WO2005102688A2 - Methods for laminating films for spd light valves and spd light valves incorporating such laminated films - Google Patents
Methods for laminating films for spd light valves and spd light valves incorporating such laminated films Download PDFInfo
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- WO2005102688A2 WO2005102688A2 PCT/US2004/023747 US2004023747W WO2005102688A2 WO 2005102688 A2 WO2005102688 A2 WO 2005102688A2 US 2004023747 W US2004023747 W US 2004023747W WO 2005102688 A2 WO2005102688 A2 WO 2005102688A2
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- suspended particle
- particle device
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
- B32B17/10064—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising at least two glass sheets, only one of which being an outer layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
- B32B17/10036—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising two outer glass sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10165—Functional features of the laminated safety glass or glazing
- B32B17/10174—Coatings of a metallic or dielectric material on a constituent layer of glass or polymer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10165—Functional features of the laminated safety glass or glazing
- B32B17/10431—Specific parts for the modulation of light incorporated into the laminated safety glass or glazing
- B32B17/10467—Variable transmission
- B32B17/10495—Variable transmission optoelectronic, i.e. optical valve
- B32B17/10532—Suspended particle layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/10761—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing vinyl acetal
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/1077—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing polyurethane
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/10788—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing ethylene vinylacetate
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10807—Making laminated safety glass or glazing; Apparatus therefor
- B32B17/10816—Making laminated safety glass or glazing; Apparatus therefor by pressing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10807—Making laminated safety glass or glazing; Apparatus therefor
- B32B17/10816—Making laminated safety glass or glazing; Apparatus therefor by pressing
- B32B17/10825—Isostatic pressing, i.e. using non rigid pressure-exerting members against rigid parts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2369/00—Polycarbonates
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/17—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on variable-absorption elements not provided for in groups G02F1/015 - G02F1/169
- G02F1/172—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on variable-absorption elements not provided for in groups G02F1/015 - G02F1/169 based on a suspension of orientable dipolar particles, e.g. suspended particles displays
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F2202/00—Materials and properties
- G02F2202/02—Materials and properties organic material
- G02F2202/022—Materials and properties organic material polymeric
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F2202/00—Materials and properties
- G02F2202/02—Materials and properties organic material
- G02F2202/022—Materials and properties organic material polymeric
- G02F2202/023—Materials and properties organic material polymeric curable
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
Definitions
- the present invention is directed to laminated films for use in suspended particle devices (SPDs) such as SPD light valves, and to methods for laminating such SPD films.
- SPDs suspended particle devices
- the invention relates to a method of laminating SPD films, wherein the film is cross-linked when cured, and laminated SPD films produced by such method.
- SPD light valves have been known for more than seventy years for the modulation of light. Such light valves have been proposed for use in numerous applications during that time including, e.g., alphanumeric displays and television displays, filters for lamps, cameras, optical fibers and displays, and windows, sunroofs, sunvisors, eyeglasses, goggles, mirrors and the like to control the amount of light passing therethrough or reflected therefrom as the case may be.
- windows include, without limitation, architectural windows for commercial buildings, greenhouses and residences, windows for automotive vehicles, boats, trains, planes and spacecraft, windows for doors including peepholes, and windows for appliances such as ovens and refrigerators including compartments thereof.
- Light valves of the type described herein are also known as suspended particle devices or SPDs.
- the term light valve describes a cell formed of two walls that are spaced apart by a small distance, with at least one wall being transparent. The walls have electrodes thereon, usually in the form of transparent, electrically conductive coatings.
- the cell contains a light-modulating element (sometimes herein referred to as an activatable material) which may, without limitation, be either a liquid suspension of particles or a plastic film in which droplets of a liquid suspension of particles are distributed.
- the liquid suspension (sometimes herein referred to as a liquid light valve suspension or as a light valve suspension) comprises small particles suspended in a liquid suspending medium.
- the particles in the liquid suspension assume random positions due to Brownian movement. Hence, a beam of light passing into the cell is reflected, transmitted or absorbed depending upon the cell structure, the nature and concentration of the particles and the energy content of the light.
- the light valve is thus relatively dark in the OFF state.
- the particles become aligned and for many suspensions most of the light can pass through the cell.
- the light valve is thus relatively transparent in the ON state.
- a plastic film in which droplets of liquid suspension are distributed is preferable to a liquid suspension alone because hydrostatic pressure effects, e.g., bulging associated with a high column of light suspension, can be avoided through use of a film and the risk of possible leakage can also be avoided.
- Another advantage of using a plastic film is that, in a plastic film, the particles are generally present only within very small droplets and, hence, do not noticeably agglomerate when the film is repeatedly activated with a voltage.
- a light valve film (also sometimes herein referred to as an SPD film) as that term is used herein, means a film or sheet, or more than one thereof comprising a suspension of particles used or intended for use in an SPD light valve.
- Such light valve film shall comprise either (a) a suspension of particles dispersed throughout a continuous liquid phase enclosed within one or more rigid or flexible solid films or sheets, or (b) a discontinuous phase of a liquid comprising dispersed particles, such discontinuous phase being dispersed throughout a continuous phase of a rigid or flexible solid film or sheet.
