal pillars 33 from being visually recognized, but from the viewpoint of ensuring the bonding strength. is preferably larger. However, the number density of the sealing columns 33 is smaller than the number density of the spacers 31. As an example, about 100 to 200 spacers 31 are provided per 1 mm square, and about 10 sealing columns 33 are provided per 1 mm square.

From the viewpoint of making each seal column 33 visually inconspicuous, each of the plurality of seal columns 33 is preferably colored (for example, black) or transparent. For example, each seal pillar 33 preferably has a black color in order to make each seal pillar 33 inconspicuous when the light control cell 11 blocks light. On the other hand, each seal pillar 33 is preferably transparent in order to make each seal pillar 33 inconspicuous when the light control cell 11 transmits light. The light control cell 11 in which the seal columns 33 are black has excellent black reproducibility, and when the incident light is blocked by the liquid crystal of the liquid crystal layer 21, the incident light is also blocked by the black seal columns 33. be. On the other hand, the light control cell 11 in which each seal column 33 is transparent (colorless) has excellent transparency. To Penetrate.

Also, from the viewpoint of making the plurality of seal columns 33 inconspicuous visually, the plurality of seal columns 33 are arranged at positions irregularly determined with respect to the direction in which the liquid crystal layer 21 extends (that is, the extension direction D2). is preferred. On the other hand, from the viewpoint of keeping the thickness of the entire liquid crystal layer 21 uniform, the plurality of seal columns 33 are arranged at regularly determined positions with respect to the direction in which the liquid crystal layer 21 extends (that is, the extending direction D2). is preferred. In this case, the bonding strength of the plurality of seal columns 33 to the first substrate 28 and the second substrate 29 can be uniformly exerted over the entire liquid crystal layer 21 .

It should be noted that the "regularly determined position" referred to here corresponds to, for example, the case where the interval between adjacent positions is regularly determined, and typically the interval between adjacent positions is a predetermined distance. is applicable. On the other hand, "positions determined irregularly" correspond to, for example, the case where the intervals between adjacent positions are determined irregularly, typically the intervals between adjacent positions are random. case applies. It should be noted that the positions of the plurality of seal columns 33 arranged at irregularly determined positions do not necessarily have to be determined irregularly, and only some of the plurality of seal columns 33 are arranged at irregularly defined positions, it can be said that the plurality of seal columns 33 are arranged at irregularly defined positions as a whole. Therefore, for example, the plurality of seal columns 33 are classified into a plurality of groups for each predetermined plane area, and one or more seal columns 33 among the two or more seal columns 33 included in each group are determined irregularly. Even when the other seal pillars 33 are arranged at regularly determined positions while arranging them in position, it can be said that the plurality of seal pillars 33 are arranged at irregularly determined positions as a whole. Note that, for example, a position randomly determined within a predetermined distance from a regularly determined predetermined position corresponds to the "irregularly determined position."

In order to satisfactorily satisfy the various conditions described above, the material forming the plurality of sealing posts 33 can include, for example, epoxy resin or acrylic resin.

As described above, according to this embodiment, by providing the seal column 33, it is possible to prevent the liquid crystal layer 21 from becoming unnecessarily thick, and the spacer 31 prevents the liquid crystal layer 21 from becoming unnecessarily thin. can be prevented with As a result, the light control cell 11 can effectively prevent the generation of the liquid crystal pool 15 and exhibit excellent light control performance, and the light control cell 11 arranged between the pair of light transmitting members 12 is provided. An optical device 10 can be provided. Further, by using the light control cell 11 described above, it is possible to fix the light control cell 11 to the pair of light transmitting members 12 while at least part of the light control cell 11 is pressed between the pair of light transmitting members 12. Based on the "manufacturing method", it is possible to manufacture the light control device 10 with high accuracy while preventing the occurrence of the liquid crystal pool 15.

In particular, by setting the bonding force of the plurality of seal columns 33 to each of the first substrate 28 and the second substrate 29 to be 25 mN/mm ² or more, the generation of the liquid crystal reservoir 15 can be prevented very effectively. Further, by forming the frame-shaped sealing member 32 and the plurality of sealing columns 33 from the same material, the frame-shaped sealing member 32 and the plurality of sealing columns 33 can be formed easily and quickly.

