JP7409125B2 - Light control device and its manufacturing method - Google Patents

Description

The present disclosure relates to a light control device and a method of manufacturing the same.

Conventionally, light control members that can be used in combination with light-transmitting members such as windows and for electronic blinds to control the transmission of external light, and light control devices using such light control members have been proposed. (For example, see Patent Documents 1 and 2). A liquid crystal film including a liquid crystal layer is known as one of such light control members. This liquid crystal film is produced by sandwiching a liquid crystal material between transparent resin base materials containing transparent electrodes, and further sandwiching the liquid crystal material between linear polarizing plates. The liquid crystal film can change the orientation of the liquid crystal by changing the electric field applied between the transparent electrodes, thereby controlling the amount of external light transmitted.

Patent No. 6135816 JP2017-187810A

When using such a liquid crystal film as a light control member that can be used for automobile roof windows, side windows, etc., it is preferable to sandwich the liquid crystal film between a pair of glasses with an interlayer interposed therebetween to form a laminated glass. be. However, with laminated glass sandwiching a liquid crystal film, if the pressure applied to the surface is not uniform when each component is crimped together, or if the shape of the glass or interlayer film used does not match on the top and bottom, the interlayer film or liquid crystal When the film wrinkles, etc., the uneven distribution of liquid crystal tends to cause liquid crystal accumulation, which is a phenomenon in which there is a large amount of liquid crystal locally, which deteriorates the quality and appearance of laminated glass with a light control function. There's a problem.

Further, when the completed light control member is placed vertically on a vertical wall or the like, the liquid crystal may fall due to gravity, and the thickness of the liquid crystal layer of the liquid crystal film may change locally. In other words, the liquid crystal increases in the downward direction in the vertical direction due to gravity, resulting in an increase in the thickness of the liquid crystal layer. In this case, the amount of liquid crystal and pigment increases in the vertically lower portion, which may cause unevenness within the surface of the light control member.

The present embodiment is a light control device that can suppress the occurrence of liquid crystal pooling, which is a phenomenon in which a large amount of liquid crystal is locally present, and also suppress the phenomenon in which liquid crystals are unevenly distributed vertically downward due to gravity. and a manufacturing method thereof.

The light control device according to the present embodiment includes a first transparent substrate, a second transparent substrate, a light control cell disposed between the first transparent substrate and the second transparent substrate, and a light control cell disposed between the first transparent substrate and the second transparent substrate. a first film and a second film disposed between the second transparent substrate, the second film is adhered to the light control cell, and the second film is disposed between the first film and the second film. A void layer, a flowable resin layer, or a curable resin layer is provided on the substrate.

In the light control device according to this embodiment, the second film may be bonded to the light control cell with an interlayer film or a transparent adhesive resin.

In the light control device according to the present embodiment, a communication hole may be provided that communicates between the first film and the second film and the outside air.

In the light control device according to this embodiment, the communication hole may be sealed.

In the light control device according to the present embodiment, a frame-shaped intermediate film formed so as to surround the light control cell in a plan view is disposed between the first transparent substrate and the second transparent substrate. The communication hole may be formed by cutting out a part of the frame-shaped intermediate film.

The method for manufacturing a light control device according to the present embodiment includes a first transparent substrate, a second transparent substrate, a light control cell disposed between the first transparent substrate and the second transparent substrate, and a light control cell disposed between the first transparent substrate and the second transparent substrate. a step of producing a laminate having a first film and a second film disposed between a light cell and the second transparent substrate; the first transparent substrate of the laminate; and the light control cell; a step of integrally bonding the first film, the second film, and the second transparent substrate, and after the bonding step, the second film is adhered to the light control cell; After the joining step, a void layer, a fluid resin layer, or a curable resin layer is provided between the first film and the second film.

According to the embodiments of the present disclosure, it is possible to suppress the occurrence of a liquid crystal pool, which is a phenomenon where a large amount of liquid crystal exists locally, and to suppress the phenomenon in which liquid crystal is unevenly distributed vertically downward due to gravity.

FIG. 1 is a perspective view showing a light control device according to one embodiment. FIG. 2 is a cross-sectional view showing a light control device according to one embodiment. FIG. 3 is an exploded perspective view showing a light control device according to one embodiment. FIGS. 4(a) to 4(d) are cross-sectional views showing a method of manufacturing a dimming cell according to an embodiment. FIGS. 5(a) to 5(c) are cross-sectional views showing a method of manufacturing a dimming cell according to one embodiment. FIGS. 6(a) to 6(f) are cross-sectional views showing a method for manufacturing a laminate. FIGS. 7(a) to 7(d) are cross-sectional views showing a method for manufacturing a laminate. FIGS. 8(a) to 8(c) are cross-sectional views showing a method of manufacturing a light control device according to an embodiment. FIGS. 9A and 9B are cross-sectional views showing a method of manufacturing a light control device according to a modified example. FIG. 10 is a cross-sectional view showing a method of manufacturing a light control device according to a modified example. FIGS. 11(a) to 11(c) are cross-sectional views showing the effect when liquid crystal accumulation in a light control cell is cleared after manufacturing a light control device. FIG. 12 is a cross-sectional view showing the effect of suppressing the liquid crystal of the liquid crystal layer from moving due to gravity when the light control device is placed vertically. FIG. 13 is a sectional view showing a light control device according to a first modification. FIG. 14 is a sectional view showing a light control device according to a second modification. FIG. 15 is a sectional view showing a light control device according to a third modification. FIG. 16 is a sectional view showing a light control device according to a fourth modification. FIG. 17 is an exploded perspective view showing a light control device according to a fourth modification. FIG. 18 is a sectional view showing a light control device according to a fifth modification. FIG. 19 is an exploded perspective view showing a light control device according to a sixth modification. FIG. 20 is an exploded perspective view showing a light control device according to a seventh modification. FIG. 21 is an exploded perspective view showing a light control device according to an eighth modification.

An embodiment will be described below with reference to FIGS. 1 to 12.

The light control device 10 described below can be applied to various technical fields where adjustment of light transmittance is required, and the scope of application is not particularly limited. The light control device 10 is used to control the light of a part such as a window glass of a building, a showcase, an indoor transparent partition, a vehicle window, etc. (a part where outside light enters, for example, the front, side, rear, etc.) They are placed on windows such as roofs, etc., and can control the amount of light incident on the inside of buildings, vehicles, etc.

Note that the light control device 10 described below is merely an example of one embodiment. Therefore, for example, some of the elements listed below as components of the light control device 10 may be replaced with other elements, or may not be included. Further, elements not listed below may be included as constituent elements of the light control device 10. Further, in the drawings, there are some parts whose scale and dimensional ratio are appropriately changed or exaggerated from those of the actual objects for the sake of ease of illustration and understanding.

(Dimmer device)
FIG. 1 is a diagram showing a light control device (laminated glass) 10 according to the present embodiment. The light control device 10 according to the present embodiment has a three-dimensional shape with a curved surface, and in FIG. 1, as an example, the light control device 10 has a shape convex on one surface. have. Note that the light control device 10 is not limited to this. For example, the surface shape may be a planar shape (that is, a flat plate shape), or the surface shape may be a two-dimensional shape having a curved surface shape (for example, a part of a cylinder). configuration), etc. Here, a three-dimensional shape is not a simple cylindrical surface, but a curved surface that cannot be constructed simply by deforming a plane without expansion or contraction; it is a two-dimensional shape curved two-dimensionally around a single axis (two-dimensional It is distinguished from a two-dimensional shape (a two-dimensional curved surface) that is two-dimensionally bent at different curvatures around a plurality of mutually parallel axes (a two-dimensional curved surface). That is, a three-dimensional shape is a shape formed by a partially or entirely curved surface about each of a plurality of axes that are inclined with respect to each other. Moreover, in this specification, planar view refers to a state viewed from a direction perpendicular to the main surface of the light control device 10.