- the light valve film or laminates comprising the light valve film may also comprise one or more additional layers such as, without limitation, a film, coating or sheet or combination thereof, which may provide the light valve film with (1) scratch resistance, (2) protection from ultraviolet radiation, (3) reflection of infrared energy, and/or (4) electrical conductivity for transmitting an applied electric or magnetic field to the activatable material.
- a film, coating or sheet or combination thereof which may provide the light valve film with (1) scratch resistance, (2) protection from ultraviolet radiation, (3) reflection of infrared energy, and/or (4) electrical conductivity for transmitting an applied electric or magnetic field to the activatable material.
- the methods of the present invention are specifically directed to the use of the latter type of film, i.e., formed by cross-linking emulsions, 1 and to the laminated films produced thereby. See, for example, U.S. Patent Nos., 5,463,491 and 5,463,492, both of which are assigned to the assignee of the present invention.
- Various types ofSPD emulsions, and methods of curing the same, are described in U.S. PatentNos.6,301,040 and 6,416,827, and in pending U.S. Patent Application SerialNo. 10/465,489, all ofwhich are assigned to the assignee to the present invention.
- Such films and variations thereof may be cured through cross-linking brought about by exposing the films to (1) ultraviolet radiation, (2) electron beams and/or (3) heat. All of the references cited in this application, including patents, are incorporated herein by reference. [0009]
- laminate usually means (1) to separate or split into thin layers, (2) to form into a thin metal plate, (3) to construct by placing one layer upon another or (4) to cover or overlay with thin layers, (see, e.g., The Random House Dictionary of the English Language, 1967 edition).
- definitions (3) and (4) above are applicable.
- the lamination process generally involves bonding a plastic interlayer in between two lites (sheets) of flat or curved glass, with the goal of producing a clear unit of shatter-resistant glass.
- the terms laminating, to laminate or the act of lamination refer to the combination as a unit an SPD film with (1) one or more plastic hot melt adhesive sheets or films and/or (2) with one or more glass or plastic sheets for the purpose(s), without limitation thereto, of protecting and or strengthening the SPD film, any of the purposes mentioned hereinbefore, and/or making it easier to install where intended for use.
- liquid light valve suspension as noted above, when used herein means a liquid suspending medium in which a plurality of small particles are dispersed.
- the liquid suspending medium comprises one or more non-aqueous, electrically resistive liquids in which there is preferably dissolved at least one type of polymeric stabilizer which acts to reduce the tendency of the particles to agglomerate and to keep them dispersed and in suspension.
- Liquid light valve suspensions useful in the present invention may include any of the so-called prior art liquid suspending media previously proposed for use in light valves for suspending the particles.
- Liquid suspending media known in the art which are useful herein include, but are not limited to, the liquid suspending media disclosed in U.S. Patent Nos. 4,247,175, 4,407,565, 4,772,103, 5,409,734, 5,461,506, and 5,463,492, the disclosures of which, as noted above, are incorporated herein by reference.
- the suspending medium or the polymeric stabilizer typically dissolved therein is chosen so as to maintain the suspended particles in gravitational equilibrium.
- the polymeric stabilizer when employed, can be a single type of solid polymer that bonds to the surface of the particles, but which also dissolves in the non-aqueous liquid(s) which comprise the liquid suspending medium.
- the particles can be coated with a first type of solid polymeric stabilizer such as nitrocellulose which, when dissolved, provides a plain surface coating for the particles, together with one or more additional types of solid polymeric stabilizer that, when dissolved, bond to or associate with the first type of solid polymeric stabilizer and also dissolve in the liquid suspending medium to provide dispersion and steric protection for the particles.
- a first type of solid polymeric stabilizer such as nitrocellulose which, when dissolved, provides a plain surface coating for the particles
- additional types of solid polymeric stabilizer that, when dissolved, bond to or associate with the first type of solid polymeric stabilizer and also dissolve in the liquid suspending medium to provide dispersion and steric protection for the particles.
- liquid polymeric stabilizers may also be used to advantage, especially in SPD light valve films, as described for example in U.S. Patent No. 5,463,492.
- Inorganic and organic particles maybe used in a light valve suspension, and such particles may be either light absorbing or light reflecting in the visible portion of the electromagnetic spectrum.
- Conventional SPD light valves have generally employed particles of colloidal size.
- colloidal means that the particles generally have a largest dimension averaging 1 micron or less.
- most polyhalide or non-polyhalide types of particles used or intended for use in an SPD light valve suspension will have a largest dimension which averages 0.3 micron or less and more preferably averages less than one-half of the wavelength of blue light, i.e., less than 2000 Angstroms, to keep light scatter extremely low.
- the invention provides a method for laminating a suspended particle device (SPD) film.
- the method comprises forming a suspended particle device film; positioning the suspended particle device film within an unlaminated stack of components for forming a laminated suspended particle device film, which stack comprises at least one hot melt adhesive sheet or film contacting an outer surface of the suspended particle device film; subjecting the unlaminated stack to at least a partial vacuum; preheating the unlaminated stack of components under such vacuum for a time and at a temperature selected to permit at least partial degassing of the stack; and applying a sufficient net pressure to the stack at a sufficient temperature and for a sufficient time to produce a laminated suspended particle device film from the unlaminated stack.
