WO2008007788A1 - Structure and process for producing the same - Google Patents

Abstract

A structure having a complicated curved shape; and a process for producing the structure. In a given reduced-pressure atmosphere, a liquid-crystal material and a spacer are disposed in a gap hermetically surrounded by first and second transparent substrates having a curved shape and a sealing material to thereby produce a liquid-crystal cell (first step). This liquid-crystal cell is exposed to an atmospheric-pressure atmosphere to cause the liquid-crystal material to fill the space and at least one of the transparent substrates to deform due to the pressure change and thereby make the cell gap almost even (second step).

Description

 Specification

 Structure and manufacturing method thereof

 Technical field

 TECHNICAL FIELD [0001] The present invention relates to a structure and a manufacturing method thereof, and more particularly to a liquid crystal element suitable for a light control roof glass, a light control side window, and the like of an automobile and a method of manufacturing the same.

 Background art

 [0002] Conventionally, a dimming laminated glass in which an electrification chromic glass or a liquid crystal dimming film is sandwiched between two glass plates has been proposed in order to provide the sunroof for automobiles with a dimming function. In Patent Document 1, a liquid crystal element made by sandwiching a liquid crystal layer between two PET (polyethylene terephthalate) films is sandwiched between two interlayer films made of EVA (ethylene-vinyl acetate copolymer) modified resin. Further, a sunroof made by sandwiching this with two glass plates is disclosed.

 Patent Document 1: Japanese Patent Laid-Open No. 6-18856

 Disclosure of the invention

 Problems to be solved by the invention

[0004] However, the light control glass window made using the electoric chromic glass has a problem that it is difficult to change the light transmission Z non-transmission state in a short time. In addition, as disclosed in Patent Document 1, a structure in which a sheet-like liquid crystal element made by sandwiching a liquid crystal layer with a resin film is sandwiched between two glass plates has a complicated glass plate shape. In the case of a curved shape, it is difficult to cause the liquid crystal element to sufficiently follow the shape of the glass plate, and there is a problem that wrinkles are likely to occur in the periphery of the liquid crystal element.

 Moreover, the following methods are known as a method of manufacturing a liquid crystal element.

 [Suction method] Two or more notches are provided in the sealing material portion of the cell produced by bonding a pair of substrates through a sealing material, and one of the notches is immersed in the liquid crystal composition and sucked from the other. how to.

[Vacuum injection method] Under reduced pressure conditions, the notch of the cell with one or more notches in the sealing material is immersed in the liquid crystal composition, and returned to atmospheric pressure in the soaked state. A method of filling a liquid crystal composition in a cell with a differential pressure between an internal pressure and an atmospheric pressure.

 [ODF (one-drop-fill) method] A predetermined amount of a liquid crystal composition is dropped on the surface of one of a pair of substrates, and then the substrate on which the liquid crystal composition is dropped under reduced pressure and the other This is a method in which the substrate is bonded together with a sealing material. The ODF method is also called a liquid crystal dropping method or a vacuum dropping method.

 Among these methods, the ODF method is effective as a method for manufacturing a large-sized liquid crystal element because the liquid crystal composition can be filled in the cell in a short time. The liquid crystal element used for the light control glass window is also larger than the liquid crystal element applied to an electronic device or the like, and the ODF method is effective as a manufacturing method thereof. On the other hand, a light control glass window used as a vehicle window (such as the sunroof described above) may have a curved shape instead of a flat plate shape. A curved substrate is made by bending a flat substrate, but the shape of the two curved substrates may not match due to manufacturing process constraints such as bending accuracy. When a liquid crystal element is manufactured using two curved substrates whose shapes do not match, there is a problem that it is difficult to make the distance between the substrates in the liquid crystal element constant.

[0005] The present invention solves such problems, and an object thereof is to provide a structure (in particular, a liquid crystal element) having a curved shape and a method for manufacturing the structure.

 Means for solving the problem

 In order to achieve the above object, the present invention provides the following inventions.

 [1] A first curved substrate, a second curved substrate having substantially the same shape as the first curved substrate and facing the first curved substrate, and all peripheral portions of the two curved substrates A sealing material that is provided on a circumference and that joins the curved substrates with a predetermined distance and seals a gap between the curved substrates; and a gap sealed by the curved substrates and the sealing material. A combination of the first and second curved substrates constituting the structure so that the surfaces facing the first and second curved substrates are substantially parallel to each other. Is a combination in which the distance between the two curved substrates at the end of the curved substrate is smaller than the maximum value of the distance between the two curved substrates. A structure characterized by that.

[0007] [2] a first curved substrate, the first curved substrate having substantially the same shape as the first curved substrate A second curved substrate facing the plate, a sealing material provided on the entire periphery of the peripheral portion of the two curved substrates, and joining the curved substrates with a predetermined distance therebetween and sealing a gap between the curved substrates And a functional material filled in a gap sealed with both the curved substrates and the sealing material, wherein a combination of the first and second curved substrates constituting the structure is provided. When the first and second curved substrates are overlapped so that the opposing surfaces are substantially parallel and are brought into contact with each other at at least one point in the opposing surfaces or the peripheral edges of the two curved substrates, A structure having a combination in which the distance between the curved substrates is 0.5 mm or less.

 [3] A first curved substrate, a second curved substrate having substantially the same shape as the first curved substrate and facing the first curved substrate, and the two curved substrates. A sealing material which is provided on the entire periphery of the peripheral portion and joins the curved substrates with a predetermined distance and seals a gap between the curved substrates; and a gap sealed between the curved substrates and the sealing material. A combination of the first and second curved substrates constituting the structure, and the surfaces facing the first and second curved substrates are substantially parallel to each other. When the two curved substrates are overlapped and brought into contact with each other at at least one point in the opposite plane or the peripheral edge of the curved substrates, the distance between the curved substrates at the end of the curved substrate is opposed to the curved substrates in the structure. The combination must be 20 times or less the predetermined distance separating the surfaces. A structure characterized by

 [4] A distribution of distances separating the opposing surfaces of both curved substrates by correcting at least one of the curved substrates by atmospheric pressure so that the opposing surfaces of both curved substrates are corrected to a predetermined shape. The structure according to any one of [1] to [3], wherein is substantially uniform.

 [5] The structure according to any one of [1] to [4], wherein the structure has a constant distance within a range of a distance force of ~ 30 m separating the opposing surfaces of both curved substrates.

 [6] A spacer having a predetermined size is disposed in the gap between the opposing surfaces of the two curved substrates, and the distance between the opposing surfaces of the two curved substrates is maintained at a predetermined constant distance. The structure according to any one of [1] to [5].

 [7] The structure according to any one of [1] to [6], wherein the functional material includes a liquid.

[8] At least one of the two curved substrates is a transparent curved substrate, Each of the opposing surfaces has an electrode layer, and the functional material is a material containing liquid crystal,

The structure according to any one of [1] to [7].

 [9] A first curved substrate, a second curved substrate having substantially the same shape as the first curved substrate and facing the first curved substrate, and the two curved substrates. A sealing material which is provided on the entire periphery of the peripheral portion and joins the curved substrates with a predetermined distance and seals a gap between the curved substrates; and a gap sealed between the curved substrates and the sealing material. A functional material filled with the first and second curved substrates and a seal disposed on the entire periphery of the peripheral portions of the two curved substrates in a predetermined reduced-pressure atmosphere. A first step of manufacturing a functional material holder by enclosing the functional material in a gap sealed with a material, and exposing the functional material holder to an atmosphere of atmospheric pressure to bring the functional material into the gap And the pressure is applied to at least one of the first and second curved substrates. And a second step of manufacturing the structure by making the distance separating the opposing surfaces of the two curved substrates in the functional material holder substantially uniform by deforming them by the change in the structure. Manufacturing method.

 [0012] [10] In the first step, a sealing material is provided on the entire periphery of one of the curved substrates, the functional material is supplied into a region surrounded by the sealing material, and the reduced pressure atmosphere is used. The other curved substrate is pressed against the surface of the one curved substrate to spread the functional material and form a sealed space in which the functional material is sandwiched in the gap between the two curved substrates. [9] The method for producing a structure according to [9].