As shown in FIG. 1, the light control device 10 according to the present embodiment includes a first glass plate 11, a first intermediate film 13, a first film 33, a second film 34, an adhesive layer 37, and a light control device 10. It includes a photocell 20, a second intermediate film 14, and a second glass plate 12. The first glass plate 11, the first intermediate film 13, the first film 33, the second film 34, the adhesive layer 37, the light control cell 20, the second intermediate film 14, and the second glass plate 12. are stacked in this order. Further, a void layer G is provided between the first film 33 and the second film 34.

FIG. 2 is a sectional view showing the layer structure of the light control device 10 according to the present embodiment, and FIG. 3 is an exploded perspective view showing the layer structure of the light control device 10 according to the present embodiment. Note that the light control device 10 of this embodiment has a three-dimensional surface shape, but in FIGS. 2 and 3, the surface shape of the light control device 10 is shown as a flat surface for ease of understanding. The diagram shows a case where the

As shown in FIG. 2, the light control device 10 includes a first glass plate 11, a second glass plate 12, and a light control cell 20 disposed between the first glass plate 11 and the second glass plate 12. It is equipped with The light control cell 20 includes a first laminate 21 including a first base material 24, a first transparent electrode 25, and a first alignment layer 26, a second base material 27, a second transparent electrode 28, and a second alignment layer 29. and a liquid crystal layer 23 disposed between the first laminate 21 and the second laminate 22.

The first glass plate (first transparent substrate) 11 and the second glass plate (second transparent substrate) 12 are plate glasses arranged on the front and back surfaces of the light control device 10, respectively, and have high translucency. The first glass plate 11 and the second glass plate 12 have a three-dimensional surface shape with a curved surface shape, and are preformed in a shape having a curved surface shape convex on one side (see FIG. 1). ). In this case, the first glass plate 11 and the second glass plate 12 are formed so that the first glass plate 11 side is convex with respect to the second glass plate 12 side, but the present invention is not limited to this. The second glass plate 12 side may be formed in a convex shape with respect to the glass plate 11 side. Further, in the present embodiment, the first glass plate 11 and the second glass plate 12 have a thickness of 0.5 mm or more and 4 mm or less, and as an example, plate glass having a thickness of 2 mm is used for both. The first glass plate 11 and the second glass plate 12 may be made of inorganic glass or resin glass. As the resin glass, for example, polycarbonate, acrylic, etc. can be used. When inorganic glass is used as the first glass plate 11 and the second glass plate 12, the light control device 10 can have excellent heat resistance and scratch resistance. On the other hand, when resin glass is used as the first glass plate 11 and the second glass plate 12, the light control device 10 can be made lighter. Furthermore, the first glass plate 11 and the second glass plate 12 may be subjected to surface treatment such as hard coating, if necessary. In addition, it may replace with the 1st glass plate 11 and the 2nd glass plate 12, and may use a transparent resin base material, respectively.

The first intermediate film 13 is a member that joins the first glass plate 11 and the first film 33 together. Similarly, the second intermediate film 14 is a member that joins the second glass plate 12 and the light control cell 20. In this embodiment, the first intermediate film 13 and the second intermediate film 14 each use a sheet made of PVB (polyvinyl butyral) resin. Note that the material for the first intermediate film 13 and the second intermediate film 14 is not limited to the above-mentioned PVB, but may also be made of EVA (ethylene-vinyl acetate copolymer), COP (cycloolefin polymer), or the like. Further, the thicknesses of the first intermediate film 13 and the second intermediate film 14 may be appropriately selected depending on the materials thereof. Specifically, the thickness of the first intermediate film 13 and the second intermediate film 14 may be 300 μm or more and 2.5 mm or less, and as an example, a thickness of 760 μm is used. Further, the first intermediate film 13 and the second intermediate film 14 may have the same size as the first glass plate 11 and the second glass plate 12, and the first intermediate film 13 and the second intermediate film 14 may have the same size as the first glass plate 11 and the second glass plate It may be larger than 12.

Further, as shown in FIGS. 2 and 3, the first intermediate film 13 and the second intermediate film 14 are connected to each other by a frame intermediate film (third intermediate film) 16 and a frame intermediate film (fourth intermediate film) 17. ing. Of these, the frame interlayer film 16 is located on the first interlayer film 13 side, and the frame interlayer film 17 is located on the second interlayer film 14 side. The frame interlayer film 16 and the frame interlayer film 17 are connected via an adhesive layer 37, which will be described later. The frame interlayer films 16 and 17 are frame-shaped interlayer films when viewed from above, and more specifically, they have a square shape (a square shape with a hollowed out center) or a shape obtained by cutting a part of a square shape. It is an interlayer film with The frame interlayer films 16 and 17 may be made of the same material as the first interlayer film 13 and the second interlayer film 14. Providing the frame interlayer films 16 and 17 prevents the side surface of the light control cell 20 or a part thereof from being exposed to the side surface of the light control device 10, and also prevents moisture etc. from entering from the side surface of the light control device 10. This can further improve the water-blocking properties of the light control device 10. Note that in this embodiment, the frame interlayer film 16 and the frame interlayer film 17 are connected via an adhesive layer 37, which will be described later, but the frame interlayer film 16 and the frame interlayer film 17 are not directly connected. You can leave it there.

When the first intermediate film 13 and the second intermediate film 14 are each larger than the light control cell 20 (in a plan view), the frame intermediate films 16 and 17 are formed in the thick portion of the light control cell 20 in a cross-sectional view. It is an interlayer film. The frame interlayer films 16 and 17 are each formed so as to surround the light control cell 20 in a plan view, and are formed by hollowing out the shape of the light control cell 20 from the shapes of the first interlayer film 13 and the second interlayer film 14. It is a shaped intermediate film. In this case, the frame intermediate film 16 is formed between the first intermediate film 13 and the second intermediate film 14 in a portion corresponding to the periphery of the first film 33, the second film 34, and the void layer G. There is. Further, a frame intermediate film 17 is formed between the first intermediate film 13 and the second intermediate film 14 in a portion corresponding to the periphery of the light control cell 20.

The outer periphery of the frame interlayer films 16 and 17 may be the same size as the outer periphery of the first glass plate 11 and the second glass plate 12, or may be larger than the outer periphery of the first glass plate 11 and the second glass plate 12. It's okay. Further, the inner periphery of the frame interlayer films 16 and 17 may be the same size as the outer periphery of the light control cell 20, or may be larger than the outer periphery of the light control cell 20. Further, the inner periphery of the frame interlayer films 16 and 17 may be the same size as the outer periphery of the first film 33 and the second film 34, or may be larger than the outer periphery of the first film 33 and the second film 34. Also good. Note that it is preferable that the width Wa of the frame interlayer film 16 and the width Wb of the frame interlayer film 17 (see FIG. 3) are each more than 0 mm and about 1/4 or less of the glass width. Further, the width Wa of the frame interlayer film 16 may be the same as the width Wb of the frame interlayer film 17 (Wa=Wb), or may be narrower than the width Wb of the frame interlayer film 17 (Wa<Wb). Alternatively, if the side surface of the light control cell 20 or a portion thereof is not exposed from the side surface of the light control device 10, the frame interlayer film 16, the frame interlayer film 17, or both may be omitted.