- the suspended particle device film is prepared, in one embodiment, by a method which comprises providing a first substrate comprised of plastic or glass having first and second opposed surfaces; bonding a first layer of a substantially transparent electrically conductive coating to at least a portion of one of the opposed surfaces of the first substrate; applying a layer of an uncured liquid SPD emulsion upon the coating, the emulsion comprising a plurality of uncrosslinked polymer chains for forming a polymer matrix and at least one liquid light valve suspension; curing the SPD emulsion by cross-linking the polymer chains to form a cured SPD emulsion having a plurality of uncrosslinked droplets of a liquid light valve suspension distributed therein; and sandwiching together with the first coated substrate a second substrate coated with a second layer of the substantially transparent electrically conductive coating, wherein the second layer of the substantially transparent electrically conductive coating is in contact with the cured SPD emulsion on the first substrate, so as to form the suspended particle device film.
- the liquid SPD emulsion may be cured by exposing the uncured emulsion to ultraviolet radiation, an electron beam and/or heat.
- the method of the invention may further comprise, in an alternate embodiment, providing the second substrate with a cured SPD emulsion upon the second layer of the substantially transparent electrically conductive coating prior to sandwiching the second substrate together with the first substrate.
- the substantially transparent electrically conductive coating is comprised of indium tin oxide.
- at least one of the substantially transparent electrically conductive coatings is further provided with a dielectric overcoat located thereon. The dielectric overcoat maybe, for example, MgF 2 or SiO.
- the hot melt adhesive used in the method is selected from the group consisting of an ethylene/vinyl acetate copolymer, apolyurethane polymer and polyvinyl butyral.
- at least one of the substrates is formed of plastic and the plastic is polyethylene terephthalate (PET) or a polycarbonate (PCA) plastic.
- the method of the invention further comprises substantially preventing contact between the hot melt adhesive, when the adhesive is heated, and the suspended particle device, as well as any protrusions extending outwardly from the film, hi one embodiment, the contact is prevented by interposing a substantially chemically inert plastic material adj acent an outer edge portion of the suspended particle device film, including any protrusions, at a location chosen to substantially prevent contact of the hot melt adhesive, when the adhesive is heated, with the film and any such protrusions.
- the substantially chemically inert plastic material may be provided on at least one opposed surface thereof with an adhesive, e.g., a pressure sensitive adhesive, to facilitate bonding thereof.
- the plastic material has a melting point higher than the melting point of the hot melt adhesive.
- the plastic material is polyethylene terephthalate, sold under the trade name Mylar®.
- the plastic material in one embodiment, has a thickness of ⁇ 2 mils, preferably ⁇ 1 mil and even possibly as thin as 0.5 mil.
- the plastic material is interposed as a plurality of sheets or strips.
- the plastic material may be shaped into the form of at least one frame, wherein the frame is configured to protect at least the outer edge portion of the suspended particle device film from contact with the hot melt adhesive, while leaving a central viewing portion of the film substantially uncovered by the plastic material.
- the central viewing portion may be configured, for example, in the shape of a polygon, a circle or an oval.
- two such frames maybe applied, i.e., one on each opposed surface of the suspended particle device film.
- the vacuum applied to the unlaminated stack of components is at least about 29 inches of mercury.
- the preheating temperature is between about room temperature and a glass transition temperature which is the lowest glass transition temperature of any hot melt adhesive in the laminate, hi a particular embodiment, the at least one hot melt adhesive sheet or film has a melting range having a low end of at least about 75 degrees C. In a further embodiment, the at least one hot melt adhesive sheet or film has a melting range with a low end of at least about 85 degrees C. [0026] In another embodiment of the invention, the net pressure ranges between about 2.8 psi and 27 psi.
- the net pressure is applied to the stack for between about 3-5 hours at a temperature high enough to substantially melt the at least one hot melt adhesive sheet or film, but below a temperature which would cause the SPD film to spread (ooze) beyond the boundary of the cured film prior to lamination.
- the liquid light valve suspension comprises a plurality of colloidal particles having a largest dimension averaging 1 micron or less. In another embodiment, the particles have a largest dimension which averages 0.3 microns or less.
- the polymer chains are comprised of a polyorganosiloxane polymer. In another embodiment the polymer matrix comprises no less than 60% of the overall emulsion.
- the matrix of the emulsion may comprise a copolymer of about 90% by weight (a) poly (dimethyl diphenyl siloxane, disilanol terminated) and about 10% by weight (b) acryloxy propyl methyl dimethoxy silane.
- the laminated suspended particle device fihn of the invention may, in one embodiment, be laminated in an autoclave adapted to provide sufficient net pressure, temperature and vacuum to permit lamination of the film.
- the invention additionally provides a method wherein a layer of polyvinyl butyral is laminated between two glass sheets to form a second laminate, following which the second laminate is laminated to the laminated suspended particle device film.
- the invention provides a method for laminating a suspended particle device which comprises forming a suspended particle device film; positioning the suspended particle device film within an unlaminated stack of components for forming a laminated suspended particle device film, which stack comprises at least one hot melt adhesive sheet or film contacting an outer surface of the suspended particle device film; subjecting the unlaminated stack to at least a partial vacuum; preheating the unlaminated stack of components under such vacuum for a time and at a temperature selected to permit at least partial degassing of the stack; and applying a sufficient net pressure to the ; stack at a sufficient temperature and for a sufficient time to produce a laminated suspended particle device film from the unlaminated stack.