 [0013] [11] The combination of the first and second curved substrates constituting the structure is such that the first and second curved substrates are superposed and curved so that the surfaces facing each other are substantially parallel. The combination according to [9] or [10], wherein the distance between the curved substrates at the edge of the curved substrate is 0.5 mm or less when the substrates are brought into contact with each other at at least one point in the opposite plane or the periphery of the substrate. Method for manufacturing the structure.

[0014] [12] The combination of the first and second curved substrates constituting the structure is such that the first and second curved substrates are superposed and curved so that the surfaces facing each other are substantially parallel. Where contact is made at at least one point on the opposite or in the peripheral surface of the substrate, the distance between the curved substrates at the end of the curved substrate separates the opposing surfaces of the curved substrates in the structure. The method for producing a structure according to any one of [9] to [11], which is a combination that is 20 times or less the constant distance.

 [13] The structure according to any one of [9] to [12], wherein the structure is a constant distance within a range of a distance force ^ to 30 m separating the opposing surfaces of both curved substrates. Body manufacturing method.

 [14] The method for producing a structure according to any one of [9] to [13], wherein a spacer having a predetermined size is enclosed together with the functional material.

 [15] The method for producing a structure according to any one of [9] to [14], wherein the functional material is a material containing a liquid.

 [16] At least one of the two curved substrates is a transparent curved substrate, has an electrode layer on each of the opposing surfaces of the two curved substrates, and the functional material is a material containing liquid crystal. [15] The method for producing a structure according to any one of the above.

 The invention's effect

 [0017] According to the present invention, it is possible to provide a structure (particularly a liquid crystal element) having a functional material sandwiched between two curved substrates. Further, even when a liquid crystal element is manufactured using two curved substrates whose shapes do not completely match, the distance between the substrates in the liquid crystal element can be kept constant.

 Brief Description of Drawings

 [0018] [FIG. 1] (a) A plan view showing one embodiment of a liquid crystal device according to the present invention,) a cross-sectional view taken along line 8-8 ', (c) a cross-sectional view taken along line BB', (d) FIG.

 FIG. 2 is a flowchart showing one embodiment of a vacuum lamination process according to the present invention.

 3A is a plan view showing a transparent substrate 101, and FIG. 3B is a plan view showing a transparent substrate 102. FIG.

 FIG. 4 (a) is a partially cutaway sectional view showing a vacuum chamber, and (b) is a top view showing a cradle.

 FIG. 5 (a) to (d) are cross-sectional views schematically showing the state of vacuum lamination.

 FIG. 6 is a flowchart showing a bending process of a transparent substrate.

 FIG. 7 is an explanatory view schematically showing a bending process of a transparent substrate.

 FIG. 8 is a partially cutaway side view showing one embodiment of a bending system.

 FIG. 9 is a top view showing one embodiment of a shuttle used for transporting a transparent substrate, (b)

FIG. 4 is a cross-sectional view taken along line D-D ′. [Fig. 10] (a) Side view of two superimposed transparent substrates after bending, and (b) Measurement lines and measurement points used to measure the gap between two transparent substrates. It is explanatory drawing shown.

 [FIG. 11] (a) and (b) are graphs showing measurement results according to an example of the present invention.

[FIG. 12] (a) and (b) are graphs showing measurement results of comparative examples.

Explanation of symbols

 100: Liquid crystal element

 101, 102: Transparent substrate

 101a, 102a: Transparent electrode

 101a, ゝ 102b ': extraction electrode

 101b, 102b: Insulating film

 101c, 102c: Alignment film

 103: Seal material

 104: Composite layer

 105: Spacer

 200: Vacuum laminator

 201: cradle

 201a, 201b, 201c: Pin

 202: Mold

 203: Vacuum Champer

 300: Bending molding system

 301: Heating furnace

 302: Elevator

 303: Door

 304: Chanore

 305: Ring frame

 306: Transport mechanism

BEST MODE FOR CARRYING OUT THE INVENTION The present invention is preferably applied to a substrate having an area of 0.04 to ² m ² . A substrate having an area in this range corresponds to a substrate having a size of approximately 200 mm × 200 mm to: LOOOmm × 1600 mm (preferably 300 mm × 300 mm to 800 mm × 1600 mm). The curved open shape means that the radius of curvature of one side of the substrate is in the range of 800R to 5000R. The thickness of the substrate is l ~ 3mm.

 The functional material in the present invention is preferably a material containing a liquid. If the functional material in the structure is a liquid-containing material, the shapes do not match sufficiently! 作 製 When a structure is made using two curved substrates, the distance between the curved substrates is a certain size. Not only is it difficult to make a seal, but the seal is insufficient, which can lead to liquid leakage and air ingress. The functional material in the present invention may have only a liquid such as a liquid crystal substance. Further, it may be a liquid and solid material such as a liquid crystal Z cured product composite described later, or a material containing liquid and solid such as a solid fine particle dispersion liquid.

 In the present invention, the functional material is preferably a material containing a liquid and a large structure. Conventionally, it has been difficult to manufacture large structures that contain liquid and are curved. In particular, it is difficult to manufacture a structure (such as a liquid crystal element described later) in which the gap between two large curved substrates is extremely thin with a thickness of several tens / zm or less and requires a uniform gap. It was. The present invention provides such a structure and a method by which it can be produced.

[0021] Hereinafter, the present invention will be described taking as an example an embodiment in which the structure is a liquid crystal element. In the liquid crystal element, at least one of the curved substrates needs to be a transparent curved substrate, and in a liquid crystal element usually used for a light control glass window, a transparent curved substrate is used for both curved substrates. Hereinafter, the transparent curved substrate in the liquid crystal element is also referred to as a transparent substrate. In addition, the liquid crystal element has an electrode layer on each of the opposite surfaces of the two curved substrates in order to drive the liquid crystal. At least one of the two electrode layers needs to be a transparent electrode layer. Hereinafter, the transparent electrode layer is also referred to as a transparent electrode.

FIG. 1 (a) is a plan view showing one embodiment of the liquid crystal element of the present invention, FIG. 1 (b) is a cross-sectional view taken along line AA ′, FIG. 1 (c) is a cross-sectional view taken along line BB ′, FIG. 4D is a cross-sectional view taken along the line CC ′. In FIG. 1 (a), the main components of the liquid crystal element 100 are transparent substrate 101, transparent electrode 101a, insulating film 101b, alignment film 101c, transparent substrate 102, transparent electrode 102a, extraction electrode 102a ′, insulating A film 102b, an alignment film 102c, a sealing material 103, a spacer 105, and a composite layer 104 are disclosed.

 The transparent substrate 101 and the transparent substrate 102 are disposed so as to face each other, and a sealing material is provided on the entire periphery of the peripheral portion of both transparent substrates. Both the transparent substrates are joined to each other at a predetermined distance by this sealing material, and the gap between the transparent substrates is sealed. In the present invention, “the sealing material is provided on the entire periphery of the peripheral portion of the substrate” means that the position where the sealing material is provided as long as a gap sealed between the two curved substrates and the sealing material can be formed. It can be determined as appropriate, meaning that there may be places where the seal material does not reach the edge of the curved substrate (the ridgeline formed by the intersection of the surfaces). For example, as shown in FIG. 1C, the edge of the sealing material 103 coincides with the edge of the transparent substrate 101 for the transparent substrate 101 in a certain part of the liquid crystal element. However, with respect to the transparent substrate 102, the edge of the sealing material 103 is located inside the edge of the transparent substrate 102. The transparent substrates 101 and 102 and the sealing material 103 form a sealed gap while maintaining the positional relationship as described above. In the present invention, such a mode is also “sealed around the entire periphery of the substrate. Materials will be provided. "

 In the gap sealed by the two transparent substrates and the sealing material, a composite layer 104 of liquid crystal and cured product is sandwiched as a layer of liquid crystal material (hereinafter referred to as composite of liquid crystal and cured product). The body is also referred to as “liquid crystal Z cured product composite” or simply “composite.”) Instead of the composite layer 104, a liquid crystal-only layer containing no cured product may be used. The transparent substrates 101 and 102 are electrically insulating transparent substrates. As the transparent substrate, for example, a glass substrate or a resin substrate such as polycarbonate or acrylic resin is used. The thickness of these glass substrates is usually a constant thickness in the range of 0.4 to LOmm. When the liquid crystal element of the present invention is used for a display device or the like, an opaque substrate may be used as one of the transparent substrates 101 and 102.