[Modification]
5 and 6 are schematic cross-sectional views showing a modified example of the light control cell 11. FIG. In the light control cell 11 shown in FIGS. 3 and 4 described above, the first substrate 28 and the second substrate 29 have a flat plate shape, but the first substrate 28 and/or the second substrate 29 are bent at least in part. For example, various curved surfaces such as a two-dimensional curved surface and a three-dimensional curved surface may be formed. The two-dimensional curved surface referred to here is a curved surface that is two-dimensionally curved around a single axis, or a curved surface that is two-dimensionally curved around multiple axes parallel to each other with the same or different curvatures. be. On the other hand, a three-dimensional curved surface means a surface partially or entirely curved around each of a plurality of non-parallel axes.

When the liquid crystal layer 21 is arranged between the curved surface of the first substrate 28 and the curved surface of the second substrate 29 as shown in FIG. A space (bubble) S may be formed at the location of . On the other hand, as shown in FIG. 6, by providing a plurality of seal columns 33 bonded to each of the first substrate 28 and the second substrate 29, the distance between the first substrate 28 and the second substrate 29 can be adjusted to a desired size. It is possible to keep the liquid crystal layer 21 at a desired thickness while preventing the formation of spaces (bubbles) S in the liquid crystal layer 21 .

1A to 2B, both the front surface and the back surface of each light-transmitting member 12 have a planar shape. At least part of the surface to which the light control cell 11 is fixed via 13 may form a curved surface. Even when the light control cell 11 is fixed to the curved surface of the translucent member 12, the light control cell 11 can be fixed by interposing the intermediate support member 13 between the curved surface and the light control cell 11. can be appropriately fixed to the curved surface of the translucent member 12 . In this manner, the light control cell 11 can be fixed with high reliability to any of the curved surface, the flat surface, or the combination of the curved surface and the flat surface of the translucent member 12 .

Also, each of the plurality of seal columns 33 may be provided so as to contact at least one or more of the plurality of spacers 31 or include at least one or more of the plurality of spacers 31 .

FIG. 13 is a schematic cross-sectional view showing another modification of the light control cell 11. As shown in FIG. Each seal column 33 shown in FIG. 13 is arranged on the spacer 31 , and the spacer 31 in contact with the seal column 33 is provided so as to bite into the seal column 33 . This makes it possible to increase the area of the portion of each seal column 33 that contributes to bonding to each of the first substrate 28 and the second substrate 29 . Also, each seal column 33 can be fixed by hooking on a spacer 31 fixed to the first substrate 28 or the second substrate 29 . Therefore, according to this modification, the bonding force of the seal column 33 to each of the first substrate 28 and the second substrate 29 can be effectively increased. In this modified example, all the spacers 31 may be fixed to only one of the first substrate 28 and the second substrate 29, but some spacers 31 may be fixed to the first substrate 28. Another spacer 31 may be fixed to the second substrate 29 . In this case, the plurality of seal columns 33 can be firmly fixed to both the first substrate 28 and the second substrate 29, and the bonding force of the seal columns 33 to each of the first substrate 28 and the second substrate 29 can be increased. It can be increased more effectively.

Moreover, the method and manner of providing the spacer 31 are not limited to the above-described contents. For example, a plurality of spacers 31 are mixed in advance with the alignment material constituting the first alignment layer 22 and the second alignment layer 23, and when the alignment layers 22 and 23 are formed, the alignment material is added together with the spacers 31 to the first alignment material. A plurality of spacers 31 may be provided on the first substrate 28 and the second substrate 29 by applying on the electrode layer 24 and the second electrode layer 25 . In this case, not only can the plurality of spacers 31 be evenly distributed on the first substrate 28 and the second substrate 29, but also the orientation material can distribute the plurality of spacers 31 to the first substrate 28 (especially the first electrode layer 24) or It can be attached relatively firmly to the second substrate 29 (especially the second electrode layer 25). Also, the plurality of spacers 31 may be mixed with the material forming the seal pillars 33 and may be applied to the first substrate 28 and the second substrate 29 together with the seal pillars 33 .

[Example of planar layout of seal columns]
Next, the arrangement of the plurality of sealing columns 33 (columnar spacers) in plan view will be described. It should be noted that the following arrangement example can be appropriately applied to any of the above-described first mode, second mode, and third mode.