- the suspended particle device film is prepared by a method which comprises providing a first substrate comprised of plastic or glass having first and second opposed surfaces; bonding a first layer of a substantially transparent electrically conductive coating to at least a portion of one of the opposed surfaces of the first substrate; applying a layer of an uncured liquid SPD emulsion upon the coating, the emulsion comprising a plurality of uncrosslinked polymer chains for forming a polymer matrix and at least one liquid light valve suspension; curing the SPD emulsion by cross-linking the polymer chains to form a cured SPD emulsion having a plurality of uncrosslinked droplets of a liquid light valve suspension distributed therein; and sandwiching together with the first coated substrate a second substrate coated with a second layer of the substantially transparent electrically conductive coating, wherein the second layer of the substantially transparent electrically conductive coating is in contact with the cured SPD emulsion on the first substrate, so as to form the suspended particle device film.
- the hot melt adhesive may be selected from the group consisting of an ethylene/vinyl acetate copolymer, a polyurethane polymer and polyvinyl butyral and, when the adhesive a polyurethane polymer or polyvinyl butyral, the method may further comprise substantially preventing contact between the hot melt adhesive, when the adhesive is heated, and the suspended particle device film, as well as any protrusions extending outwardly from the film.
- the contact is prevented by interposing a substantially chemically inert plastic material (e.g., Mylar®) adj acent an outer edge portion of the suspended particle device film, including any protrusion from the film, at a location chosen to substantially prevent contact of the hot melt adhesive, when the adhesive is heated, with the film and any such protrusion.
- a substantially chemically inert plastic material e.g., Mylar®
- the method may further comprise laminating at least one layer of polyvinyl butyral between two glass (or plastic) sheets to form a second laminate, and then laminating the second laminate to one side of the laminated suspended particle device film.
- an embodiment of the invention may entail using either a polyurethane polymer, or a sheet or film of ethylene/vinyl acetate copolymer between glass sheets located on the outer surfaces of both laminates.
- the method may additionally comprise providing the second substrate with a cured SPD emulsion upon the second layer of the substantially transparent electrically conductive coating, prior to sandwiching the second substrate with the first substrate.
- at least one of the transparent, electrically conductive coatings may be further provided with a dielectric overcoat located thereon.
- the dielectric overcoat may comprise, for example, MgF 2 and or SiO.
- the substantially chemically inert plastic material has a melting point higher than the melting point of the hot melt adhesive, as well as a thickness of less than about 2 mils.
- the plastic material is, in one embodiment, interposed as a plurality of sheets or strips.
- the plastic material may be formed into the shape of at least one frame, configured to protect the outer edge portion of the suspended particle device film, while leaving a central viewing portion of the film substantially uncovered by the plastic material.
- the vacuum applied to the unlaminated stack of components is at least about 29 inches of mercury.
- the pre-heating temperature is between about room temperature and a glass transition temperature which is the lowest glass transition temperature of any hot melt adhesive in the laminate.
- the net pressure may range between about 2.8 psi and 27 psi.
- the net pressure is applied to the stack for between about 3-5 hours at a temperature high enough to substantially melt the at least one hot melt adhesive sheet or film, but below a temperature which would cause the SPD film to spread during lamination beyond a boundary which the cured film had prior to lamination.
- the liquid light valve suspension used in the method described above comprises aplurality of colloidal particles having a largest diameter averaging 1 micron or less.
- the polymer chains are comprised of a polyorganosiloxane polymer.
- the polymer matrix comprises no less than 60% of the overall emulsion.
- the matrix of the emulsion may comprise a copolymer of about 90% by weight (a) poly (dimethyl diphenyl siloxane, disilanol terminated) and about 10% by weight (b) acryloxy propyl methyl dimethoxy silane.
- the suspended particle device film is laminated in an autoclave adapted to provide sufficient net pressure, temperature and vacuum to laminate the film.
- the invention is further directed to a laminated suspended particle device film produced according to any of the methods described above.
- the invention is additionally directed to a light valve comprising a cell formed of opposed cell walls, a light modulating unit located between the cell walls, and opposed electrode means operatively associated with the cell walls for applying an electrical field across the light modulating unit, wherein the light modulating unit comprises a laminated suspended particle device produced according to any of the methods described above.
- a light valve comprising a cell formed of opposed cell walls, a light modulating unit located between the cell walls, and opposed electrode means operatively associated with the cell walls for applying an electrical field across the light modulating unit, wherein the light modulating unit comprises a laminated suspended particle device produced according to any of the methods described above.
- DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION Apparatus for laminating layers of glass and plastic, which is also useful for laminating plastic with other plastic layers, is very well known among those of ordinary skill in the art and is generally described in Crockett, D., "USG Machinery-Autoclaves for Glass Lamination", U.