According to the present invention, using the transparent substrate 101 and the transparent substrate 102 having a curved shape, a liquid crystal element in which the distance separating the opposing surfaces between the two transparent substrates is maintained at a predetermined constant distance is manufactured. be able to. Hereinafter, the distance separating the opposing surfaces of both transparent substrates in the liquid crystal element is also referred to as a cell gap. The shape of the two curved substrates is not necessarily the same shape as the constraint force in the manufacturing process of the bending process. Therefore, when the two curved substrates are overlapped so that the opposing surfaces are substantially parallel, a gap is generated between the substrates, and the cell gap may not be a predetermined constant distance when a liquid crystal element is used. Concerned. However, according to the present invention, it is possible to produce a liquid crystal element in which the cell gap is maintained at a predetermined constant distance even when a curved substrate whose shape does not completely match is used.

 In the present invention, since it is easy to produce a liquid crystal element in which the cell gap is maintained at a predetermined constant distance, the transparent substrate 101 and the transparent substrate 102 each having a curved shape have substantially the same shape. Is preferred. Here, “substantially the same shape” means that (A) the combination of the transparent substrate 101 and the transparent substrate 102 constituting the liquid crystal element is such that the surfaces facing the transparent substrate 101 and the transparent substrate 102 are substantially parallel. In a combination in which the distance between the curved substrates at the end of the curved substrate is smaller than the maximum value of the distance between the curved substrates when they are overlapped and brought into contact with each other at least one point in the opposite or peripheral edges of both transparent substrates. (B) The combination of the transparent substrate 101 and the transparent substrate 102 constituting the liquid crystal element is such that the transparent substrate 101 and the transparent substrate 102 are overlapped so that the surfaces facing each other are substantially parallel to each other. When contact is made at at least one point on the opposite surface or the periphery, the gap between the curved substrates at the edge of the curved substrate is 0.5 mm or less, or (C) the liquid crystal element is constituted Transparent substrate 101 and Combined force of the transparent substrate 102 When the transparent substrate 101 and the transparent substrate 102 are overlapped so that the opposing surfaces are substantially parallel, and contact is made at least at one point in the opposing surface or the peripheral edge of both transparent substrates This means that the distance between the curved substrates at the end of the curved substrate is a combination that is not more than 20 times the predetermined distance separating the opposing surfaces of the curved substrates in the structure.

 In the present invention, the combination of the transparent substrates 101 and 102 is the combination of the above (A), (B) or (C), so that the liquid crystal is formed using two curved substrates whose shapes do not completely match. Even when the element is manufactured, the distance separating the opposing surfaces of the two substrates in the liquid crystal element can be made substantially uniform.

In the structure of the present invention, in order to make the distance separating the opposing surfaces of both substrates uniform The transparent substrates 101 and 102 must have the same shape on the opposing surfaces. When only the transparent substrate 101 and the transparent substrate 102 are overlapped and brought into contact with each other so that the opposing surfaces are substantially parallel to each other, if the opposing surfaces have the same shape, the opposing surfaces theoretically contact each other. However, in actuality, there are parts that do not come into contact due to the difference in shape. Therefore, it is necessary to elastically deform the non-contacting portion so that the opposing surfaces have substantially the same shape. Similarly, when the spacing between the opposing surfaces of the transparent substrate 101 and the transparent substrate 102 is made uniform via a spacer or the like, the portion with the wide spacing is similarly deformed by elastically deforming the substrate. Must be an interval. In this case, if a portion having a large interval exists at the end portion or the peripheral portion of the substrate, a stress for expanding the interval remains at the end portion or the peripheral portion of the assembled structure. If this stress is large, the seal may be broken or deformed. In particular, during the manufacturing process as described later, when the functional material holder is moved from the reduced pressure atmosphere to the atmospheric pressure atmosphere while the sealing material is in an uncured state, the seal is likely to be broken. On the other hand, if the gap is wide and there is no part at the edge or peripheral edge of the substrate, the stress that attempts to widen the gap at the edge or peripheral edge of the assembled structure is reduced, and the seal is broken. And the risk of deformation is reduced.

 In (A), since the distance between the curved substrates at the end of the curved substrate is smaller than the maximum distance existing at the other portions, the stress in the direction in which the distance between the curved substrates is widened at the curved substrate end. There is little risk of concentration. Therefore, it is possible to obtain a structure having opposing surfaces that have substantially the same shape due to elastic deformation of the curved substrate (that is, the spacing between the opposing surfaces is uniform), and the seal is broken or deformed in the structure. There is little risk of this.

Wherein (B), the case the combination of the transparent substrate 101 and the transparent substrate 102 is less than 0. 5m ² 0. 04m ² or more areas of force transparent substrate depends on the area and the curvature of the transparent substrate, both a transparent substrate periphery A combination with an interval of 50 m or less is preferred, and a combination with 30 m or less is particularly preferred. In addition, when the area of the transparent substrate is 0.5 m ² or more and 2 m ² or less, a combination in which the distance between the peripheral edges of both transparent substrates is 0.4 mm or less is preferable, and a combination in which the distance between the transparent substrates is 0.2 mm or less is particularly preferable.

In the above (C), the distance between the peripheral edges of both transparent substrates is the same as A combination that is 15 times or less of the predetermined distance separating the opposing surfaces is preferred, and a combination that is 10 times or less is particularly preferred.

 It is particularly preferable that the two transparent substrates having a curved shape are preferably smaller than or equal to the distance between the two substrates in the space 1S plane between the two curved substrates at the edge of the curved substrate. The smaller the distance between the two substrates at the end of the curved substrate is, the easier it is to seal the periphery. The distance between the two substrates is not necessarily monotonously decreasing from the in-plane toward the end, and the distance between the two substrates is greater than the center of the surface. There may be big points. Furthermore, the distance between the two substrates at the end of the curved substrate does not need to be smaller than the distance between the two substrates at all points in the plane. There may be a growing point.

 In the present invention, the combination of the transparent substrates 101 and 102 is the condition of both (A) and (B), the condition of both (A) and (C), or the condition (B) and (C). Both of the above conditions may be satisfied, and the above three conditions (A) to (C) may be satisfied.

 On the surface of the transparent substrate 101 facing the transparent substrate 102, a substantially rectangular transparent electrode 101a that is slightly smaller than the transparent substrate 101 is formed. Similarly, a substantially rectangular transparent electrode 102b that is slightly smaller than the transparent substrate 102 is formed on the surface of the transparent substrate 102 facing the transparent substrate 101. The transparent electrodes 101a and 102a are made of, for example, ITO (Indium Tin Oxide). However, when the liquid crystal element 100 is used as a display panel, a reflective electrode of A1 (aluminum) or a dielectric multilayer film may be used for one of the transparent electrodes 101a and 102a. The pattern shape of the transparent electrodes 101a and 102a is appropriately selected depending on the use of the liquid crystal element 100, and may be a solid electrode as described above, or may be a stripe shape in which the transparent electrodes 101a and 102a are arranged orthogonal to each other. Furthermore, it may be a specific shape such as a mark, a character, a letter, a number, or a symbol.

Insulating films 101b and 102b are formed on the transparent electrodes 101a and 102a, respectively. Further, alignment films 101c and 102c are formed on the insulating films 101b and 102b, respectively. The insulating films 101b and 102b are formed by firing a sol-gel solution of silica and titania. The alignment films 101c and 102c are made of polyimide or the like . The alignment films 101c and 102c are appropriately selected depending on the purpose, which may or may not be subjected to a rubbing treatment. Here, at least one of the alignment films 101c and 102c is preferably an alignment film that aligns the liquid crystal perpendicularly to the inner surfaces of the transparent substrates 101 and 102. Specifically, an alignment film having a pretilt angular force of ½0 ° or more is preferable. Thereby, the transmittance | permeability in a permeation | transmission state can be made high.