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

As shown in FIG. 2, the first laminate 21 is formed by stacking a first base material 24, a first transparent electrode 25, and a first alignment layer 26. That is, the first base material 24, the first transparent electrode 25, and the first alignment layer 26 are stacked in this order from the first intermediate film 13 side. Further, the second laminate 22 is formed by laminating a second base material 27, a second transparent electrode 28, and a second alignment layer 29. That is, the second base material 27, the second transparent electrode 28, and the second alignment layer 29 are stacked in this order from the second intermediate film 14 side.

Furthermore, a plurality of bead spacers 31 are arranged between the first laminate 21 and the second laminate 22. The liquid crystal layer 23 is disposed in a filling manner between the plurality of bead spacers 31 between the first laminate 21 and the second laminate 22 . The plurality of bead spacers 31 may be arranged irregularly or regularly.

The light control cell 20 is controlled by the guest host liquid crystal composition provided in the liquid crystal layer 23 by driving the first transparent electrode 25 and the second transparent electrode 28 provided in the first laminate 21 and the second laminate 22. It changes the orientation of the liquid crystal material, thereby changing the amount of transmitted light.

The first base material 24 and the second base material 27 are made of transparent resin, and a flexible film can be applied thereto. As the first base material 24 and the second base material 27, it is possible to use a transparent resin film that has small optical anisotropy and has a transmittance of 80% or more in the visible wavelength range (380 nm or more and 800 nm or less). desirable. Examples of materials for the transparent resin film include acetyl cellulose resins such as triacetyl cellulose (TAC), polyester resins such as polyethylene terephthalate (PET) and polyethylene naphthalate (PEN), polyethylene (PE), and polypropylene (PP). , polyolefin resins such as polystyrene, polymethylpentene, and EVA, vinyl resins such as polyvinyl chloride and polyvinylidene chloride, acrylic resins, polyurethane resins, polysulfone (PEF), polyethersulfone (PES), polycarbonate ( Examples include resins such as PC), polysulfone, polyether (PE), polyether ketone (PEK), (meth)acronitrile, cycloolefin polymer (COP), and cycloolefin copolymer. As the material for the transparent resin film, resins such as polycarbonate, cycloolefin polymer, and polyethylene terephthalate are particularly preferred. Further, the thickness of the transparent resin film used as the first base material 24 and the second base material 27 depends on the material thereof, but can be appropriately selected within a range in which the transparent resin film has flexibility. The thickness of the first base material 24 and the second base material 27 may be 50 μm or more and 200 μm or less, respectively. In this embodiment, a polyethylene terephthalate film with a thickness of 125 μm is used as an example of the first base material 24 and the second base material 27.

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

Examples of tin oxide (SnO ₂ )-based materials include NESA (tin oxide SnO ₂ ), ATO (antimony tin oxide), and fluorine-doped tin oxide. Examples of indium oxide (In ₂ O ₃ )-based materials include indium oxide, ITO (Indium Tin Oxide), and IZO (Indium Zinc Oxide). Examples of zinc oxide (ZnO)-based materials include zinc oxide, AZO (aluminum-doped zinc oxide), and gallium-doped zinc oxide. In this embodiment, the transparent conductive films forming the first transparent electrode 25 and the second transparent electrode 28 are made of ITO.

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

Note that in this embodiment, the bead spacer 31 is provided in the second laminate 22, but is not limited to this, and is provided in both the first laminate 21 and the second laminate 22, or in the first laminate 22. It may be provided only in the laminate 21. Moreover, the bead spacer 31 does not necessarily have to be provided. Alternatively, a columnar spacer may be used instead of the bead spacer 31 or together with the bead spacer 31.

The first alignment layer 26 and the second alignment layer 29 are members for aligning a group of liquid crystal molecules included in the liquid crystal layer 23 in a desired direction. The first alignment layer 26 and the second alignment layer 29 are formed by photoalignment layers. The photo-alignment material that can be applied to the photo-alignment layer can be a wide variety of materials to which photo-alignment methods can be applied; examples include photodecomposition type, photodimerization type, photoisomerization type, etc. can. In this embodiment, a photodimerizable material is used. Examples of photodimerizable materials include polymers containing cinnamate, coumarin, benzylidene phthalimidine, benzylidene acetophenone, diphenylacetylene, stilbazole, uracil, quinolinone, maleimide, or cinnamylidene acetic acid derivatives. Among these, polymers containing one or both of cinnamate and coumarin are preferably used because of their good alignment control ability.

Note that a rubbed alignment layer may be used instead of the photoalignment layer. Regarding the rubbed alignment layer, the rubbing treatment may not be performed, or the alignment layer may be prepared by performing the rubbing treatment and forming a fine line-like uneven shape. Note that in this embodiment, the light control cell 20 includes the first alignment layer 26 and the second alignment layer 29, but is not limited to this, and may not include the first alignment layer 26 and the second alignment layer 29. It may also be a form.

A wide variety of guest-host liquid crystal compositions and dichroic dye compositions can be applied to the liquid crystal layer 23. The guest-host liquid crystal composition may contain a chiral agent so that when the liquid crystal material is horizontally aligned, it is oriented in a helical shape in the thickness direction of the liquid crystal layer 23. Further, between the first laminate 21 and the second laminate 22, a sealing material 32 that is ring-shaped or frame-shaped in plan view is arranged so as to surround the liquid crystal layer 23. This sealing material 32 holds the first laminate 21 and the second laminate 22 together and prevents leakage of the liquid crystal material. The sealing material 32 can be made of thermosetting resin such as epoxy resin or acrylic resin, ultraviolet curable resin, or the like.

The light control cell 20 applies an alignment regulating force related to pretilt to the first alignment layer 26 and the second alignment layer 29 in a certain direction so that the alignment of the guest-host liquid crystal composition during light shielding is the same as when an electric field is applied. It is configured with a set vertical alignment layer, and is configured as normally clear. Note that this setting during light transmission may be configured as normally dark when an electric field is applied. Here, normally dark is a structure in which the transmittance is at its minimum when no voltage is applied to the liquid crystal, resulting in a black screen. Normally clear is a structure in which the transmittance is maximum and becomes transparent when no voltage is applied to the liquid crystal.

In addition, although the light control cell 20 of this Embodiment showed the example provided with the guest-host type liquid crystal layer 23, it is not limited to this. The light control cell 20 may have a structure including a liquid crystal layer 23 of a TN (Twisted Nematic) system, a VA (Vertical Alignment) system, an IPS (In-Plane-Switching) system, etc. that do not use a dichroic dye composition. When such a liquid crystal layer 23 is provided, by further providing a linear polarizing layer on each of the surfaces of the first base material 24 and the second base material 27, they can be made to function as a light control film.

In this embodiment, a first film 33 and a second film 34 are arranged between the light control cell 20 and the first glass plate 11. More specifically, the first film 33 is arranged between the light control cell 20 and the first intermediate film 13, and the second film 34 is arranged between the first film 33 and the light control cell 20. . Of these, the first film 33 is bonded to the first intermediate film 13.