- the main problems which are observed in an SPD film as a result of faulty lamination procedure(s) are one or more of the following types of defects: (1) trapped air bubbles, (2) trapped water vapor, (3) oozing (spreading) of cured SPD emulsion out of the film, (4) reduction of the light transmission range of the SPD film when activated compared to the same film prior to lamination, (5) increased on-state haze of the SPD film when activated compared to the same fihn prior to lamination and (6) delamination of the hot melt adhesive plastic layer from an adjacent layer or layers to which it had been bonded, or failure of the hot melt adhesive(s) to bond to part or all of an adjacent layer or layers (non-lamination or partial lamination).
- composition of the SPD emulsion matrix and of the droplets of liquid suspension distributed therein each have an important effect on the tolerable and/or desirable levels of heat and pressure that can be applied to achieve a successful lamination.
- appropriate procedures for laminating non-crosslinked SPD films such as those described in U.S. Patent No. 5,409,734, are different than the laminating procedures recommended for use with the cross-linked SPD films used in the methods of the present invention because, among other reasons, the matrix polymer disclosed in U.S. Patent No.
- 5,409,734 is poly (methyl methacrylate) which has a relatively high glass transition temperature (softening point), whereas the matrix polymer in the best known type of cross- linked SPD film is a relatively soft polyorgansiloxane material which has a relatively low glass transition temperature.
- the liquid suspension is selected to be immiscible with the matrix material at room temperature (25 degrees C), if the temperature is raised to too high a level during lamination, some degree of miscibility of the matrix and liquid suspension may occur, in which event certain properties of the film will be degraded. Accordingly, the heat and pressure parameters that maybe applied during successful lamination of cross-linked SPD films are necessarily somewhat different than for anon-cross- linked SPD film.
- the unit may comprise the cured SPD layer with only plastic sheets and films, i.e., without any glass sheets.
- ultraviolet absorbing materials maybe incorporated in the plastic hot melt adhesive sheets or films and/or in the polyethylene terephthalate (PET) or alternative plastic sheets usually used in the SPD film, to reduce or prevent degradation by ultraviolet radiation of the SPD film or particles or other components of the film and/or to protect objects on the side of the unit opposite from impinging ultraviolet radiation.
- hot melt adhesive means a plastic sheet or film which softens and melts over a temperature range above room temperature (room temperature is defined herein as 25 degrees C), and is generally effective when used as an intermediate layer (a) to bond one type of plastic to another or (b) to bond a plastic sheet or film to a glass sheet.
- types of hot melt adhesives useful with the present invention include plastic sheets or films of ethylene/vinyl acetate copolymers (EVA), various types of polyurethane (PU) polymers and polyvinyl butyral (PVB).
- EVA ethylene/vinyl acetate copolymers
- PU polyurethane
- PVB polyvinyl butyral
- Such hot melt adhesive sheets or films may have any desired thickness and may have a wide variety of melting ranges, depending on the nature of the plastic material and its viscosity or molecular weight.
- a simple non-limiting embodiment of a light valve film is used.
- This exemplary embodiment comprises two sheets of transparent polyethylene terephthalate (PET) plastic sheet, each of which has on one surface thereof facing one another, a transparent electrically conductive coating of indium tin oxide (ITO), and sandwiched in between the two facing ITO coatings is a layer of cured cross-linked SPD emulsion.
- PET sheets maybe of any desired thickness, e.g., 5 or 7 mils, but maybe thinner or thicker when appropriate.
- An autoclave which is a device well known in the art (and which is broadly described in the Crockett Article), may be used in carrying out the lamination methods described herein. Autoclaves are intended to apply heat, pressure and vacuum uniformly within a controlled environment, even for curved glass or plastic shapes. Autoclaves can generally handle a plurality of items to be laminated, and can be rapidly heated and cooled to accommodate mass production. Some autoclaves can achieve a pressure capability of up to 700 pounds per square inch and temperatures of up to 1 , 100 degrees F, although lower pressures and temperatures are more commonly employed. [0049] There are numerous manufacturers of autoclaves worldwide, having a variety of engineering features, operational capabilities, specifications and prices.
- the Carver Press is manufactured by Carver, Inc. of Wabash, Indiana. If an SPD lamination is successfully achieved by using a laminating press such as the aforementioned Carver Press, one is substantially assured of successful lamination in an autoclave because of more uniform and precise pressure and temperature controls in an autoclave.
- Methods of making and curing SPD films are disclosed in the prior art and in pending U.S. Patent Application Serial No. 10/465,489 mentioned above.
- EXAMPLES [0052] The following examples are provided only for the purpose of illustrating the invention and should not be construed as limiting the invention in any manner. The procedures described herein for preparing and laminating an SPD film are particularly effective in overcoming the main lamination problems noted above in an expeditious manner.
- an SPD film having a refractive index (Ri) of 1.4720 ( ⁇ .005) for both its matrix and liquid suspension was prepared by curing an SPD emulsion open face, i.e., by exposing to ultraviolet radiation an uncured liquid SPD emulsion which had been spread as an approximately 2-mil thick coating on a very thin ITO transparent electrically conductive coating bonded to and overlying a first plastic (PET) substrate. Exposure to the ultraviolet radiation, preferably in an inert atmosphere, e.g., without limitation, nitrogen or argon, cured the SPD emulsion by cross-linking polymer chains therein.