As shown in FIG. 14, the plurality of seal columns 33 are arranged at positions corresponding to respective vertices of a figure filled with a plurality of triangles in plan view. Specifically, each seal column 33 is arranged on each vertex (lattice point of an equilateral triangular lattice) of a figure obtained by filling a plurality of identical equilateral triangles TR1, which are minimum units, in plan view. Each equilateral triangle TR1 has the same side length (L1). Therefore, the distance (L1) between each seal column 33 and the seal column 33 adjacent to the seal column 33 is uniform. Note that the interval L1 between the seal columns 33 may be 230 μm or more and 2000 μm or less. In this case, since the distance (interval L1) between the plurality of seal columns 33 becomes uniform, the thickness (cell gap) of the liquid crystal in the light control cell becomes uniform within the plane, and the occurrence of spotty unevenness can be suppressed. A triangle having three sides of different lengths may be used instead of the equilateral triangle TR1.

Note that the spotty unevenness refers to a phenomenon in which the thickness of the liquid crystal layer 21 in the light control cell 11 is non-uniformly distributed in the plane, so that the light transmittance of the light control cell 11 becomes non-uniform in the plane. In particular, when the seal pillars 33 are arranged irregularly, the distance between the seal pillars 33 is not constant, so that a phenomenon called unevenness is likely to occur. That is, in the laminated glass with the light control cell 11 sandwiched therebetween, pressure is applied to the surface when the respective members are pressure-bonded together. At this time, the cell gap (thickness of the liquid crystal layer 21) is small where the distance between the seal pillars 33 is long, and the cell gap (thickness of the liquid crystal layer 21) is large where the distance between the seal pillars 33 is short. Cheap. Therefore, when the seal columns 33 are arranged irregularly, the thickness of the liquid crystal layer 21 in the light control cell 11 is unevenly distributed within the plane, and as a result, the light transmittance becomes uneven within the plane. Unevenness occurs.

In this specification, when the light control cell 11 is sandwiched between the first glass plate and the second glass plate, for example, when viewed from a direction perpendicular to the surface of the first glass plate or the second glass plate You can say the case. Even when the surfaces of the first glass plate and the second glass plate are curved, the spacing between the seal columns 33 is sufficient for the amount of curvature in the thickness direction of the first glass plate and the second glass plate. is small, it can be approximately considered that the first glass plate and the second glass plate are flat.

Next, modified examples of the arrangement of the plurality of seal columns 33 in plan view will be described with reference to FIGS. 15 to 18. FIG.

As shown in FIG. 15, the plurality of seal columns 33 may be arranged at positions corresponding to respective vertices of a figure filled with a plurality of pentagons in plan view. Specifically, each seal column 33 is arranged at a position corresponding to each vertex of a figure obtained by filling a plurality of identical equilateral pentagons PE1, which are minimum units, in plan view. The length (L2) of one side of each equilateral pentagon PE1 is the same between each equilateral pentagon PE1. Therefore, the distance L2 between each seal column 33 and the seal column 33 adjacent to the seal column 33 is uniform. The interval L2 between the seal columns 33 may be 115 μm or more and 2000 μm or less. In this case, since the regularity of the seal pillars 33 is low (because they are not formed continuously (in a straight line) at a low pitch), interference of diffracted light by the plurality of seal pillars 33 is less likely to occur periodically. A pentagon having five sides of different lengths may be used instead of the equilateral pentagon PE1.

As shown in FIG. 16, the plurality of seal pillars 33 may be arranged at positions corresponding to the vertices of a figure obtained by filling a plurality of polygons of three types out of triangles, quadrilaterals, and hexagons in plan view. good. Specifically, each seal column 33 is arranged at a position corresponding to each vertex of a figure filled with a plurality of equilateral triangles TR2, squares SQ1, and regular hexagons HE1, which are minimum units, in plan view. In this case, the plurality of equilateral triangles TR2 have the same shape, the plurality of squares SQ1 have the same shape, and the plurality of regular hexagons HE1 have the same shape. Also, the length L3 of one side of each equilateral triangle TR2, the length L3 of one side of each square SQ1, and the length L3 of one side of each regular hexagon HE1 are the same. Therefore, the distance L3 between each seal column 33 and the seal column 33 adjacent to the seal column 33 is uniform. The interval L3 between the seal columns 33 may be 115 μm or more and 2000 μm or less. A triangle having three sides of different lengths may be used instead of the equilateral triangle TR2, and a quadrangle having four sides of different lengths may be used instead of the square SQ1. Instead of the regular hexagon HE1, a hexagon having six sides of different lengths may be used.