Further, the second film 34 is bonded to the first base material 24 of the light control cell 20 by an adhesive layer 37. In this way, by adhering the second film 34 to the light control cell 20, when the light control device 10 is placed vertically on a vertical wall, etc., part of the liquid crystal in the liquid crystal layer 23 is prevented by gravity, as described later. You can prevent it from falling. As a result, the amount of liquid crystal in the liquid crystal layer 23 in the lower part in the vertical direction is locally larger than in the upper part in the vertical direction, and it is possible to suppress a phenomenon in which the appearance of the light control device 10 becomes uneven (gravitational unevenness). . In other words, the rigidity of the second film 34 allows the liquid crystal in the liquid crystal layer 23 to be held on the second glass plate 12 side, so that the liquid crystal in the liquid crystal layer 23 is prevented from falling due to gravity, and the amount of liquid crystal in the liquid crystal layer 23 is reduced. can be made uniform within the plane.

The first film 33 and the second film 34 (hereinafter also referred to as films 33 and 34) are made of transparent resin, and may be flexible resin films. As the films 33 and 34, it is desirable to use transparent resin films that have small optical anisotropy and have a transmittance of 80% or more in the visible wavelength range (380 nm or more and 800 nm or less). As the material of the transparent resin film, the same material as the transparent resin film used for the first base material 24 and the second base material 27 described above can be used. Alternatively, the films 33 and 34 may be functional films such as an infrared (IR) reflective film or an ultraviolet (UV) cut film. Furthermore, the films 33 and 34 are a light control cell, an AR (Anti-Reflection) film, an AG (Anti-Glare) film, a reflective polarizing film, a light control film having a light control method other than liquid crystal, or a defroster function. It may be a film having. Further, the thickness of the films 33 and 34 may be, for example, 50 μm or more and 250 μm or less, although it depends on the material thereof, and preferably 100 μm or more and 125 μm or less. Further, the planar shapes of the films 33 and 34 may be smaller than or the same as the planar shapes of the first intermediate film 13 and the second intermediate film 14. Further, the planar shape of the films 33 and 34 is preferably larger than the planar shape of the entire light control cell 20, and particularly preferably larger than the planar shape of the liquid crystal layer 23 located inside the sealing material 32. As a result, the films 33 and 34 cover the entire liquid crystal layer 23, which prevents liquid crystal pooling, which is a phenomenon where a large amount of liquid crystal is locally present in a part of the liquid crystal layer 23, and liquid crystals that are unevenly distributed vertically downward due to gravity. The occurrence of the phenomenon of shrinkage can be suppressed throughout the entire surface. Alternatively, the planar shape of the films 33 and 34 may be made smaller than the inside of the sealing material 32 (liquid crystal layer 23) of the light control cell 20, and liquid crystal pools may be induced in areas where the films 33 and 34 are not present. The portion (outer periphery) where the liquid crystal pool is guided in this way can be hidden when the light control device 10 is placed in a vehicle window or the like. Additionally, a functional film such as an infrared (IR) reflective film, an ultraviolet (UV) cut film, an AR (Anti-Reflection) film, an AG (Anti-Glare) film, etc. is placed between the second film 34 and the light control cell 20. May be added. In this case, the functional film may be bonded to the second film 34 or the light control cell 20. Further, the functional film may be added between the first intermediate film 13 and the first film 33.

Note that the second film 34 may have the same configuration (material, thickness, etc.) as the first film 33, or may have a different configuration from the first film 33. In the latter case, for example, the second film 34 may be made of a material with higher rigidity than the first film 33, or may be thicker than the first film 33. In this case, the rigidity of the second film 34 allows the liquid crystal layer 23 to be more firmly held on the second glass plate 12 side, so that it is possible to more effectively suppress the liquid crystal in the liquid crystal layer 23 from falling due to gravity. .

The adhesive layer 37 is capable of adhering the second film 34 to the light control cell 20, and is transparent, specifically, has a transmittance of 80% or more in the visible wavelength range (380 nm or more and 800 nm or less). It is desirable to use one. It is preferable that each adhesive layer 37 has a substantially rectangular shape in plan view and covers the entire light control cell 20 . The planar shape of the adhesive layer 37 is preferably larger than the planar shape of the entire light control cell 20, and particularly preferably larger than the light control cell 20 by 5 mm or more over the entire outer circumference. Thereby, it is possible to absorb some misalignment of the adhesive layer 37 and to reliably bond the second film 34 to the entire area of the light control cell 20. Further, the adhesive layer 37 may be arranged so as to cover the whole or a part of the frame interlayer film 17. The thickness of this adhesive layer 37 may be 2.5 mm or less. The adhesive layer 37 may be composed of an intermediate film. In this case, the adhesive layer 37 may be made of the same material as the first intermediate film 13 and the second intermediate film 14. Alternatively, the adhesive layer 37 may be made of a transparent adhesive resin such as OCR (Optical Clear Resin) or OCA (Optical Clear Adhesive).

In this embodiment, a void layer G is provided between the first film 33 and the second film 34. That is, the first film 33 and the second film 34 are not joined to each other and are arranged at a constant interval in the thickness direction. The void layer G is filled with air, but is not limited to this, and may be filled with a gas such as nitrogen or an inert gas. The thickness of this void layer G is, for example, greater than 0 μm and less than 10,000 μm, preferably greater than or equal to 0.1 μm and less than or equal to 100 μm. The planar shape of the void layer G may be substantially the same as the planar shape of the films 33 and 34. In this way, by forming the void layer G between the first film 33 and the second film 34, cell gap defects in the light control cell 20 are reduced, as will be described later, and a portion of the liquid crystal layer 23 is It is possible to suppress the occurrence of liquid crystal pooling, which is a phenomenon where a large amount of liquid crystal is locally present in the area. Further, by providing the void layer G between the first film 33 and the second film 34, the heat insulation of the light control device 10 is improved, and the heat retention of the vehicle or building in which the light control device 10 is arranged is improved. be able to. In addition, when the light control cell 20 is placed in a light-blocking state, the light control device 10 causes reflection at the interface between the first film 33 and the gap layer G and the interface between the second film 34 and the gap layer G to cause the light to fall on the first glass plate 11 side. When viewed from above, it appears mirror-like.

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

The dimming controller 91 can adjust the electric field applied to the liquid crystal layer 23 based on any method. The light control controller 91 adjusts the electric field applied to the liquid crystal layer 23 according to, for example, the measurement result of the sensor device 92 or an instruction (command) input by the user via the user operation unit 93, and controls the light control by the light control device 10. It is possible to switch between blocking and transmitting light, and changing the degree of light transmission. Therefore, the dimming controller 91 may automatically adjust the electric field applied to the liquid crystal layer 23 according to the measurement result of the sensor device 92, or manually according to a user's instruction via the user operation unit 93. It may be adjusted to Note that the object to be measured by the sensor device 92 is not particularly limited. For example, the brightness of the usage environment may be measured. In this case, the light control device 10 may be used to switch between blocking and transmitting light or changing the transmittance of light. This is done depending on the brightness of the environment. Further, both the sensor device 92 and the user operation unit 93 do not necessarily need to be connected to the dimming controller 91, and only one of the sensor device 92 and the user operation unit 93 may be connected. .

The external electrode substrate 35 is sandwiched between the first laminate 21 and the second laminate 22. In the region where the external electrode substrate 35 is formed, the first laminate 21 and the second laminate 22 have electrode protrusions 36 that protrude outward in the surface direction. The external electrode substrate 35 is embedded inside the electrode protruding piece 36. The external electrode substrate 35 and the electrode protrusion piece 36 are sandwiched between the frame intermediate film 17 and the second intermediate film 14, as shown by the arrows in FIG. protrude in one direction. However, the present invention is not limited to this, and the external electrode substrate 35 and the electrode protrusion piece 36 may be sandwiched between the frame intermediate film 16 and the first intermediate film 13.