- an inert atmosphere e.g., without limitation, nitrogen or argon
- the cured SPD emulsion comprised a solidified cured matrix constituting a majority of the cured emulsion, within which a vast number of extremely small (uncrosslinked) droplets of liquid suspension were distributed.
- a second ITO-coated PET substrate was then sandwiched with the first substrate so that the ITO coating of the second substrate was in contact with the cured emulsion on the first ITO-coated PET substrate.
- the cured SPD emulsion when sandwiched between PET (or alternative) substrates comprises what is herein referred to as an "SPD film". It should be understood, however, that other related embodiments of such an SPD film are within the scope of the present invention.
- the second PET substrate may also be provided thereon with another layer of a cured SPD emulsion before being sandwiched.
- the ITO coatings may have dielectric overcoatings thereon such as, without limitation, MgF 2 or SiO, to prevent or minimize any possible chemical reaction between the ITO or its substrate and the emulsion.
- the sandwiched SPD film described in 1(b) above is then combined with all other components of the intended laminate. For example, two sheets of hot melt adhesive (such as polyurethane or ethylene/vinyl acetate) are placed on opposite sides of the SPD film, and then glass sheets are placed on opposite sides of the stack of components, outside the hot melt adhesive sheets.
- hot melt adhesive such as polyurethane or ethylene/vinyl acetate
- the stack comprises, in sequence, a first glass sheet, a first sheet of hot melt adhesive, the SPD film (comprising cured SPD emulsion sandwiched between two ITO-coated PET substrate sheets), a second sheet of hot melt adhesive and a second glass sheet, all "stacked" substantially congruent to one another with electrically conductive leads protruding therefrom, or with the SPD film or at least one of the SPD film's ITO-coated PET substrates protruding slightly to enable electrical connections to be more easily made to the SPD film and laminated SPD film.
- this unlaminated group of components is sometimes referred to herein as the "stack" or the "unlaminated stack”.
- the inert plastic sheets may be placed over only the exposed edge of the cured emulsion, located between the two ITO coated glass or plastic (e.g., PET) substrates, i.e. without wrapping the sheets along the outer edges of the glass or plastic substrates.
- the idea is to prevent the components of the hot melt adhesive, when such adhesive is heated, from contacting the cured SPD emulsion.
- the vacuum is continued for 30 minutes in order to effectively degas and simultaneously preheat the stack and, in particular, the hot melt adhesive.
- Degassing the stack substantially removes therefrom any volatile solvents, trapped water vapor and air bubbles.
- the vacuum is thereafter maintained substantially throughout the lamination process.
- the 70 degrees C temperature is not critical and a lower temperature, e.g., 50 degrees C could also be effective.
- the preheating temperature should preferably be below the lowest end of the glass transition temperature range of the hot melt adhesive.
- preheating before applying greater than atmospheric pressure to the unlaminated stack can be achieved by alternate means which are well known in the art, such as the use of a high-pressure inert gas, which offers enhanced uniformity of the pressure applied to the stack. [0057] 4. After preheating the unlaminated stack as described in no.
- moderate pressure above atmospheric pressure is equal to 14.69594 psi
- the net pressure is applied to the stack for 3-5 hours at a temperature high enough to completely melt the hot melt adhesive sheets but not high enough to cause the SPD film to ooze (spread) beyond the boundaries of the cured film prior to lamination, or to significantly degrade the performance of the film.
- a net pressure ranging from about 2.8 psi (pounds per square inch) to 26.1 psi was effective in combination with lamination temperatures in the range of 95 degrees C to 98 degrees C.
- the net pressure applied during lamination is the excess pressure applied above standard atmospheric pressure (14.69594 psi).
- SPD films which have a relatively soft polyorganosiloxane matrix slight oozing of the film has sometimes been observed at or above 105 degrees C. Therefore, for such films the lamination temperature should be below 105 degrees C.
- Other SPD films which have different matrices disclosed in the prior art which have a higher glass transition temperature should be able to tolerate lamination temperatures of 120 degrees C or more, however.
- Table 1 below provides numerous examples of SPD films which have been successfully laminated using the Carver Press under the conditions described above and in the Table, subj ect to the qualifications and protective measures described herein wherein laminates are formed with polyurethane or polyvinyl butyral as the hot melt adhesive.
- the urethane linkages in the polyurethane hot melt adhesive degrade some of the polyiodide particles in the cured emulsion layer while the polyurethane is melted, when the molten polyurethane contacts the outer edges of the cured emulsion.
- One means for avoiding the creation of such a frame is to use particles in the emulsion which are not degraded upon contact with molten polyurethane. Since, however, in the present invention, it is often desirable to use particles which may suffer such degradation, an alternate method (as described below) has been developed for preventing the creation of such dark areas in the emulsion.
- the hot melt adhesive in the molten state
- the cured emulsion is prevented by placing pieces (e.g., sheets, strips, etc.) of (preferably transparent)substantially chemically inert plastic including, but not limited to polyethylene terephthalate sheets sold under the trade name Mylar®, with or without a pressure-sensitive adhesive on one or both opposed surfaces, all along and overlapping the outer edges of the SPD film and also overlapping any and all protrusions from the SPD film, which protrusions typically comprise a two-layer ITO (indium tin oxide) PET substrate.