 [0026] Sealing material 103 is provided around the entire periphery of transparent substrates 101 and 102, and joins transparent substrates 101 and 102 at a predetermined distance and seals the gap between the transparent substrates 101 and 102. 102, as well as a gap sealed with the sealing material 103 is formed. As the material of the sealing material 103, for example, an ultraviolet curable resin or a thermosetting resin is used. Specifically, acrylic resin, epoxy resin, silicone resin or urethane resin can be used. Moreover, the spacer mentioned later may be contained in the sealing material.

 Spacer 105 is disposed in the gap between the opposing surfaces of transparent substrates 101 and 102, and maintains a predetermined constant distance between the opposing surfaces of both transparent substrates in the liquid crystal element (hereinafter referred to as liquid crystal element). The distance between the opposing surfaces of both transparent substrates in the crystal element is also referred to as a cell gap). The spacers 105 are uniformly arranged in the gap. The cell gap generally corresponds to the diameter of the spacer 105, and a value of 1 to 50 m is preferable, and a value of 1 to 30 m is more preferable, and 2 to 20 m is particularly preferable. If the cell gap is too small, the contrast will decrease, and if it is too large, the drive voltage will increase.

 Spacer 105 is a particle that also has a hard material force such as glass, silica, or cross-linked acrylic resin. In addition, for the purpose of eliminating the influence of the displacement of both transparent substrates due to vibration, etc. in the situation where they are transported or used as liquid crystal elements (as finished products) A spacer whose surface is coated with rosin may be used. The shape of the spacer 105 is not limited to a spherical shape, but may be a fiber shape. Further, a rib-shaped member may be formed on either one of the substrates 101 or 102 and used as a spacer.

The composite layer 104 is sealed in a gap sealed with the transparent substrates 101 and 102 and the sealing material 103. The composite layer 104 is made of a composite of a liquid crystal and a cured product. The composite layer 104 has a liquid crystal material containing a liquid crystal and a curable compound sealed in the gap. It is preferable that the composite strength obtained by curing the curable compound in the liquid crystal material is obtained by polymerization.

 [0029] As the liquid crystal constituting the composite, nematic liquid crystal or the like, which is an electric field drive type material, is used. As the liquid crystal, two or more kinds of liquid crystals may be used in combination. The polarity of the dielectric anisotropy of the liquid crystal may be positive or negative. For the purpose of electric field display, it is preferable to use liquid crystal with negative dielectric anisotropy. This is because the transmittance in the transparent state can be increased by using a liquid crystal having a negative dielectric anisotropy and making the alignment direction of the liquid crystal molecules perpendicular to the transparent substrate by the vertical alignment film. In order to reduce the drive voltage, it is preferable that the absolute value of dielectric anisotropy is large.

 [0030] The composite layer 104 used in the liquid crystal element according to the embodiment of the present invention includes at least one bifunctional polymerizable compound (A) represented by the following formula (1) and the following formula (2 It is preferably a composite layer obtained by polymerizing a liquid crystal material containing at least one of the bifunctional polymerizable compound (B) represented by formula (B) and the non-polymerizable liquid crystal.

[0031] A ¹ — R ¹ — X ¹ — (Q ³ — Z ² ) — Q ¹ — Z ¹ — Q ² — (Z ³ — Q ⁴ ) — X ² — R ² — A ² (1)

 P q

[0032] A ³ — R ³ — A ⁴ (2)

 [0033] The bifunctional polymerizable compound (A) is a component that forms a skeleton portion having rigidity in the composite. On the other hand, the bifunctional polymerizable compound (B) is a component that forms a flexible portion that can play a role of shock absorption in the composite. By combining these compounds having different physical properties, a layer 104 of a liquid crystal Z cured product composite suitable for the liquid crystal element 100 can be obtained. Of course, the curable compound (polymerizable compound) for forming the cured product is not limited to this.

 [0034] The bifunctional polymerizable compound (A) is a compound having a mesogenic structure, and the following first to third embodiments are preferable among the compounds represented by the formula (1).

 [First embodiment of bifunctional polymerizable compound (A)]

 In the first embodiment, the symbols in formula (1) have the following meanings.

A \ A ² each independently represents atalyloxy group, methacryloyloxy group or

-Ruether group.

Q \ Q ² , Q ³ , and Q ⁴ are each independently 1, 4 -phenylene Group or 1,4 cyclohexylene group.

X ¹ and X ² are each independently a single bond, an oxygen atom or an ester bond.

R \ R ² each independently has a single bond or one or more etheric oxygen atoms between carbon atoms, and may be a linear or branched alkylene group having 2 to 20 carbon atoms. It is.

zzz ³ is independently a single bond, c (= o) —o—, -oc (= o)

—CH 2 —CH 1, C≡C 1, —CH 2 O—, —O—CH 1.

 2 2 2 2

 p and q are both zero or one is 0 and the other is 1.

[Second embodiment of bifunctional polymerizable compound (A)]

 In the second embodiment, the symbols in formula (1) have the following meanings.

A \ A ² are each independently, Ru Atari Roy Ruo alkoxy group or a methacryloyloxy Ruo alkoxy group der.

Q \ Q ² is an optionally substituted 1, 4 -phenylene group, and Q ³ and Q ⁴ are each independently an optionally substituted 1, 4 phenol. -Len group or 1,4 cyclohexane group.

X ¹ , X ² and R ¹ R ² have the same meaning as described above.

zz ² and z ³ are each independently a single bond, c (= o) — o—, — o— c (= o) —,

— CH—CH or C≡C.

 twenty two

 p and q are both zero or one is 0 and the other is 1.

[Third Embodiment of Bifunctional Polymerizable Compound (A)]

 In the third embodiment, the symbols in the formula (1) have the following meanings.

A \ A ² are both Atari Roy Ruo alkoxy group.

Q \ Q ² is an optionally substituted 1, 4 -phenylene group, and Q ³ and Q ⁴ are each independently an optionally substituted 1, 4 phenol. -Len group or 1,4 cyclohexylene group.

X ¹ and X ² have the same meaning as described above.

Each R ² is independently a linear or branched alkylene group having 2 to 20 carbon atoms. Z ¹ is a single bond, C (= 0) — OOC (= 0) -CH -CH or C

 twenty two

≡c is one, and z ² and z ³ are both single bonds.

 p and q are both zero or one is 0 and the other is 1.

[0038] As a specific example of the above-mentioned bifunctional polymerizable compound (A), a compound of the following formula (3) can be exemplified.

[0039] [Chemical 1]

[0040] The bifunctional polymerizable compound (i) may be a liquid crystal compound or a non-liquid crystal compound. As the bifunctional polymerizable compound (Α), only a non-liquid crystalline bifunctional polymerizable compound (よ) or a liquid crystalline bifunctional polymerizable compound (Α) is used. However, a non-liquid crystalline bifunctional polymerizable compound (Α) and a liquid crystalline bifunctional polymerizable compound (Α) may be used in combination.

 [0041] The bifunctional polymerizable compound (Β) is a compound having no mesogenic structure and is preferably a compound represented by the following formula (2).

Α ³ -R ³ -Α ⁴ (2)

Α ³ and Α ⁴ are each independently an allyloyloxy group, a methacryloyloxy group or a butyl ether group.

R ³ is R ⁴ — or one (R ⁵ —0) —R ⁵ —.

However, R ⁴ and R ⁵ have the following meanings (i) or (ii).

(i) R ⁴ is a linear or branched alkylene group having 2 to 20 carbon atoms, R ⁵ is a linear or branched alkylene group having 2 to 8 carbon atoms, and n is an integer of 1 to 10 It is.

 ()! ^ Is a straight-chain alkylene group having 2 to 20 carbon atoms, and is — (di 11) —, —CH— C

 2 r 2

H (CH) CH— CH— CH (CH) — or one CH— CH— C (CH) —

3 2 2 3 2 2 3 2 (where r is an integer from 2 to 5), n is an integer from 1 to 10.