(Manufacturing method of dimming cell)
Next, a method for manufacturing the light control cell 20 of the light control device 10 according to the present embodiment will be explained using FIGS. 4(a) to 4(d) and FIGS. 5(a) to (c). 4(a)-(d) and FIG. 5(a)-(c) are cross-sectional views showing a method of manufacturing the light control cell 20 according to this embodiment.

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

Next, as shown in FIG. 4(c), a coating liquid for the second alignment layer 29 is applied onto the second base material 27 on which the second transparent electrode 28 is formed, and then exposed to light to form a second alignment layer. Create layer 29. In this way, the second laminate 22 in which the second base material 27, the second transparent electrode 28, and the second alignment layer 29 are laminated is prepared.

Note that a first laminate 21 in which a first base material 24, a first transparent electrode 25, and a first alignment layer 26 are stacked is also prepared in the same manner as the steps shown in FIGS. 4(a) to 4(c). do.

Subsequently, as shown in FIG. 4(d), bead spacers 31 are placed on the second alignment layer 29 of the second laminate 22. The bead spacers 31 can be arranged by a wide variety of methods in addition to wet/dry spreading. For example, by partially applying a coating liquid produced by dispersing bead spacers 31 together with a resin component in a solvent, and then sequentially performing drying and baking processes, beads can be randomly distributed on the second alignment layer 29. A spacer 31 may be placed to hold it so that it is difficult to move. Although not shown, the outer periphery of the bead spacer 31 may be covered with the second alignment layer 29. Specifically, by mixing the bead spacers 31 with the coating liquid for the second alignment layer 29 to form the second alignment layer 29, the bead spacers 31 are thinly covered and held by the second alignment layer 29. It can be made into a form that

Next, as shown in FIG. 5A, a sealing material 32 is applied onto the second alignment layer 29 of the second laminate 22 using a dispenser or screen printing. This sealing material 32 is applied in a frame shape so as to surround the area where the liquid crystal layer 23 is to be formed.

Next, as shown in FIGS. 5(b) and 5(c), the second laminate 22 and the first laminate 21 are stacked on each other, and the liquid crystal layer 23 is disposed. During this time, first, as shown in FIG. 5(b), liquid crystal constituting the liquid crystal layer 23 is dropped in an area surrounded by the sealing material 32. At this time, the liquid crystal layer 23 is filled inside the sealing material 32 and around the bead spacers 31.

Subsequently, as shown in FIG. 5C, the second laminate 22 on which the liquid crystal layer 23 is arranged and the first laminate 21 prepared in advance are stacked and pressed together. Thereafter, the sealing material 32 is semi-cured by irradiation with ultraviolet rays, and then heated, thereby integrating the first laminate 21 and the second laminate 22. Thereafter, the thus produced laminate of the first laminate 21 and the second laminate 22 is cut into a desired size by trimming.

Note that, as described above, it is preferable to stack the second laminate 22 and the first laminate 21 on each other after disposing the liquid crystal layer 23, but the present invention is not limited to this. The liquid crystal layer 23 may be arranged after the body 21 is laminated on each other. Thereafter, by attaching an external electrode substrate 35 (see FIG. 3) between the first laminate 21 and the second laminate 22, the light control cell 20 according to the present embodiment is obtained.

(Manufacturing method of light control device)
Next, regarding the manufacturing method (laminated glass processing method) of the light control device 10 according to the present embodiment, FIGS. 6(a)-(f), FIGS. 7(a)-(d), and FIGS. This will be explained using c). 6(a)-(f), FIG. 7(a)-(d), and FIG. 8(a)-(c) are cross-sectional views showing a method of manufacturing the light control device 10.

First, as shown in FIGS. 6(a)-(f) and FIGS. 7(a)-(d), a first glass plate 11, a first intermediate film 13, a first film 33, a second film 34, and an adhesive layer are prepared. 37. A laminate 30 is produced in which the light control cell 20, the second intermediate film 14, and the second glass plate 12 are laminated.

In this case, the second glass plate 12 is first prepared (FIG. 6(a)), and the second intermediate film 14 is laminated on the second glass plate 12 (FIG. 6(b)).

Next, the light control cell 20 is laminated on the second intermediate film 14 (FIG. 6(c)). Subsequently, a frame interlayer film 17 is placed on the second interlayer film 14 and around the light control cell 20 (FIG. 6(d)).

Next, an adhesive layer 37 is laminated on the light control cell 20 (FIG. 6(e)). The adhesive layer 37 may be larger than the light control cell 20 and may cover the whole or part of the frame interlayer film 17. Subsequently, the second film 34 is laminated on the adhesive layer 37 (FIG. 6(f)). Note that the second film 34 is not adhered to the adhesive layer 37 at this point.

Next, the first film 33 is laminated on the second film 34 (FIG. 7(a)), and then the first film 33 and the second film are laminated on the frame intermediate film 17 via the adhesive layer 37. The frame interlayer film 16 is placed around the frame 34 (FIG. 7(b)).

Next, the first intermediate film 13 is laminated on the frame intermediate film 16 and the first film 33 (FIG. 7(c)). Thereafter, the first glass plate 11 is laminated on the first intermediate film 13 to obtain a laminate 30 (FIG. 7(d)).

Next, a method for manufacturing the light control device 10 by processing the laminated body 30 obtained in this way into a laminated glass will be described.

First, as shown in FIG. 8(a), the above-mentioned laminate 30 is prepared. Here, the first glass plate 11 and the second glass plate 12 are shaped in advance into a curved shape having a three-dimensional surface shape.

Next, as shown in FIG. 8(b), the laminate 30 is enclosed in a bag (vacuum bag) 51. The bag 51 is preferably made of rubber or silicone, which have flexibility and airtightness. Further, a ventilation pipe 52 is connected to this bag 51. After the laminate 30 is sealed in the bag 51 in this manner, the laminate 30 is placed together with the bag 51 into a heating device 54 such as an oven. Subsequently, the laminate 30 together with the bag 51 is heated at a predetermined temperature and time. In this case, the laminate 30 is heated at a temperature equal to or higher than the softening temperature of the first intermediate film 13, second intermediate film 14, frame intermediate film 16, and frame intermediate film 17 for a predetermined period of time. At this time, it is preferable that the air inside the bag 51 is sucked through the ventilation pipe 52 by a pump (not shown). Thereby, the air remaining between each member of the laminate 30 can be sucked, and poor crimping caused by air bubbles remaining inside the light control device 10 can be suppressed. In this embodiment, an example is given in which suction is applied so that the inside of the bag 51 and the inside of the laminate 30 are in a vacuum state, and a pressure of about atmospheric pressure (0.1 MPa) is applied to the laminate 30 due to a pressure difference. explain. However, the present invention is not limited to this. For example, the suction force of a pump (not shown) may be adjusted so that although the inside of the bag 51 is not completely vacuumed, the air between each member of the laminate 30 is sufficiently sucked and the laminate 30 is On the other hand, a pressure lower than atmospheric pressure may be applied due to a pressure difference. In this way, each member of the laminate 30 is temporarily press-bonded.

