Composite interlayer film for laminated panel, laminated panel, and manufacturing method thereof

Abstract

A composite interlayer film (10) for a laminated panel is used for applications in which the composite interlayer film is sandwiched between and integrated with a pair of transparent panels to manufacture a laminated panel and includes a thermoplastic resin sheet (11) and an electrically controllable sheet-shaped object (12) embedded in the thermoplastic resin sheet (11).

Description

Composite interlayer film for laminated panels, laminated panels, and manufacturing methods thereof

[0001] The present invention relates to a composite interlayer film for a laminated panel that is sandwiched between two transparent panels, a laminated panel that includes the composite interlayer film for a laminated panel, and methods for manufacturing these.

[0002] In recent years, smartification has progressed in various fields, including smart homes and smart mobility. Along with this progress, there is a growing market need for materials to be turned into devices. For example, there is a growing demand for glass to have smart functions that can be realized through electrical control. Therefore, there is growing interest in attaching electrically controllable substrates or films with electrical circuits to glass.

[0003] On the other hand, as glass, laminated glass in which two glass sheets are integrated with an interlayer film is widely used. For laminated glass, it has been considered to provide an electrically controllable film or substrate in the interlayer film. For example, Patent Document 1 discloses laminated glass in which the interlayer film is composed of two or more interlayers and an electrically controllable functional element is provided between the interlayers. Patent Document 1 discloses that the laminated glass disclosed is manufactured by stacking and integrating a glass panel, an interlayer, a barrier film, a functional element, a barrier film, an interlayer, and a glass panel in this order.

[0004] Special Publication No. 2020-510232

[0005] As described in Patent Document 1, when an electrically controllable functional element is provided in an interlayer film, air tends to accumulate around the edges of the interlayer film and around the functional element during the production of laminated glass, which can cause bubbles to form and result in poor appearance.

[0006] Therefore, an object of the present invention is to provide a composite interlayer film for laminated panels that can prevent air from accumulating near the edges of the interlayer film or around an electrically controllable film or substrate, thereby preventing poor appearance.

[0007] The present invention provides the following [1] to

[25] . [1] A composite interlayer film for a laminating panel, which is sandwiched between a pair of transparent panels and integrated with them to produce a laminating panel, the composite interlayer film for a laminating panel comprising a thermoplastic resin sheet and an electrically controllable sheet-like material embedded in the thermoplastic resin sheet. [2] The composite interlayer film for a laminating panel according to [1] above, wherein the thermoplastic resin sheet has a compressibility of 3% to 90% when maintained at 90°C and 0.08 MPa for 5 minutes. [3] The composite interlayer film for a laminating panel according to [1] or [2] above, wherein the peripheral edge of the sheet-like material is positioned 8 mm or more inward from the peripheral edge of the thermoplastic resin sheet. [4] The composite interlayer film for a laminating panel according to any one of [1] to [3] above, having a thickness of 1,000 μm to 2,500 μm. [5] The composite interlayer film for a laminating panel according to any one of [1] to [4] above, wherein the sheet-like material includes a portion having a thickness of 100 μm or more. [6] The composite interlayer film for a laminating panel according to any one of [1] to [5] above, wherein the surface roughness (Rz) is 1 μm or more and 120 μm or less. [7] The composite interlayer film for a laminating panel according to any one of [1] to [6] above, wherein the composite interlayer film has a contour shape that matches the shape of the transparent panel. [8] The composite interlayer film for a laminating panel according to any one of [1] to [7] above, wherein the thermoplastic resin constituting the thermoplastic resin sheet is at least one selected from the group consisting of ethylene-vinyl acetate copolymer, polyolefin-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, polyolefin-based resin, cyclic olefin-based resin, polyvinyl acetal-based resin, and ionomer resin. [9] The thermoplastic resin constituting the thermoplastic resin sheet is at least one selected from the group consisting of polyvinyl acetal resins, ethylene vinyl acetate copolymers, polyolefin thermoplastic elastomers, and ionomer resins. [1] The composite interlayer film for laminated panels according to any one of [1] to [8].