[0042] The bifunctional polymerizable compound (B) may be used alone or in combination of two or more. May be. Examples of the bifunctional polymerizable compound (B) include compounds represented by the following formula (4).

[0043] [Chemical 2]

Η \

 CH

² ^ 0- (CH ₂ CH ₂ CH ₂ CH ₂ 0) ₉ — C… ( ₄₎

 CH-C 0

 , \

 0

The bifunctional polymerizable compound (B) has a polymerizable group A ³ , A ⁴ and a divalent group R ³ linking the polymerizable group A ³ and A ⁴ . As R ³ , it is preferable to select a group having a portion in which atoms constituting R ³ are connected by a single bond and having a high degree of freedom of rotation in the molecule. By comprising in this way, the softness | flexibility of the hardened | cured material obtained by hardening reaction can be improved. In addition, the polymerization phase separation can proceed smoothly.

[0045] A ^3, carbon atoms of the radicals R ³ present between A ^4, the number of etheric oxygen atoms many more, flexibility of the cured product obtained after hardening is improved. On the other hand, the greater the number of these atoms, the lower the compatibility with the liquid crystal when preparing the liquid crystal material. When the ODF method is employed, the number of carbon atoms of the bifunctional polymerizable compound (B) is 8 or more, preferably 11 or more in consideration of volatility. In view of these circumstances, it is preferable to appropriately select the structure (number of atoms and constituent atoms) of the group R ³ .

The group R ³ contains, but does not contain, an etheric oxygen atom. When it contains an etheric oxygen atom, the flexibility of the cured product is improved, which is preferable.

[0046] Since the bifunctional polymerizable compound (B) does not contain a group (ring group) such as Q ^{1 in} the molecule, it does not significantly increase the number of carbon atoms contained in the entire compound. It is relatively easy to increase the number of carbon atoms contained in R ³ . By adopting this structure, the flexibility of the cured product obtained by curing the cured product of the liquid crystal material can be greatly improved while ensuring compatibility with the liquid crystal.

[0047] In the present invention, the liquid crystal material may contain a curing agent for initiating curing of the curable compound and a curing accelerator (such as a curing catalyst) for promoting curing. In particular, polymerization initiators Is preferably used. Such a polymerization initiator can be appropriately selected from known polymerization catalysts. For example, when using a photopolymerization phase separation method, a general photopolymerization initiator such as a benzoin ether type, a acetophenone type, or a phosphine oxide type can be used.

Furthermore, various compounds may be added to the liquid crystal material for the purpose of improving the contrast ratio and stability. For example, for the purpose of improving contrast, various dichroic dyes such as anthraquinone, styryl, azomethine, and azo may be used. In that case, it is preferable that the dichroic dye is basically compatible with the liquid crystal compound and not compatible with the curable compound. In addition, the addition of antioxidants, UV absorbers and various plasticizers is also preferred for improving stability and durability.

 Next, the operation of the liquid crystal element 100 described above will be described.

 For example, in a liquid crystal element that is in a scattering state when a voltage is applied and is in a transmission state when no voltage is applied, when a voltage is applied between the transparent electrodes 101a and 102a, the liquid crystal in the composite layer 104 is generated by the electric field between these electrodes. The molecules are randomly oriented, and the composite layer 104 is in a scattered state. On the other hand, when no voltage is applied between the transparent electrodes 101a and 102a, since the liquid crystal molecules are aligned, the composite layer 104 is in a transparent state. The composite layer 104 in the transparent state can be observed from the front surface (the surface on the side where the observer is present) to the back surface (the surface opposite to the side where the observer is present) of the liquid crystal element 100. As described above, since the scattering state and the transparent state change when voltage is not applied and Z is not applied, a desired image or the like can be displayed.

 [0050] Note that a liquid crystal element that is in a transmission state when a voltage is applied and in a scattering state when a voltage is not applied may be used. However, when used as a window glass of a vehicle, from the viewpoint of fail-safety, a liquid crystal element that is in a scattering state when a voltage is applied and is in a transmission state when no voltage is applied is preferable. However, if it is a sunroof, it may be a liquid crystal element that becomes turbid in a scattering state when no voltage is applied and becomes transparent in a transmission state when a voltage is applied.

The present invention is also a method for producing the structure such as the liquid crystal element. The manufacturing method of the present invention manufactures a functional material holder enclosing a functional material under reduced pressure, and then exposes the functional material holder to an atmosphere of atmospheric pressure to make the distance between the two curved substrates substantially uniform. It is characterized by that. That is, it has the following first step and the following second step, It is a manufacturing method of the structure.

 First step: A functional material is sealed in a gap sealed by a first and second curved substrates and a sealing material disposed on the entire periphery of the peripheral portions of both curved substrates in a predetermined reduced-pressure atmosphere. The process of manufacturing a functional material holder.

 Second step: The functional material holding body is exposed to an atmosphere of atmospheric pressure to fill the functional material into the gap, and at least one of the first and second curved substrates is pressurized. A step of manufacturing the structure by making the distance separating the opposing surfaces of the two curved substrates in the functional material holding body substantially uniform by being deformed by the change of the above.

 In the first step, a sealing material is provided on the entire peripheral edge of one curved substrate, the functional material is supplied into a region surrounded by the sealing material, and the one curved substrate is provided in the reduced-pressure atmosphere. The other curved substrate is pressed against the surface of the substrate to spread the functional material and form a sealed space in which the functional material is sandwiched in the gap between the two curved substrates. preferable.

 Next, the manufacturing method of the present invention will be described using the liquid crystal element 100 as an example.

 FIG. 2 is a diagram showing an example of a manufacturing flow of the liquid crystal element of the present invention. First, transparent substrates 101 and 102 formed in a predetermined curved shape are prepared, and in order to form transparent electrodes 1 Ola and 102a on these surfaces, a transparent conductive film is formed by a sputtering method or a vacuum evaporation method ( Step Sl). ITO is suitable as the transparent conductive film. Next, the transparent conductive film is patterned by, for example, a photolithography method to form transparent electrodes 101a and 102a and lead electrodes 101a ′ and 102a ′ having a pattern shape as shown in FIGS. 3A and 3B, for example. .

 Next, insulating films 101b and 102b and alignment films 10lc and 102c are sequentially formed on transparent electrodes 101a and 102a (step S2). The alignment films 101c and 102c may be subjected to a rubbing treatment in order to align the liquid crystal molecules contained in the composite layer 104 in a predetermined direction (for example, a direction substantially normal to the transparent substrate).

Next, the spacer 105 is spread on the surface of the transparent substrates 101 and 102 on which the alignment film or the like is formed, using an existing spreader (step S3). As a method of spraying the spacer, Misalignment methods such as wet spraying and dry spraying can also be used.

 As described above, when using a spacer whose surface is coated with a resin for fixing to the transparent substrate, the spacer is heated at a constant temperature when spraying the spacer in order to develop a fixing function with the transparent substrate. It is preferable to move to the next step after the resin on the surface of the spacer is melted and fixed to the surface of the transparent substrate.

 Spacers can be dispersed on the surface of the transparent substrate where the alignment film, etc. is formed, and can also be included in the seal material described below!

Next, a sealing material 103 is applied along the entire peripheral edge of the transparent substrates 101 and 102.

 (Step S4). The sealing material 103 is applied to the entire periphery of the peripheral portion of the transparent substrate so as to have a thickness larger than the cell gap of the finished liquid crystal element. The sealing material 103 can be applied to the entire circumference of one or both of the transparent substrates 101 and 102. As the sealing material 103, ultraviolet curable resin, thermosetting resin, or the like can be used.