Subsequently, as shown in FIG. 8(c), the bag 51 and the laminate 30 are taken out from the heating device 54, and after the laminate 30 is taken out from the bag 51, the laminate 30 is placed into the heating/pressing device 53. Deploy. Subsequently, the laminate 30 is heated at a predetermined temperature and time. In this embodiment, the laminate 30 is heated at a temperature equal to or higher than the softening temperature of the first intermediate film 13, the second intermediate film 14, the frame intermediate film 16, and the frame intermediate film 17 for a predetermined period of time. The heating/pressurizing device 53 may be any device as long as it can sufficiently heat and pressurize the laminate 30, such as an autoclave device. By this heating, the first intermediate film 13, the second intermediate film 14, the frame intermediate film 16, and the frame intermediate film 17 are melted, and the first glass plate 11, the first intermediate film 13, the frame intermediate film 16, and the frame intermediate film 16 of the laminate 30 are melted. 17. The first film 33, the second film 34, the light control cell 20, the second intermediate film 14, and the second glass plate 12 are pressed (main pressure bonded) and joined together to obtain the light control device 10. Note that at this time, since the first film 33 and the second film 34 are not directly joined to each other, a void layer G is formed between them. By providing such a gap layer G, the pressure applied to the liquid crystal layer 23 of the light control cell 20 is released after the light control device 10 is manufactured, so that the liquid crystal of the liquid crystal layer 23 is released in the light control cell 20. Even if there is uneven distribution of the liquid crystal in the liquid crystal layer 23, the uneven distribution of the liquid crystal in the liquid crystal layer 23 is naturally eliminated.

Alternatively, as shown in FIG. 9(a), each member of the laminate 30 sealed in the bag 51 is temporarily compressed in a heating device 54 such as an oven, and then, as shown in FIG. 9(b), the bag 51 is The laminate 30 may be heated and pressurized together with the bag 51 using a heating/pressurizing device 53 such as an autoclave while the laminate 30 is still sealed in the bag 51 . During this time, it is preferable that the air inside the bag 51 is sucked through the ventilation pipe 52 by a pump (not shown).

Alternatively, as shown in FIG. 10, each member of the laminate 30 may be joined together in one process without providing a temporary pressure bonding process. Specifically, with the laminate 30 enclosed in the bag 51, the laminate 30 together with the bag 51 may be heated and pressurized by a heating/pressurizing device 53 such as an autoclave device. During this time, it is preferable that the air inside the bag 51 is sucked through the ventilation pipe 52 by a pump (not shown).

By the way, during laminated glass processing for manufacturing the light control device 10 in this manner, pressure is applied to each member of the laminate 30. At this time, the original cell gap (thickness of the liquid crystal layer 23) is maintained in the part where the spacer (bead spacer 31) is located, but as it moves away from the bead spacer 31, the value of the cell gap becomes smaller than the original value. . If such a cell gap becomes uneven, there is a risk that the quality of the light control device 10 may be deteriorated, such as the appearance of the light control device 10 becoming defective or the light control function becoming uneven.

On the other hand, according to the present embodiment, the first film 33 and the second film 34 are arranged between the light control cell 20 and the first intermediate film 13, and the first film 33 and the second film 34 are arranged between the light control cell 20 and the first intermediate film 13. A void layer G is provided between them. As a result, even if a liquid crystal pool (a phenomenon in which a large amount of liquid crystal exists locally) occurs in the liquid crystal layer 23 of the light control cell 20, after the light control device 10 is manufactured, the liquid crystal layer 23 can be removed before each member completely hardens. When the pressure applied to the liquid crystal layer 23 is released, the liquid crystal in the liquid crystal layer 23 moves naturally using the void layer G so that the cell gap (thickness of the liquid crystal layer 23) becomes uniform (Figs. )reference). Thereby, liquid crystal accumulation in the liquid crystal layer 23 is eliminated, the liquid crystal layer 23 of the light control cell 20 can be uniformly distributed within the plane, and the quality and appearance of the light control device 10 can be improved. Immediately after the light control device 10 is manufactured, the second film 34 and the adhesive layer 37 are in a soft state due to heat, so the movement of the liquid crystal in the liquid crystal layer 23 is prevented by the second film 34 and the adhesive layer 37. There is little risk of interference.

Further, according to this embodiment, the second film 34 is adhered to the light control cell 20. Thereby, after each member of the light control device 10 is completely hardened, the rigidity of the second film 34 allows the liquid crystal layer 23 of the light control cell 20 to be held on the second glass plate 12 side. Therefore, when the light control device 10 is placed vertically on a vertical wall or the like, part of the liquid crystal in the liquid crystal layer 23 is prevented from falling vertically downward due to gravity, and the amount of liquid crystal in the liquid crystal layer 23 is reduced. It can be made uniform within the plane of the light control device 10 (see FIG. 12). As a result, the phenomenon of uneven appearance of the light control device 10 (gravitational unevenness) can be suppressed, and the quality and appearance of the light control device 10 can be improved. In particular, even when the liquid crystal of the liquid crystal layer 23 is easily moved due to the presence of the void layer G, the thickness of the light control cell 20 can be kept constant due to the rigidity of the second film 34, and the light control device 10 When the liquid crystal layer 23 is placed vertically, the liquid crystal of the liquid crystal layer 23 can be prevented from moving due to gravity.

Further, according to the present embodiment, by providing the void layer G between the first film 33 and the second film 34, the heat insulation of the light control device 10 is improved, and the light control device 10 is It is possible to improve the heat retention inside the vehicle or building in which it is installed.

Further, according to the present embodiment, the frame intermediate films 16 and 17 are formed so as to surround the light control cell 20 in a plan view, and the frame intermediate films 16 and 17 are different from the first intermediate film 13 and the second intermediate film. It is connected to the membrane 14. Thereby, it is possible to prevent moisture and the like from entering from the side surface of the light control device 10, and to further improve the water-blocking properties of the light control device 10.

Further, according to the present embodiment, the second film 34 is bonded to the light control cell 20 with an adhesive layer 37 that is an intermediate film or a transparent adhesive resin. Thereby, when manufacturing the light control device 10 by laminated glass processing, the second film 34 can be bonded to the light control cell 20 using the adhesive layer 37. In addition, since the adhesive layer 37 is soft immediately after manufacturing the light control device 10, when the pressure applied to the liquid crystal layer 23 is released, the liquid crystal of the liquid crystal layer 23 of the light control cell 20 is naturally adjusted so that the cell gap becomes uniform. can be moved to

(Modified example)
Next, various modifications of this embodiment will be described with reference to FIGS. 13 to 21. 13 to 21 are diagrams each showing a light control device according to a modification of this embodiment. In FIGS. 13 to 21, the same parts as those in the form shown in FIGS. 1 to 12 are given the same reference numerals, and detailed explanations will be omitted.

(First modification)
FIG. 13 shows a light control device 10A according to a first modification. In the light control device 10A shown in FIG. 13, a transparent fluid resin layer L is provided between the first film 33 and the second film 34. This fluid resin layer L is sealed in the space between the first film 33 and the second film 34. The fluid resin layer L is, for example, a transparent resin that softens at a temperature lower than that of the first intermediate film 13 and the second intermediate film 14, and may be an uncured liquid or a gel. Further, it is preferable that the refractive index of the fluid resin layer L is matched to that of the first film 33 and the second film 34. As such a fluid resin layer L, for example, glycerin or the like can be used. Further, the fluid resin layer L may be a fluid liquid layer. The thickness of the fluid resin layer L may be greater than 0 μm and less than 10000 μm. By providing the fluid resin layer L between the first film 33 and the second film 34 in this manner, the fluid resin layer L can be made to flow after laminated glass processing. Thereby, the thickness of the liquid crystal layer 23 of the light control cell 20 can be made uniform, and the occurrence of liquid crystal accumulation can be suppressed. Note that also in the examples shown in FIGS. 15 to 21 described later, a fluid resin layer L may be provided between the first film 33 and the second film 34 instead of the void layer G.