As shown in FIG. 17, the plurality of seal columns 33 may be arranged at positions corresponding to respective vertices of a figure obtained by filling two types of polygons, one of triangles and quadrilaterals, in plan view. Specifically, each seal column 33 is arranged at a position corresponding to each vertex of a figure filled with a plurality of equilateral triangles TR3 and squares SQ2, which are minimum units, in plan view. In this case, the shapes of the equilateral triangles TR3 are the same, and the shapes of the squares SQ2 are the same. Also, the length L4 of one side of each equilateral triangle TR3 and the length L4 of one side of each square SQ2 are the same. Therefore, the distance L4 between each seal column 33 and the seal column 33 adjacent to the seal column 33 is uniform. The interval L4 between the seal columns 33 may be 115 μm or more and 2000 μm or less. A triangle having three sides of different lengths may be used instead of the equilateral triangle TR3, and a quadrangle having four sides of different lengths may be used instead of the square SQ2.

In FIGS. 15 to 17, since the regularity of the arrangement of the seal columns 33 is low, interference of diffracted light by the plurality of seal columns 33 is less likely to occur periodically. In addition, since the distances (intervals L2, L3, L4) between the plurality of seal columns 33 are uniform, the thickness (cell gap) of the liquid crystal layer 21 in the light control cell 11 is uniform within the plane, resulting in unevenness. can be suppressed.

As shown in FIG. 18, the plurality of seal columns 33 may be arranged at positions corresponding to respective vertices of a figure formed by filling a plurality of squares in plan view. Specifically, each seal column 33 is arranged on each vertex (lattice point of a square lattice) of a figure obtained by filling a plurality of identical squares SQ3, which are the minimum units, in plan view. In this case, the length (L5) of one side of each square SQ3 is the same. Therefore, the distance (L5) between each seal column 33 and the seal column 33 adjacent to the seal column 33 is uniform.

The interval L5 between the seal columns 33 is preferably 408 μm or more and 2000 μm or less, more preferably 560 μm or more and 950 μm or less. In this case, the seal pillars 33 are arranged regularly, but the interval L5 is 408 μm or more, which is sufficiently large for the wavelength of light. Therefore, interference of diffracted light due to the plurality of seal columns 33 can be made difficult to occur. In addition, since the distance (interval L5) between the plurality of sealing columns 33 is 950 μm or less, the distance between the sealing columns 33 does not greatly increase. Therefore, the thickness (cell gap) of the liquid crystal layer 21 in the light control cell 11 is less likely to be non-uniform in the plane, and the occurrence of spotty unevenness can be suppressed.

FIG. 19 is a schematic cross-sectional view showing the periphery of the external electrode substrate 35 in the light control cell 11. As shown in FIG. As shown in FIG. 19, an external electrode substrate 35 is sandwiched between a first substrate (first laminate) 28 and a second substrate (second laminate) 29 . The external electrode substrate 35 has an outer end electrically connected to a light control controller (not shown) and an inner end connected to the first electrode layer (first transparent electrode) 24 via a metal layer 36 and a conductive film 37 . and is electrically connected to the second electrode layer (second transparent electrode) 25 . The external electrode substrate 35 may be made of, for example, an FPC (Flexible Printed Circuit). Also, the metal layer 36 is made of a highly conductive metal such as copper. The conductive film 37 may be made of, for example, an anisotropic conductive film (ACF). In this case, the thickness of the external electrode substrate 35 is thicker than the thickness of the liquid crystal layer 21 . Therefore, the distance between the first substrate 28 and the second substrate 29 is wider in the portion where the external electrode substrate 35 is arranged than in the portion where the liquid crystal layer 21 is arranged.

As shown in FIG. 19, the sealing columns 33 and the bead-shaped spacers 31 are also formed in the region where the frame-shaped sealing material 32 is provided. In this case, the sealing column 33 and the spacer 31 are included in or embedded in the frame-like sealing material 32 to be integrated. As a result, the adhesion between the second substrate 29 to which the sealing columns 33 and the spacers 31 are adhered and the frame-shaped sealing material 32 can be improved.

