The present invention pertains to a curved light filter that changes from a light-transmission-state to a dark-transmission-state in response to incident light. The curved switchable filter has at least one liquid-crystal layer disposed between thin, flexible, glass substrates.
Automatic darkening filters commonly have a switchable filter that automatically changes from a light-transmission-state to a dark-transmission-state in response to incident light. The switching is generally achieved through use of a photodetector that is located on, or as part of, personal protective equipment. The photodetector recognizes the presence of the incident light-to-be-filtered, and an electronic module generates a control voltage that, when applied to the switchable filter, causes the filter to change from the light-transmission-state to the dark-transmission-state.
Automatic light filters have been designed which contain liquid-crystal cells located between polarizing films. U.S. Pat. No. 4,240,709 to Hörnell describes a switchable filter that has a single-twisted, nematic, liquid-crystal cell sandwiched between a pair of mutually crossed polarizers. The liquid-crystal cells are generally flat, optically-transparent, glass substrates that include transparent electrode and alignment layers. The liquid-crystal molecules orientate themselves in a particular direction when a voltage is applied across the liquid-crystal cell under the control of an electronic module. Many commercially available products use this kind of switchable filter.
The use of an automatic-darkening filter in a protective shield gives significant ergonomic benefits. Previously welders, for example, had to “nod” their welding shield down when they struck the welding arc to ensure that their eyes were protected from the torch light. Automatic welding filters eliminated this action since the welding shield could be continuously placed in the down position. As a result, weld pattern quality has been generally improved because more accurate electrode placement can be achieved. Productivity improvements also have been noted since grinding and rework have been correspondingly reduced.
Existing flat-glass automatic darkening filters can, however, add considerable weight to the final product (such as welding shield), which in turn, can create stress and tension in the user's neck and shoulders. The rectangular configuration of the typical glass sandwich construction also tends to limit the wearer's field of view. Known welding filters have been generally limited to rectangular constructions because of difficulties in scribing and breaking the rigid glass substrates.
The terms set forth below will have the meanings as defined:
“Automatic darkening filter” means a device that attenuates light in response to an input from the light itself and without an input from a person;
“Band pass filter” means a device that allows light of a certain range of frequency(s) to pass therethrough but rejects the passage of light of other frequencies;
“Curved” means not following a straight line when viewed in cross-section;
“Deformation” with respect to a glass layer means being able to be bent 5 millimeters (mm) over a cantilevered distance of 50 mm from the fixed point without fracture;
“Electric field” means a region surrounding an electric charge, which region can generate a force that can be exerted upon charged particles or molecules;
“Flexible” means being able to withstand deformation into a curved shape without breaking;
“Glass” means an inorganic amorphous non-crystalline solid material that is capable of transmitting visible light;
“Glass layer” or “glass sheet” means glass that has dimensions that are substantially greater in width and length than in thickness;
“Juxtaposed” means to place side by side but not necessarily in contact with each other;
“Liquid crystal layer” means a layer that has molecules in a liquid phase which molecules have some orientational order with respect to each other and have the ability to align in response to an electric field;
“Low twist” means having a twist angle of less than 90 degrees;
“Nematic molecules” means molecules that exhibit parallel axes in response to an electric field;
“Optically-transparent” means that visible light can pass therethrough sufficiently to see the desired image on the opposing side of the structure;
“Orthogonal” means at right angles thereto;
“Polarize” means to cause light to vibrate in a definite pattern;
“Polarizer” means having the ability to polarize visible light;
“Polarization direction” means an orientation resulting from the polarization of light;
“Rotate” means to change orientation;
“Sensor” means a device that can detect the presence of a defined light source and that can send a signal to another device;
“Signal” means an electrical quantity such as voltage; and
“Twist angle” means an angular difference in orientation between two surfaces.
The present invention provides a switchable filter that comprises a first polarizer, a second polarizer, and a first liquid-crystal cell. The first polarizer has a first polarization direction, and the second polarizer has a second polarization direction. The second polarization direction may be the same or different from the first polarization direction. The liquid-crystal cell is disposed between the first and second polarizers. The liquid crystal cell contains first and second optically-transparent, flexible, glass layers and has a liquid crystal layer located between the first and second curved, optically-transparent flexible glass layers.
The inventive switchable filter is beneficial in that overall product weight can be reduced relative to known commercially-available products. Reductions in weight are achieved by the, low weight of the flexible glass layers. These flexible layers tend to be thinner than the flat glass substrates that have been used in previous conventional products. Further, the inventive switchable filter can be fashioned to have a non-rectangular shape, which improves the user's view field. The user can be provided with an expanded peripheral range of vision in both the horizontal and vertical dimensions. The switchable filter also may be configured in various shapes, for example, to follow the contours of the wearer's face and to accommodate goggles or eye glasses.
In the practice of the present invention, flexible glass layers define an enclosed area where liquid-crystal molecules are free to rotate under the influence of an electric field to produce a light-filtering effect. The use of flexible glass layers in the manufacture of a switchable filter enables the components of the switchable filter to be laminated together in curved form. This assembly enables a larger viewing area to be achieved for the same (or even less) weight.