- ITO indium tin oxide
- the inert plastic may, if desired, be pre-formed into a frame of a particular shape (e.g., a square, oval, circle, rectangle, etc.) configured to cover the edges of the laminated stack and preventing contact between the molten hot melt adhesive and the cured emulsion.
- the frame may be formed from a single sheet of film, or alternately, be pieced together from a plurality of pieces, strips or sheets of such film or maybe formed from a single sheet of film.
- the plastic sheets, strips, etc. used for this purpose are preferably very thin, typically two mils or less in thickness, preferably 1 mil or less and more preferably 0.5 mil in thickness.
- the inert plastic should have a melting point higher than the melting point of the hot melt adhesive used in forming the stack.
- the cured emulsion must be protected on both sides of the stack and thus, in one embodiment, two plastic "frames" are included, one on each side of the SPD film.
- the protection from contact with the molten adhesive can be provided by multiple pieces, e.g., strips, sheets, etc. placed on either side of the SPD film at locations appropriate for preventing contact between the hot melt adhesive (when made molten during the lamination process) and the emulsion.
- the inert plastic material may be positioned inwardly from the two ITO-coated substrates used in forming the SPD film, forming a protective perimeter around the cured SPD emulsion.
- plastic strips and/or a plastic frame are preferred since they cover only the edges of the laminate, i.e., they do not cover the viewing area, the invention additionally contemplates the use of a continuous sheet or film of the inert plastic, which may or may not have a pressure sensitive adhesive on one or both sides, which is placed on both external sides of the SPD film and which thus does cover the entire surface of the laminate including the viewing area.
- PVB polyvinyl butyral
- a laminate stack i.e., instead of polyurethane
- pieces such as strips of the substantially chemically inert, preferably transparent plastic (e.g., Mylar®) in the manner as discussed above to prevent contact between molten PVB and the cured emulsion during formation of the laminate.
- transparent plastic e.g., Mylar®
- the sheets or films of PVB contain therein a somewhat electrically conductive plasticizer which is liquid when the PVB becomes molten.
- the plasticizer is believed to at least partially permeate the cured emulsion during lamination, without necessarily chemically degrading the emulsion. It is noted that if the droplets of liquid suspension in the cured emulsion become somewhat more electrically conductive because some conductive plasticizer was added thereto, when after lamination one applies a given voltage to the laminated stack, the range of light transmission will be less than the range of light transmission of the SPD film alone, observed prior to its lamination within the stack, with the same applied voltage. However, with the use of the inert plastic strips, frames, etc. the cured emulsion is protected from the molten PVB during lamination, and a very satisfactory laminated stack is achieved, using PVB as the hot melt adhesive, as detailed in Table 1 below.
- the term 'net pressure' is the pressure applied to the lamination in excess of atmospheric pressure.
- Column 1 indicates the type of hot melt adhesive sheets used in each lamination test.
- Polyurethane (PU) sheets of 25 mil thickness show excellent adhesion and performance for this purpose, and may be obtained from, for example, Deerfield Urethane, P. O. Box 186, South Deerfield, MA 01373 (telephone: (413) 665-7016) under the trade name Deerfield Dureflex® A4100/A4700 Aliphatic Polyurethane Sheet. Although 25 mil thick sheets were used in the examples listed in Table 1, other appropriate thicknesses are also satisfactory.
- EVA hot melt adhesive sheets may be purchased from, among others, TOSOH Corporation, 3-8-2, Shiba, Minato-ku, Tokyo 105-8623, Japan.
- Sheets of PVB are obtainable from Solutia, Inc., 575 Maryville Center Drive, P.O. Box 66760, St. Louis, MO (telephone: 1-314-674-6661).
- the ratio of matrix to liquid suspension in the emulsion is shown in Column 2 of Table 1.
- the matrix portion of each of the emulsions used in the examples set forth in Table 1 comprises a co-polymer of 90% by weight (a) poly (dimethyl diphenyl siloxane, disilanol terminated) and 10% by weight (b) acryloxy propyl methyl dimethoxy silane, a cross- linkable monomer.
- the second item of data in Column 3 shows for each example the length of time the stack was held at the specified temperature during the main portion of lamination.
- the net pressure applied to the stack is listed in Column 9, i.e., the last column at the right of the Table. In many cases; the pressure on the platens increased when the temperature was raised from 70 degrees C to a higher temperature during the main part of lamination due to expansion of the hot melt adhesive.
- the data in Column 3 demonstrates that, while maintaining above atmospheric pressure, after the short cool-down period listed in Column 4, the stack was thereafter maintained under the indicated pressure for an additional 30 minutes at room temperature (25 degrees C) before the pressure was reduced to atmospheric pressure and the sample removed from the Carver Press.
- the low end of the melting range of the hot melt adhesive be at least 75 degrees C and preferably at least 85 degrees C. It is also preferable that it be possible within 5 hours to completely melt a film or sheet of the hot melt adhesive having a thickness in the range of 5 to 50 mils, at a temperature of 105 degrees C or less in order to prevent or reduce the risk of film oozing during lamination and to avoid taking an unreasonably long time to effect the lamination.