(Second modification)
FIG. 14 shows a light control device 10B according to a second modification. In the light control device 10B shown in FIG. 14, a transparent curable resin layer 38 is provided between the first film 33 and the second film 34. This curable resin layer 38 is filled into the space between the first film 33 and the second film 34 and then cured. As such a curable resin layer 38, for example, a thermosetting resin, an ultraviolet curable resin, or the like can be used. The thickness of the curable resin layer 38 may be greater than 0 μm and less than 10,000 μm. This curable resin layer 38 is filled between the first film 33 and the second film 34 after laminated glass processing, and is then cured by heat, ultraviolet rays, or the like. By providing the curable resin layer 38 between the first film 33 and the second film 34 in this manner, the uncured curable resin layer 38 can be made to flow immediately after laminated glass processing. Thereby, the thickness of the liquid crystal layer 23 of the light control cell 20 can be made uniform, and the occurrence of liquid crystal accumulation can be suppressed. Thereafter, by curing the curable resin layer 38, the liquid crystal layer 23 of the light control cell 20 can be held on the second glass plate 12 side by the rigidity of the curable resin layer 38. Thereby, when the light control device 10B is placed vertically, it is possible to prevent part of the liquid crystal of the liquid crystal layer 23 from falling vertically downward due to gravity. Note that also in the examples shown in FIGS. 15 to 21 described later, a curable resin layer 38 may be provided between the first film 33 and the second film 34 instead of the void layer G.

(Third modification)
FIG. 15 shows a light control device 10C according to a third modification. In the light control device 10C shown in FIG. 15, a plurality of spacers 39 are provided in the gap layer G between the first film 33 and the second film 34. As the spacer 39, a spherical bead spacer having the same configuration as the bead spacer 31 of the light control cell 20 described above may be used. The plurality of spacers 39 may be arranged regularly or irregularly in plan view. In this case, the diameter of the spacer 39 may be in the range of greater than 0 μm and less than 10000 μm, and from the viewpoint of visibility, is preferably in the range of 1 μm to 100 μm. Alternatively, as the spacer 39, a columnar spacer may be used. By arranging the spacers 39 in the void layer G in this way, the thickness of the void layer G can be ensured. This prevents the first film 33 and the second film 34 from sticking to each other, and prevents rainbow-like unevenness and liquid crystal pooling from occurring in the liquid crystal layer 23. Furthermore, instead of or together with the spacer 39, the surface of the first film 33 or the second film 34 may be roughened to prevent the first film 33 and the second film 34 from sticking together. .

(Fourth modification)
16 and 17 show a light control device 10D according to a fourth modification. In the light control device 10D shown in FIGS. 16 and 17, an extension portion 61 is formed by a portion of the first film 33 and a portion of the second film 34. This extension portion 61 projects outward in the surface direction from the light control device 10D. Further, the extension portion 61 has a substantially rectangular shape in plan view, and extends outward from the first glass plate 11 and the second glass plate 12. In this case, the first film 33 has a protrusion piece 33a that protrudes outward, and the second film 34 has a protrusion piece 34a that protrudes outward. The extension portion 61 is constituted by a protruding piece 33a of the first film 33 and a protruding piece 34a of the second film 34. The protruding piece 33a of the first film 33 and the protruding piece 34a of the second film 34, which constitute the extension part 61, have the same shape.

In this modification, a communication hole (ventilation hole) 62 is provided that communicates the void layer G between the first film 33 and the second film 34 with the outside air. This communication hole 62 is formed inside the extension part 61, and specifically, it is provided in the gap between the first film 33 and the second film 34 in the extension part 61. In this case, even if air escapes from the void layer G between the first film 33 and the second film 34 during laminated glass processing, air or a gas such as nitrogen is injected through the communication hole 62 to restore the void layer G. can do. Thereby, it is possible to suppress the formation of a liquid crystal pool in the liquid crystal layer 23 of the light control cell 20. After restoring the void layer G between the first film 33 and the second film 34, the communication hole 62 may be sealed with an adhesive, a liquid intermediate film, or the like. Although the location where the extension portion 61 (extension portion 61) is provided is not limited, it is preferably provided outside the vicinity of the corner of the light control cell 20 in order to suppress the occurrence of wrinkles and the like.

Further, the width W2 (FIG. 17) of the extension portion 61 is preferably 5 mm or more and 40 mm or less, and more preferably 10 mm or more and 20 mm or less. By setting it within the above range, the width W2 of the extension portion 61 can be kept narrow, and liquid crystal accumulation due to distortion of the communication hole 62 can be made less likely to occur. Further, in this modification, it is desirable that the width W3 (FIG. 17) of the frame interlayer films 16 and 17 at least in the portion where the communication hole 62 is formed is narrower than in other portions. Specifically, it is preferable that the width W3 of the frame interlayer films 16 and 17 is approximately 0 mm or more and 10 mm or less. This makes it possible to ensure a wide air passage through the communication holes 62, making it easier to improve liquid crystal accumulation. Note that when the fluid resin layer L (FIG. 13) or the curable resin layer 38 (FIG. 14) is sealed between the first film 33 and the second film 34, the fluid resin layer L or A curable resin layer 38 may also be injected. Further, when a plurality of spacers 39 are provided in the gap layer G between the first film 33 and the second film 34 (FIG. 15), it is preferable to provide the spacers 39 in the extension portion 61 as well. Note that the communication hole 62 may be any hole as long as it allows the void layer G between the first film 33 and the second film 34 to communicate with the outside air. For example, the extension portion 61 may be formed over one entire side of the first film 33 and the second film 34 .

(Fifth modification)
FIG. 18 shows a light control device 10E according to a fifth modification. In the light control device 10E shown in FIG. 18, a communication tube 63 is arranged between the first film 33 and the second film 34. This communication pipe 63 protrudes outward in the plane direction from the light control device 10E. That is, the communication tube 63 has an elongated tube shape and extends outward from the first glass plate 11 and the second glass plate 12. In this case, the communication tube 63 is sandwiched between the first film 33 and the second film 34. Further, a communication hole (ventilation hole) 62A is provided that communicates the void layer G between the first film 33 and the second film 34 with the outside air. This communication hole 62A is formed inside the communication pipe 63 in the radial direction. In this case, even if air escapes from the void layer G between the first film 33 and the second film 34 during laminated glass processing, the void layer G can be restored by injecting air from the communication hole 62A. Thereby, it is possible to suppress the formation of a liquid crystal pool in the liquid crystal layer 23 of the light control cell 20. Furthermore, when the fluid resin layer L (FIG. 13) or the curable resin layer 38 (FIG. 14) is enclosed between the first film 33 and the second film 34, the fluid resin layer L or A curable resin layer 38 may also be injected.

(Sixth modification)
FIG. 19 shows a light control device 10F according to a sixth modification. In the light control device 10F shown in FIG. 19, a portion of the first film 33 and a portion of the second film 34 form a plurality of (two) extension portions 61A, 61B. The two extension parts 61A and 61B each protrude outward in the plane direction from the light control device 10F. That is, each extension part 61A, 61B has a substantially rectangular shape in plan view, and extends outward from the first glass plate 11 and the second glass plate 12. Although the two extension parts 61A and 61B are located on the same side of the light control device 10F, they are not limited to this, and may be located on different sides. In this case, each of the extension parts 61A and 61B is formed by a protruding piece 33a of the first film 33 and a protruding piece 34a of the second film 34, respectively. In this modification, communication holes (vents) 62B and 62C are provided that communicate the gap layer G between the first film 33 and the second film 34 with the outside air. The communication holes 62B and 62C are formed in the extension parts 61A and 61B, respectively, and specifically, they are provided in the gaps between the first film 33 and the second film 34 in the extension parts 61A and 61B. In this way, by providing a plurality of (two) extension parts 61A and 61B, the fluid resin layer L (see FIG. 13 ) or the curable resin layer 38 (FIG. 14), the other extension part 61B (61A) can be evacuated, and the fluid resin layer L or the curable resin layer 38 can be smoothly encapsulated. can. In addition, the configuration of each of the extension parts 61A and 61B is substantially the same as the configuration of the extension part 61 shown in FIGS. 16 and 17.