 [0055] In addition, the sealing material 103 is about 400, 000 ± 200, 000 mPa, s to prevent the liquid crystal material from leaking from the sealed portion and air from entering the composite layer 104. Those having a viscosity are desirable. If the viscosity of the sealing material is too high, application with a dispenser becomes difficult. On the other hand, if the viscosity is too low, air may enter the liquid crystal cell when the liquid crystal cell is exposed from a reduced-pressure atmosphere to an atmospheric pressure atmosphere in step 7 described later. This is because the external force of the cell is also pressurized by the action of atmospheric pressure, and a hole is formed in the sealing material that can withstand this pressure, or the sealing material peels off from the substrate surface and air enters. It is predicted that.

 Next, the transparent substrate 102 is placed on the cradle 201 shown in FIGS. 4 (a) and 4 (b) with the surface on which the alignment film or the like is formed facing up. The cradle 201 has a rectangular frame shape when viewed from above, is an aluminum jig for supporting the peripheral edge of the transparent substrate 102, and has a structure that can be taken in and out of the vacuum chamber 203. As shown in Fig. 4 (a), the surface of the cradle 201 in contact with the transparent substrate 102 is processed into a substantially concave shape in a side view so as to match the shape of the transparent substrate 102 that has been bent in advance! Speak.

The transparent substrate 102 is placed on the cradle 201 outside the vacuum chamber 203. Then transparent A liquid crystal material made of a mixture of a nematic liquid crystal and a photocurable compound is dropped onto the surface of the substrate 102 on which the alignment film or the like is formed (step S5). The total drop amount of the liquid crystal material is adjusted so that it does not protrude when the vacuum lamination process described later is performed, and a predetermined interval is provided on the surface of the transparent substrate 102 on which the alignment film and the like are formed. Quantitatively supplied

[0058] Note that the ODF method employed in the present invention is simpler and shorter in time than the suction method or the vacuum injection method, and the liquid crystal material is sealed in the gap between the transparent substrates 101 and 102 and the sealing material 103. Can be encapsulated. This ODF method is particularly suitable when a large liquid crystal element is manufactured using a liquid crystal with high viscosity such as a chiral nematic liquid crystal.

 [0059] Next, polytetrafluoroethylene pins 201a, 201b and 201c whose tip portions are processed into a hemispherical shape are inserted into three recesses (not shown) provided in the cradle 201. After inserting the tip portion upward, the transparent substrate 101 is placed on the tip portion of these pins with the surface on which the orientation film or the like is formed facing down. Thereby, the state where the transparent substrate 101 and the transparent substrate 102 are separated from each other by a certain distance is maintained.

 [0060] The depth of the recess is adjusted to be longer than the length of the pin 201a and the like, and the diameter of the pin 201a and the like is adjusted to be slightly larger than the diameter of the recess. For this reason, a frictional force acts between the recess and the pin 201a, etc., and the transparent substrate 101 is placed so that the pin 201a etc. cannot be inserted into the interior of the recess unless a certain level of force is applied. The pin 201a etc. will not sink into the recess.

 Next, the cradle 201 on which the transparent substrates 101 and 102 are mounted is stored in the vacuum chamber 203. The cradle 201 can be moved up and down in the vacuum chamber by a predetermined lifting mechanism. In the vacuum chamber 203, an aluminum mold 202 is fixed and held vertically above the stored cradle 201. The mold 202 has a substantially convex shape in side view so as to be fitted to the surface of the cradle 201 on which the transparent substrate 102 or the like is mounted.

[0062] Next, when the cradle 201 is stored in the vacuum chamber 203 and further sealed, the vacuum chamber 203 is filled with a predetermined reduced-pressure atmosphere by the vacuum pump. Specifically, a state called a vacuum is generally created in which a pressure of 50 Pa (pascal) or less, particularly 20 Pa or less is preferred. In addition, a series of processes performed in the vacuum chamber (hereinafter also referred to as vacuum lamination process). The temperature of the transparent substrates 101 and 102 is preferably controlled. For example, an electric heater and a thermocouple are installed in the cradle 201 and Z or mold 202, and the heat generated by each heater is adjusted by the PID controller that receives the signal from the thermocouple. This enables control within the set temperature ± 0.1 ° C. As a result, the transparent substrates 101 and 102 and the liquid crystal material sandwiched between them can be maintained at a constant temperature throughout.

 [0063] The liquid crystal material supplied into the cell space is preferably maintained in a temperature range 5 to 60 ° C higher than the temperature at which the curable compound contained in the liquid crystal material is deposited. If the difference between the holding temperature of the liquid crystal material and the precipitation temperature of the curable compound is less than 5 ° C, the curable compound may be precipitated, and if it exceeds 60 ° C, the liquid crystal material may be damaged. There is a possibility that the curable compound may be cured before Step 8. Further, it is more effective to appropriately install a heater or a thermocouple on the wall, floor or ceiling surface of the vacuum chamber 203 and use the radiant heat from the wall surface.

 [0064] After the inside of the vacuum chamber 201 reaches a predetermined reduced pressure atmosphere, the cradle 201 is raised, and the peripheral portions of the transparent substrates 101 and 102 are pressed by the mold 202 and the cradle 201. When the cradle 201 is raised, the transparent substrate 101 first comes into contact with the mold 202. When the cradle 201 is further lifted, the pins 201, 201b and 201c, which cannot resist the friction force, gradually enter the recesses provided in the cradle 201. The distance between the transparent substrates 101 and 102 gradually decreases (Fig. 5 (a)). As the distance between the two transparent substrates decreases, the liquid crystal material on the surface of the transparent substrate 102 is spread between the two transparent substrates. Finally, the transparent substrates 101 and 102 are bonded together through the sealing material 103 to form a so-called liquid crystal cell in which the liquid crystal material is sealed in the sealed gap (step S6, FIG. 5 (b)). ). Thereafter, the raising of the cradle 201 is stopped and then lowered to return to the initial position.

[0065] Next, the pressure is returned to atmospheric pressure by supplying air to the vacuum chamber 203, and the transparent substrate 101 and 102 (liquid crystal cell) bonded together through the sealant 103 are placed together with the receiving table 201 and the chamber 201. Remove outside (step S7). At that time, due to the difference in pressure between the inside and outside of the liquid crystal cell, a force is applied to the two transparent substrates 101 and 102 which also presses the outside force of the cell, and both transparent substrates are drawn to the cell gap maintained by the spacer 105, Inside the liquid crystal material The fee will be charged (Fig. 5 (c), (d)).

 [0066] Next, the sealant 103 and the photocurable compound in the liquid crystal material are exposed to UV light and cured (step S8). A layer 104 of the liquid crystal Z cured product composite is formed by curing the photocurable compound in the liquid crystal material. Note that when the sealing material 103 is not a photocurable cured product, the sealing material needs to be cured separately.

 By adopting the manufacturing method of the present invention, the cell gap of the obtained liquid crystal cell can be made uniform even if the shapes of the curved transparent substrates 101 and 102 do not completely match. Further, when the combination of the curved transparent substrates 101 and 102 satisfies at least one of the conditions (A), (B), and (C), this effect is more effectively exhibited. Note that the manufacturing method of the present invention is effective even when the transparent substrate is not a substrate made of a flexible material such as resin but is a rigid substrate made of glass.

 [0068] Next, a method for manufacturing the curved transparent substrate used above will be described.

 FIG. 6 is a flowchart showing the bending process of the transparent substrate. First, outside of the heating furnace, a flat plate-like glass force made by a float method or the like is pretreated by cutting out a glass plate having a desired shape and chamfering its peripheral edge. Next, a release agent made of powder of radiolite, baking soda, celite, magnesium oxide, silica, or the like is sprayed between the two transparent substrates that have been pretreated, and then the transparent substrates 101 and 102 are overlaid. Then, it is placed on a metal ring frame 305 (step Sl l, Fig. 7 (a)).

 [0069] Next, the transparent substrates 101 and 102 together with the ring frame 305 are carried into the heating furnace 301 of the bending molding system 300, and heat treatment is performed using an electric heater or a gas spanner, not shown in the figure. As a result, the transparent substrates 101 and 102 are heated and softened, and as shown in FIGS. 7 (b) to (d), the transparent substrates 101 and 102 are gradually dropped by the dead weight of the substrate until the desired curved shape is obtained. Is applied (step S12).