Liquid crystal cells 16, 20, and 28 may be a twisted, nematic, liquid-crystal cell type cell that provides a “fail-safe” intermediate transmission state in the case of electronic module failure. An automatic darkening filter that has low-twist, liquid-crystal, cells is described in U.S. Pat. No. 6,097,451 to Palmer et al.; see also U.S. Pat. No. 5,825,441 to Hörnell et al. The twisted, nematic, liquid-crystal cell may have a twist angle of less than 100 degrees, typically zero or 1 to 99 degrees. The liquid-crystal cell also may have a low twist angle of 1 to 85 degrees. More specifically, the twist angle of a low-twist, liquid-crystal, cell may be about 30 to 70 degrees. A “fail-safe” liquid crystal cell is in many ways similar in design to the low-twist, liquid-crystal, cell, but its operation is different because it is sandwiched between parallel polarizers, as opposed to crossed or orthogonal polarizers. Liquid crystal cell 20 is in a dark transmission state (a nearly optically-opaque state in which the majority of the incident light is blocked) when no voltage is applied to the connectors 26. Liquid crystal cell 20 may become optically transparent when a certain voltage is applied.
Switchable filters of the present invention may be curved about one, two, or three axis. Typically a switchable filter used in a welding helmet (
The automatic darkening filter apparatus of the present invention can be used in connection with industrial operations, for example welding (e.g. arc welding, torch welding, acetylene welding), cutting (e.g. laser cutting, acetylene cutting), brazing, soldering and the like. They also can be used in connection with medical procedures involving high intensity light (e.g. laser surgery, hair removal, tattoo removal, light-curing of dental resins, etc.) and other uses as well. One or more automatic-darkening filter apparatuses may be provided in any other suitable equipment or articles and for other applications. For example, an automatic-darkening filter apparatus may be supplied as part of protective eyewear rather than a full-face coverage helmet. Alternatively, an automatic darkening filter apparatus may be provided in a hand-held device, or in a window or aperture allowing inspection of a room, enclosure, machinery space, etc., in which high intensity light may be present.
Liquid Crystal Cell Assembly
A curved liquid crystal cell for an automatic welding filter was made in the following manner.
The starting flexible glass layer was a 0.1 mm thick D263T glass from Schott Glass of Schott Glas Export, GmbH, located at Rheinallee 145, 55120 Mainz, Germany. The glass was sputter deposited with indium tin oxide (ITO). The conductivity of the coated ITO was roughly 100 ohm/square. The ITO glass was coated with a thin layer of polymide polymer. A commercially-available polyimide alignment material was coated onto the glass using a spin coating technique. The dried coating thickness was between 80 nanometers (nm) and 200 nm. The thin polymide layer was aligned by brushing it with using a rotating felt cloth. This brushed polymide, ITO/glass piece was cut into pieces for the top and bottom portion of the liquid crystal cell. A first piece (top) of glass was rotated 90° from the orientation of the second (bottom) piece of glass to provide proper alignment.
The curved, liquid-crystal cell was formed using a metal cylinder that had a radius of approximately 90 millimeters (mm) as the template. The bottom portion of the cell, the ITO glass having the rubbed polyimide coating, was taped to the metal cylinder using 3M Magic Tape™. An edge adhesive (UV curing Norland 68 optical adhesive) was applied to the bottom portion using a syringe and needle. A twisted, nematic, liquid-crystal mixture was combined with 1% by weight of 4 micrometer (μm) ceramic spacer beads. The liquid crystal/spacer bead mixture was placed on the bottom portion of the cell using a pipette. The top portion of the cell was attached to the bottom portion at the leading edge using 3M Removable Tape™. A polyester film, that was attached to the metal cylinder on one end, was used to wrap and curve the top portion of the cell onto the bottom portion. A rubber roll was used to compress the top portion onto the bottom portion. Tension was maintained on the polyester film to keep the components of the cell in close contact. Using a UV light source for 5 minutes, the UV curing edge adhesive was then cured. The completed cell was then removed from the cylinder by removing the polyester film and pieces of tape. Polarizing films were attached to the bottom and top portions using a pressure-sensitive adhesive. The polarizing films were orthogonal to each other and corresponded to the alignment that was rubbed into the polyimide layer. Copper tape, with conductive adhesive, was attached to the ITO on the top portion, and another piece of copper tape with conductive tape was attached to the ITO on the bottom portion. A 10 volt potential was placed across the cell through the copper tape. The cell switched from a light state to a dark state when the voltage was applied. The dimensions of the finished cell were approximately 75 mm wide and 75 mm long (5625 mm2; 56.25 cm2) with a curvature that was slightly less than the 100 mm radius of the original cylinder.
This invention may take on various modifications and alterations without departing from its spirit and scope. Accordingly, this invention is not limited to the above-described but is to be controlled by the limitations set forth in the following claims and any equivalents thereof.
This invention also may be suitably practiced in the absence of any element not specifically disclosed herein.
All patents and patent applications cited above, including those in the Background section, are incorporated by reference into this document in total. To the extent there is a conflict or discrepancy between the disclosure in such incorporated document and the above specification, the above specification will control.
This application is a continuation of U.S. patent application Ser. No. 13/713,331, filed on Dec. 13, 2012, which is incorporated by reference herein in its entirety.
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Number | Date | Country | |
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Child | 15162242 | US |