(Seventh modification)
FIG. 20 shows a light control device 10G according to a seventh modification. In the light control device 10G shown in FIG. 20, the periphery of the first film 33 and the periphery of the second film 34 are bonded to each other by a sealing material 64. This sealing material 64 is provided along the periphery of the void layer G. As the sealing material 64, the same material as the sealing material 32 of the light control cell 20 described above can be used. Polymer resin, etc. can be applied. The width W4 of the sealing material 64 may be 0.1 mm or more and 50 mm or less. This sealing material 64 may be applied along the periphery of the second film 34, and may be formed by laminating the first film 33 and the second film 34 and then curing with, for example, ultraviolet rays (UV) or heat. . Note that the sealing material 64 may be provided on substantially the entire periphery of the first film 33 and the second film 34, or may be provided only on a part of the periphery of the first film 33 and the second film 34. By integrating the first film 33 and the second film 34 in this manner, the rigidity of the first film 33 and the second film 34 is increased, and it is possible to suppress the occurrence of wrinkles and liquid crystal pooling. Furthermore, since the gap layer G between the first film 33 and the second film 34 does not come into direct contact with the frame interlayer film 16, deterioration of the frame interlayer film 16 due to air or the like is suppressed. Furthermore, since the first film 33 and the second film 34 are integrated, the process of laminating them can be simplified. In addition, in FIG. 20, since the distance between the first film 33 and the second film 34 can be adjusted by the sealing material 64, the light reflected by the first film 33 and the light reflected by the second film 34 do not interfere with each other. , it is possible to prevent rainbow unevenness from occurring. In this case, a spacer (for example, similar to the bead spacer 31 described above) may be mixed into the sealing material 64 to adjust the distance between the first film 33 and the second film 34. Moreover, when the fluid resin layer L (FIG. 13) or the curable resin layer 38 (FIG. 14) is enclosed between the first film 33 and the second film 34, the first film 33 and the second film 34 are It is possible to suppress leakage of the fluid resin layer L or the curable resin layer 38 from between.

In FIG. 20, an extension portion 61 is formed by a portion of the first film 33 and a portion of the second film 34. Further, in the extension portion 61, the first film 33 and the second film 34 are bonded to each other by a sealing material 64. The sealing material 64 is formed on both ends of the extension portion 61 in the width direction. Note that the sealing material 64 is not provided at the base end portion of the extension portion 61, and communication between the communication hole 62 and the void layer G is not obstructed. In this modification, when enclosing the fluid resin layer L or the curable resin layer 38 from the extension part 61 into the space between the first film 33 and the second film 34, with this space under negative pressure, By immersing the tip of the extension portion 61 into a container containing the fluid resin layer L or the curable resin layer 38, the fluid resin layer L or the curable resin layer 38 can be smoothly enclosed in the space. Note that, among the four sides of the first film 33 and the second film 34, the sealing material 64 may be formed in a U-shape in plan view along three sides where the extension portion 61 does not exist. In this case, the entire sides of the first film 33 and the second film 34 where the extension portion 61 is present are immersed in a container containing the fluid resin layer L or the curable resin layer 38, and the first film 33 and the second film 34 are A fluid resin layer L or a curable resin layer 38 may be enclosed in the space between the two.

(Eighth modification)
FIG. 21 shows a light control device 10H according to an eighth modification. In the light control device 10H shown in FIG. 21, a portion of the frame interlayer films 16 and 17 is cut out to form a communication hole (ventilation hole) 62D. This communication hole 62D communicates the void layer G between the first film 33 and the second film 34 with the outside air. This communication hole 62D has a shape as if the frame intermediate films 16 and 17 were removed in the width direction. Further, the communication hole 62D may not be formed in both the frame intermediate films 16 and 17, but may be formed in only one of the frame intermediate films 16 and 17. In this case, even if air escapes from the void layer G between the first film 33 and the second film 34 during laminated glass processing, the void layer G can be restored by injecting air from the communication hole 62D. Thereby, it is possible to suppress the formation of a liquid crystal pool in the liquid crystal layer 23 of the light control cell 20. Further, when the fluid resin layer L (FIG. 13) or the curable resin layer 38 (FIG. 14) is sealed between the first film 33 and the second film 34, the fluid resin layer L or A curable resin layer 38 may also be injected. Further, it is preferable that the communication hole 62D is closed using the material of the frame interlayer films 16 and 17 or a sealing material after the fluid resin layer L or the curable resin layer 38 is injected.

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

10, 10A to 10H Light control device 11 First glass plate 12 Second glass plate 13 First intermediate film 14 Second intermediate film 16 Picture frame intermediate film (third intermediate film)
17 Picture frame interlayer film (fourth interlayer film)
20 Light control cell 21 First laminate 22 Second laminate 23 Liquid crystal layer 24 First base material 25 First transparent electrode 26 First alignment layer 27 Second base material 28 Second transparent electrode 29 Second alignment layer 30 Laminate 31 Bead spacer 32 Sealing material 33 First film 34 Second film 35 External electrode substrate 36 Protruding piece for electrode 37 Adhesive layer

Claims (7)

a first transparent substrate;
a second transparent substrate;
a light control cell disposed between the first transparent substrate and the second transparent substrate and having a liquid crystal layer ;
comprising a first film and a second film disposed between the light control cell and the first transparent substrate,
the second film is adhered to the light control cell;
A curable resin layer that holds the liquid crystal layer of the light control cell on the second transparent substrate side is provided between the first film and the second film ,
A light control device including a communication hole that communicates between the first film and the second film and the outside air . The light control device according to claim 1 , wherein the second film is bonded to the light control cell with an interlayer film or a transparent adhesive resin. An extension part is formed by a part of the first film and a part of the second film, and the extension part extends outward from the first transparent substrate and the second transparent substrate in plan view, and the extension part extends outward from the first transparent substrate and the second transparent substrate in a plan view. The light control device according to claim 1 or 2 , wherein the hole is formed in the extension. The light control device according to any one of claims 1 to 3 , wherein the communication hole is sealed. A frame-shaped intermediate film formed so as to surround the periphery of the light control cell in plan view is disposed between the first transparent substrate and the second transparent substrate, and the communication hole is formed in the frame-shaped intermediate film. The light control device according to claim 1 or 2 , which is formed by cutting out a part of an intermediate film. a first transparent substrate, a second transparent substrate, a light control cell disposed between the first transparent substrate and the second transparent substrate, and a light control cell disposed between the light control cell and the first transparent substrate. a step of producing a laminate having a first film and a second film;
a step of temporarily press-bonding the first transparent substrate , the first film, the second film, the light control cell, and the second transparent substrate of the laminate together;
After the step of temporarily press-bonding, the second film is permanently press-bonded to the dimming cell by heating and pressurizing,
A method for manufacturing a light control device, wherein a curable resin layer is provided between the first film and the second film after the temporary pressure bonding step. The method for manufacturing a light control device according to claim 6 , wherein the curable resin layer is cured after filling a space between the first film and the second film.