 [0070] Next, the bent transparent substrates 101 and 102 are gradually cooled while being placed on the ring frame 305, and are then transported out of the furnace together with the ring frame (step S13). After the transparent substrates 101 and 102 are cooled to room temperature, both substrates are removed from the ring frame and washed with water (step S14).

[0071] Here, in an embodiment of a bending furnace used for manufacturing a curved substrate in the present invention. explain about.

 FIG. 8 is a cross-sectional view showing an embodiment of a bending furnace used in the present invention. As shown in the figure, the heating furnace 301 is made by stacking refractory bricks in the shape of a tunnel, and heats the transparent board with the upper outbound path, the ring frame 305 used in the outbound path, etc. And a lower return path for moving to The forward path and the return path are divided into a plurality of zones (in this case, having zones 1 to 7), and the transparent substrate put into the furnace external force zone 1 is moved to the subsequent zones one after another and subjected to heat treatment or the like. Zones 2 to 5 are heating zones in which an electric heater or the like is installed on the furnace wall, zone 6 is a slow cooling zone, and zone 7 is a cooling zone for carrying the transparent substrate out of the furnace.

 [0072] In addition, between the zone 1 and the zone 2, between the zone 5 and the zone 6, and between the zone 6 and the zone 7, the door slidable up and down for partitioning adjacent zones 303 Are provided. By opening and closing the door 303, the ambient temperature in each zone is individually maintained. Further, an elevator 302 force S is installed before and after the bending system 300, and the elevator 302 moves the shuttle 304 and the ring frame 305 from the forward path to the backward path or from the backward path to the forward path.

 On the other hand, the ring frame 305 on which the transparent substrate is placed is fixed to a movable shuttle 304, and the shuttle 304 is connected to a transport mechanism 306 including a chain, a sprocket, a motor, and the like. The ring frame 305 and the shuttle 304 are intermittently conveyed by the conveyance mechanism 306 to the right in the figure in the forward path in the upper part of the figure and intermittently to the left in the figure in the return path in the lower part of the figure. That is, the ring frame 305 is transported together with the shuttle 304, stays in each zone for a certain period of time, and then moves to the next zone repeatedly.

[0074] The details of the ring frame 305 and the shuttle 304 are as shown in FIGS. 9 (a) and 9 (b). A shuttle frame 304 that also has SUS (stainless alloy) isotropic force is provided with a ring frame 305 that also has SUS isotropic force. Is held by a fastener. The ring frame 305 is a frame member having a shape that substantially matches the product shape, and the surface that receives the transparent substrate is inclined toward the inside of the frame and inclined downward. The surface of the ring frame 305 is made of glass fiber, silica fiber, ceramic fiber, metal fiber, etc. to prevent contact scratches on the transparent substrate. Covered with heat-resistant woven or non-woven fabric made of

 Example

 Next, examples of the present invention will be described.

 [Example 1]

 Prepare two glass plates made of soda lime of 300 [mm] X 300 [mm] X 2 [mm thickness], and radio light between the substrates so that the two glass plates are not welded during the bending process. Overlaid after spraying. The stacked glass plates were placed in a heating and bending jig with 1000R (curvature radius 1000mm) and 4000R (curvature radius force 000mm) on the two opposite sides. After that, the two glass plates were carried into the heating furnace together with this jig and subjected to natural heavy bending.

 [0077] When the shape of the end of the obtained curved glass plate was measured, it was as shown in Fig. 11 (a). Figure 11 (b) shows the distance between the two glass plates calculated with the contact point of the two substrates as zero. Compared with the both ends of the glass plate, it can be seen that the deviation is larger than the both ends. The edge shape of the glass plate was measured along the “measurement line” in FIG. 10 (b) with a linear gauge for each glass plate.

These glass plates were subjected to various film-forming processes such as transparent electrodes and insulating films, and a spacer with a diameter of 8 m was sprayed on the surface on which one of the glass sheets was subjected to the film-forming process, and then a sheet was applied to the periphery. The lumber was applied. Next, after a predetermined amount of liquid crystal material is supplied into the surface on which the film formation process has been performed, the surface on which the sealing material is applied and the liquid crystal material is supplied to the cradle 201 shown in FIG. This glass plate was set up. Thereafter, the other glass plate was placed on the pins 201a to 201c with the film-formed surface facing down, and the two glass plates were set with a certain gap between them. After that, these glass plates are set together with the cradle and in the vacuum chamber 203 having a press mechanism. After the pressure in the vacuum chamber is reduced to 20 Pa or less, the press mechanism in the vacuum chamber 203 is operated and held by a pin. The glass plate being pressed was pressed against the mold 202, and the two glass plates were bonded together via a sealing material. Subsequently, the inside of the vacuum chamber 203 was opened to atmospheric pressure. As a result, each glass plate was deformed by the action of atmospheric pressure, and a liquid crystal device in which the cell gap was kept almost uniform over the entire surface of the glass substrate could be produced. [0078] Tables 1 and 2 show cell gaps of the cells after vacuum lamination. The above embodiment is the same except that the liquid crystal material is not sandwiched (encapsulated) in the glass cell. Tables 1 and 2 show the measurement results of the distance (cell gap) between the two glass plates. The cell gap at each part of the measurement point is close to the spacer diameter of 8 μm, indicating that a substantially uniform cell gap can be achieved in the plane. The cell gap was measured along the measurement lines L1, L2 and L3 shown in Fig. 10 (b) (measured by shifting the position from the base of the arrow).

 [0079] [Table 1]

[0080] [Table 2]

Position [mm] L3 [jU m]

 20 8.46

 25 8.35

 30 8.39

 60 8.32

 90 8.32

 120 8.33

 150 8.42

 180 8.34

 210 8.35

 240 8.31

 270 8.31

 300 8.24

 330 8.45

 360 8.32

 390 8.79

 395 8.33

 400 8.38

[0081] [Comparative Example]

 Prepare two 300 [mm] X 300 [mm] X 2 [mm thick] soda-lime glass plates, and put a radio light between the substrates so that the two glasses are not welded during the bending process. Overlaid after spreading. The two superposed substrates are fixed at the center of each side with heat-resistant glass tape, and the opposite two sides are 1000R and 4000R respectively! ] Installed on a hot bending jig. After that, the two substrates were carried into a heating furnace together with a bending jig and subjected to natural gravity bending. When the end shape of the obtained substrate was measured along the “measurement line” shown in FIG. 10 (b), it was as shown in FIG. 12 (a). Figure 12 (b) shows the distance between two substrates calculated with the contact point of the substrate as zero. Compared with the both ends of the substrate, the portion between them (in the plane of the substrate) shows a larger value than the both ends, and it can be seen that there is a portion.

These substrates were laminated in a vacuum by the same operation as in the example, released to atmospheric pressure, and then the substrates were checked. As a result, leakage occurred from the center of the side having a curvature radius of 4000R. O Sealed material could not be sealed in the form of correcting the distance between two glass sheets o

 [Other Examples, etc.]

Prepare two glass plates made of soda lime of 300 [mm] X 300 [mm] X 2 [mm thickness], and radio light between the substrates so that the two glass plates are not welded during the bending process. Sprayed Overlaid on top. The superposed substrates were placed on a heating and bending cage with two opposite sides, 1000R and 4000R, respectively. After that, the two substrates were put together with this jig into a calorie furnace and subjected to natural gravity bending.

 The edge shape of the obtained substrate was measured and as shown in Table 1. Table 1 shows the presence or absence of polishing of the transparent substrate, the shape of the spacer, the gap values measured after bending, their minimum and maximum values, the average value of the cell gap after sealing, and the sealing state. Is described. Here, the gap measurement after bending was performed as follows. In other words, in order to know the shape error of the two transparent substrates, the distance between the substrates was measured using a laser gap measuring instrument made by Keyence with the overlapping of these. The interval was measured at measurement points along L2 shown in Fig. 10 (b).