- the emulsion incorporates a matrix which is not a polyorganosiloxane and which has a sufficiently high glass transition point, and if the particles in the liquid suspension of the emulsion will tolerate the temperature, a hot melt adhesive with a melting point of greater than 105 degrees C may be employed.
- a layer of PVB may be laminated between two glass sheets, whereas an SPD film is laminated separately as described above. Then the two laminates can be laminated together using PU or EVA in between a glass or plastic sheet on the exterior of the film and one of the glass sheets of the glass/PVB/glass laminate.
- SPD light valves which comprise laminated SPD films which have been laminated by using the methods disclosed herein are superior to prior art SPD light valves, including even those comprising prior art laminated SPD films. This is because prior art SPD films were made substantially in the manner described in the above-mentioned U.S. Patent No. 5,409,734 which discloses a type of non-crosslinked light valve film that is formed by phase separation from a homogeneous solution.
- SPD light valves comprising such non-crosslinked light valve films have much poorer optical performance characteristics than SPD light valves comprising crosslinked SPD films toward which the present invention is directed.
- the SPD light valves comprising non-crosslinked light valve films have a much smaller range of light transmission and much greater haze than comparable SPD light valves comprising crosslinked light valve films activated at the same voltage and frequency and having about the same off-state light transmission.
- an SPD light valve comprising a non-crosslinked laminated light valve film, and having an off-state light transmission of 9%, when activated with a voltage of 50 volts RMS at a frequency of 400 Hertz, would typically attain an on-state light transmission o of 44%, or a light transmission range of 35%. On-state haze would typically be about 18%, which is quite objectionable.
- SPD light valve comprising a crosslinked laminated light valve film, and having an off-state light transmission of 8%, when activated with a voltage of 50 volts RMS and a frequency of 400 Hertz, would typically attain an on-state light transmission of 67%, or a light transmission range of 59%.
- SPD films In general, for most application, SPD films must be laminated in order to be useful in SPD devices by protecting the films from the environment and by providing other performance benefits. Because the matrices and liquid suspensions used with the crosslinked emulsions of the present invention are quite different from the comparable materials used to make non-crosslinked films, as ' discussed above, prior art lamination methods are not applicable. It is essential therefore to find lamination procedures for the crosslinked SPD films which will avoid the problems listed herein above. The methods disclosed herein are effective in avoiding those problems, and provide not only excellent laminates but also excellent SPD devices which comprise said laminates.
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Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2004318735A AU2004318735B2 (en) | 2004-04-13 | 2004-07-23 | Methods for laminating films for SPD light valves and SPD light valves incorporating such laminated films |
KR1020067022380A KR101113919B1 (en) | 2004-04-13 | 2004-07-23 | Methods for laminating films for spd light valves and spd light valves incorporating such laminated films |
EP04779006.8A EP1735156B1 (en) | 2004-04-13 | 2004-07-23 | Methods for laminating films for spd light valves and spd light valves incorporating such laminated films |
ES04779006.8T ES2598406T3 (en) | 2004-04-13 | 2004-07-23 | Film lamination procedures for SPD type light valves and SPD type light valves incorporating said laminated films |
CA 2563303 CA2563303C (en) | 2004-04-13 | 2004-07-23 | Methods for laminating films for spd light valves and spd light valves incorporating such laminated films |
JP2007508320A JP5173408B2 (en) | 2004-04-13 | 2004-07-23 | Method for laminating thin films for SPD light valves and SPD light valves incorporating the laminated thin films |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US56232904P | 2004-04-13 | 2004-04-13 | |
US60/562,329 | 2004-04-13 |
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WO2005102688A3 WO2005102688A3 (en) | 2006-06-29 |
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PCT/US2004/023747 WO2005102688A2 (en) | 2004-04-13 | 2004-07-23 | Methods for laminating films for spd light valves and spd light valves incorporating such laminated films |
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US (1) | US7361252B2 (en) |
EP (1) | EP1735156B1 (en) |
JP (2) | JP5173408B2 (en) |
KR (1) | KR101113919B1 (en) |
AU (1) | AU2004318735B2 (en) |
CA (1) | CA2563303C (en) |
ES (1) | ES2598406T3 (en) |
PL (1) | PL1735156T3 (en) |
WO (1) | WO2005102688A2 (en) |
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Also Published As
Publication number | Publication date |
---|---|
JP2007533490A (en) | 2007-11-22 |
JP5173408B2 (en) | 2013-04-03 |
WO2005102688A3 (en) | 2006-06-29 |
AU2004318735B2 (en) | 2009-07-30 |
CA2563303A1 (en) | 2005-11-03 |
EP1735156A4 (en) | 2011-10-26 |
AU2004318735A1 (en) | 2005-11-03 |
KR20070007164A (en) | 2007-01-12 |
EP1735156B1 (en) | 2016-07-20 |
ES2598406T3 (en) | 2017-01-27 |
EP1735156A2 (en) | 2006-12-27 |
US7361252B2 (en) | 2008-04-22 |
KR101113919B1 (en) | 2012-02-29 |
JP2011189751A (en) | 2011-09-29 |
PL1735156T3 (en) | 2017-01-31 |
CA2563303C (en) | 2012-05-15 |
US20050227061A1 (en) | 2005-10-13 |
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