The seal columns 33 and spacers 31 are also formed in the region where the external electrode substrate 35 is provided. In this case, the seal column 33 and spacer 31 are integrated with the conductive film 37 that connects the external electrode substrate 35 . Thereby, the adhesion between the second substrate 29 to which the seal column 33 and the spacer 31 are adhered and the external electrode substrate 35 can be improved.

[Application example]
The application target of the above-described light control device 10 is not particularly limited, and typically the light control device 10 can be applied to windows, doors, and the like. In particular, since the relative positions of the first substrate 28 and the second substrate 29 are relatively firmly fixed by the spacers 31 and the seal columns 33, the light control device 10 can be installed even in an environment where an external force such as vibration is applied. It is possible to Therefore, the light control device 10 can be applied not only to the windows and doors of buildings, but also to the windows and doors of vehicles such as airplanes, ships, trains, automobiles, and other moving bodies.

As described above, the above-described light control device 10 can be applied to both a moving object and a non-moving object. For example, as shown in FIG. It is possible to use For example, when outside light such as sunlight is desired to be taken into the vehicle 50, the voltage applied between the electrode layers 24 and 25 via an FPC or the like is adjusted by a light control controller (not shown) to adjust the light transmittance of the liquid crystal layer 21. Increase. As a result, the light transmission through the liquid crystal layer 21 is allowed, and the external light entering the light control device 10 (that is, the sunroof 51 ) enters the interior of the vehicle 50 . On the other hand, when outside light is not desired to enter the vehicle 50, the light transmittance of the liquid crystal layer 21 is reduced by adjusting the voltage applied between the electrode layers 24 and 25 via the FPC or the like by the light control controller. As a result, light transmission through the liquid crystal layer 21 is restricted or blocked, and the amount of external light entering the light control device 10 (that is, the sunroof 51 ) is restricted or not guided into the interior of the vehicle 50 . The adjustment of the light transmittance in the light control device 10 (that is, the liquid crystal layer 21) may be manually performed based on an instruction from a vehicle passenger, or may be directly performed by a device such as a sensor (not shown). It may be automatically performed based on information about the external environment (for example, brightness) of the vehicle 50 obtained indirectly or indirectly.

Further, the light control device 10 itself may be fixedly provided with respect to a support portion (roof 52 in the example shown in FIG. 20) that supports the light control device 10, or an operating mechanism such as a slide mechanism or a tilt mechanism may be provided. It may be movably attached to the support via the support. In particular, even when the light control device 10 is provided movably relative to the supporting portion and the light control device 10 is used in a state where an external force is likely to act, the light control cell 11 is Since it is protected by the translucent member 12 and the intermediate support member 13, it is possible to use the light control device 10 with high reliability.

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

For example, in the above-described first to third modes, the first resin base material 26 and the second resin base material 27 containing resin are used, but are not limited to these. Substrates that do not contain may also be used.

10 light control device 11 light control cell 12 translucent members 13, 13a, 13b intermediate support member 15 liquid crystal reservoir 16 bubble 21 liquid crystal layer 22 first alignment layer 23 second alignment layer 24 first electrode layer 25 second electrode layer 26 First resin base material 27 Second resin base material 28 First substrate 29 Second substrate 31 Spacer 32 Frame-shaped sealing material 33 Seal column 50 Vehicle 51 Sunroof 52 Roof D1 Lamination direction D2 Extension direction F Pressure force S Space (bubbles)

Claims (1)

A first composition comprising an uncured first sealing material and first spacers dispersed in the first sealing material is applied to a circumferential region on one of the first substrate and the second substrate. process and
supplying a liquid crystal material to a region on the one of the first substrate and the second substrate surrounded by the first composition applied to the circumferential region;
A frame holding the first spacer by curing the first composition while the other of the first substrate and the second substrate is placed on the one of the first substrate and the second substrate. forming a frame-shaped sealing material, and bonding the first substrate and the second substrate via the frame-shaped sealing material;
In the step of applying the first composition, a second composition including an uncured second sealing material and second spacers dispersed in the second sealing material is dispersed in the circumferential region. and apply the coating,
In the step of bonding the first substrate and the second substrate, the second composition is cured to form a seal column holding the second spacer in a region surrounded by the frame-shaped sealing material. , a method for manufacturing a dimming cell.

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