 [0085] [Table 3]

In Table 3, “normal” means a radiolite with a particle size of # 300 mesh or less,

“Classification” means radiolite with a particle size of 30 μm or less, “Spherical” refers to silica beads with an average particle size of 8.01 μm and standard deviation of 0.08 μm. “Shape 1” refers to an end shape that has substantially the same shape as FIG.

 “Shape 2” refers to an end shape having substantially the same shape as FIG.

[0087] In Examples (1) to (5), since the bending was performed in the furnace in a state where the glass plates were simply overlaid, the distance between the substrates in the state where the two formed substrates were overlaid. As a result, the shape was monotonously decreased and distributed from the central part to the peripheral part of the transparent substrate.

[0088] On the other hand, in Comparative Examples (1) to (3), since the substrates were fixed with glass tape at the time of bending, the above shape was not reproduced, and as shown in the above [Comparative Example]. The substrate spacing at the center was wide and the substrate spacing was narrow at the center. As a result, leakage occurred during vacuum lamination, and it was impossible to produce the desired liquid crystal element.

 Industrial applicability

 [0089] As described above, the liquid crystal element according to the present invention can control the light transmission state and the light scattering state, and therefore can be used for other purposes as well. For example, architectural interiors such as windows (for automobiles (side windows, door glass, rear quarters, etc.), construction, aircraft, ships, railway vehicles, etc.), skylights, partitions, doors, etc. It can be applied to signboards, commercial advertising media, large partition devices, etc. For example, when it is used for a refrigerator door, it is possible to check the food contained inside the refrigerator door. Alternatively, information can be provided to the user by displaying a combination of figures and patterns or displaying characters. Moreover, you may give decorations, such as a character, to a transparent plate as needed.

 [0090] Although the above embodiment is exemplified by a noisy liquid crystal element, the present invention is not limited to this. The present invention can also be applied to other drive type liquid crystal elements such as a static type and an active type.

In addition, according to the present invention, a structure other than the liquid crystal element can be manufactured. That is, by using a solution or gel containing ITO ultrafine particles as a functional layer instead of a liquid crystal layer, a structure having a heat ray cutting function can be produced. This can be used in place of window glass for automobiles and buildings. Further, a colored solution or a colored gel can be used for the functional layer. In addition, the substrate may be a seed such as glass, resin, metal or semiconductor. Substrates with various material strengths can also be used. It should be noted that the entire contents of the specification, claims, drawings and abstract of Japanese Patent Application No. 2006-194290 filed on July 14, 2006 are cited here as disclosure of the specification of the present invention. Incorporate.

Claims

The scope of the claims

 [1] A first curved substrate, a second curved substrate having substantially the same shape as the first curved substrate and facing the first curved substrate, and the entire peripheral edge of both curved substrates And a sealing material that seals the gap between the two curved substrates and seals the gap between the two curved substrates and the gap sealed by the two curved substrates and the sealing material. A functional material comprising:

 The combination of the first and second curved substrates constituting the structure is superposed so that the surfaces facing the first and second curved substrates are substantially parallel, and the in-plane or opposite surfaces of both curved substrates are aligned. A structure having a combination in which the distance between the curved substrates at the edge of the curved substrate is smaller than the maximum value of the distance between the curved substrates when contacted at at least one point on the periphery.

 [2] A first curved substrate, a second curved substrate having substantially the same shape as the first curved substrate and facing the first curved substrate, and the entire circumference of the peripheral portions of both curved substrates And a sealing material that seals the gap between the curved substrates and seals the gap between the curved substrates, and a gap sealed between the curved substrates and the sealing material. A functional material comprising:

 The combination of the first and second curved substrates constituting the structure is superposed so that the surfaces facing the first and second curved substrates are substantially parallel, and the in-plane or opposite surfaces of both curved substrates are aligned. A structure having a combination in which the distance between the curved substrates at the edge of the curved substrate is 0.5 mm or less when contacted at at least one point on the periphery

[3] a first curved substrate, a second curved substrate having substantially the same shape as the first curved substrate and facing the first curved substrate, and the entire circumference of the peripheral portions of both curved substrates And a sealing material that seals the gap between the two curved substrates and seals the gap between the two curved substrates and the gap sealed by the two curved substrates and the sealing material. A functional material comprising:

The combination of the first and second curved substrates constituting the structure is overlapped so that the surfaces facing the first and second curved substrates are substantially parallel, A combination in which the distance between the curved substrates at the end of the curved substrate is 20 times or less the predetermined distance separating the opposed surfaces of the curved substrates in the structure when contact is made at at least one point in the opposite plane or the peripheral edge. A structure characterized by being.

[4] At least one of the curved substrates is deformed by atmospheric pressure, so that the opposing surfaces of the curved substrates are corrected to a predetermined shape, and the distance distribution separating the opposing surfaces of the curved substrates is substantially uniform. The structure according to any one of claims 1 to 3, wherein

[5] The structure according to any one of [1] to [4], wherein in the structure, the distance is within a range of a distance force of ~ 30 m separating the opposing surfaces of both curved substrates.

[6] The spacer of a predetermined size is disposed in a gap between the opposing surfaces of the two curved substrates, and a distance between the opposing surfaces of the two curved substrates is maintained at a predetermined constant distance. The structure according to any one of 5 above.

 [7] The structure according to any one of claims 1 to 6, wherein the functional material is a material containing a liquid.

[8] The at least one of the two curved substrates is a transparent curved substrate, has an electrode layer on each of the surfaces of the two curved substrates facing each other, and the functional material is a material containing liquid crystal. The structure according to any one of 7 above.

[9] The first curved substrate, the second curved substrate having substantially the same shape as the first curved substrate and facing the first curved substrate, and the entire circumference of the peripheral portions of the two curved substrates And a sealing material that seals the gap between the curved substrates and seals the gap between the curved substrates, and a gap sealed between the curved substrates and the sealing material. A structure having a functional material,

 In a predetermined reduced pressure atmosphere, the functional material is sealed in a gap sealed by the first and second curved substrates and the sealing material disposed around the entire periphery of the curved substrates, and the functional material holder A first step of manufacturing

Exposing the functional material holder to an atmosphere of atmospheric pressure to fill the functional material in the gap and deforming at least one of the first and second curved substrates by a change in pressure; And a second step of manufacturing the structure by making the distance separating the opposing surfaces of the two curved substrates in the functional material holding body substantially uniform.

[10] In the first step, a sealing material is provided on the entire periphery of one of the curved substrates, the functional material is supplied into a region surrounded by the sealing material, and in the reduced pressure atmosphere, The other curved substrate is pressed against the surface of the one curved substrate to spread the functional material and form a sealed space in which the functional material is sandwiched in the gap between the two curved substrates; A method for manufacturing the structure according to claim 9.

 [11] The combination of the first and second curved substrates constituting the structure is overlapped so that the surfaces facing the first and second curved substrates are substantially parallel, and the curved substrates are opposed to each other. 11. The method for manufacturing a structure according to claim 9, wherein the structure is a combination in which the distance between the curved substrates at the end portion of the curved substrate is 0.5 mm or less when they are brought into contact with each other at least one point in the plane or the periphery.

 [12] The combination of the first and second curved substrates constituting the structure is overlapped so that the surfaces facing the first and second curved substrates are substantially parallel, and both the curved substrates are opposed to each other. When contacting at least one point in the plane or at the periphery, the distance between the curved substrates at the end of the curved substrate is a combination that is 20 times or less the predetermined distance separating the opposing surfaces of the curved substrates in the structure. The method for producing a structure according to any one of claims 1 to 9.

 [13] The method for manufacturing a structure according to any one of [9] to [12], wherein in the structure, the distance is within a range of a distance force of ~ 30 m separating the opposing surfaces of both curved substrates.

 [14] The method for manufacturing a structure according to any one of [9] to [13], wherein a spacer having a predetermined size is enclosed together with the functional material.

 [15] The method for producing a structure according to any one of [9] to [14], wherein the functional material is a material containing a liquid.

 [16] The at least one of the two curved substrates is a transparent curved substrate, has an electrode layer on each of the opposing surfaces of the two curved substrates, and the functional material is a material containing liquid crystal. 16. A method for producing the structure according to any one of 15 above.