[10] The composite interlayer film for a laminating panel according to any one of [1] to [9] above, wherein the sheet-like material comprises at least one device selected from the group consisting of a light control body, a coil, an antenna, a piezo element, an LED element, a battery, sensors, switches, and an integrated circuit.

[11] The composite interlayer film for a laminating panel according to any one of [1] to

[10] above, wherein the sheet-like material is either a film or a flexible printed circuit board comprising the device.

[12] The composite interlayer film for a laminating panel according to any one of [1] to

[11] above, which does not contain a light control film.

[13] The composite interlayer film for a laminating panel according to any one of [1] to

[12] above, which is other than a composite interlayer film in which two or more light control films are arranged in the thickness direction.

[14] The composite interlayer film for a laminating panel according to any one of [1] to

[13] above, wherein the maximum thickness of the sheet-like material is 1,500 μm or less.

[15] The composite interlayer film for laminating panels according to any one of [1] to

[14] above, wherein the sheet-like material occupies 0.2% to 99% of the thermoplastic resin sheet in the thickness direction.

[16] The composite interlayer film for laminating panels according to any one of [1] to

[15] above, wherein the sheet-like material occupies 30% to 99% of the area of ​​the thermoplastic resin sheet.

[17] A method for producing a composite interlayer film for laminating panels according to any one of [1] to

[16] above, comprising placing the sheet-like material between sheets for forming the thermoplastic resin sheets and embedding the sheet-like material within the thermoplastic resin sheets.

[18] A method for producing a composite interlayer film for laminating panels according to

[17] above, wherein the sheets for forming the thermoplastic resin sheets are processed into a contour shape that matches the shape of the transparent panel.

[19] A method for producing a composite interlayer film for laminating panels according to

[17] or

[18] above, wherein the sheet-like material is placed between sheets for forming the thermoplastic resin sheets and thermocompression bonded.

[20] The method for manufacturing a composite interlayer film for a laminating panel according to the above

[19] , wherein the thermocompression bonding is performed under pressure or negative pressure.

[21] The method for manufacturing a composite interlayer film for a laminating panel according to the above

[19] or

[20] , wherein the surface roughness (Rz) of the composite interlayer film is adjusted to 1 μm or more and 120 μm or less during the thermocompression bonding.

[22] A method for producing a composite interlayer film for a laminating panel according to

[21] above, wherein the surface of the sheet for forming the thermoplastic resin sheet is textured before the thermocompression bonding, or a release sheet with textured surfaces is superimposed on the sheet for forming the thermoplastic resin sheet so as to be in contact with the sheet for forming the thermoplastic resin sheet during the thermocompression bonding.

[23] A laminating panel comprising the composite interlayer film according to any one of [1] to

[16] above and a pair of transparent panels, wherein the composite interlayer film is disposed between the pair of transparent panels and the pair of transparent panels is integrated via the composite interlayer film.

[24] A method for producing a laminating panel, wherein the composite interlayer film according to any one of [1] to

[16] above is disposed between a pair of transparent panels and the pair of transparent panels is integrated via the composite interlayer film.

[25] A method for using a composite interlayer film for a laminating panel according to any one of [1] to

[16] above, wherein the composite interlayer film for a laminating panel is sandwiched between a pair of transparent panels and integrated with them to produce a laminating panel.

[0008] The composite interlayer film for laminated panels of the present invention can prevent air from accumulating near the edges of the interlayer film or around the electrically controllable sheet-like material, thereby preventing poor appearance.

[0009] 1 is a schematic cross-sectional view showing a composite interlayer film for a laminating panel according to one embodiment of the present invention. 2 is a schematic cross-sectional view showing a composite interlayer film for a laminating panel according to one embodiment of the present invention. 3 is a schematic cross-sectional view showing a composite interlayer film for a laminating panel according to one embodiment of the present invention. 4 is a schematic cross-sectional view showing a composite interlayer film for a laminating panel according to one embodiment of the present invention. 5 is a schematic cross-sectional view showing a method for manufacturing a laminating panel using a composite interlayer film for a laminating panel according to one embodiment of the present invention.

[0010] <Composite Interlayer Film> The composite interlayer film for a laminating panel of the present invention (hereinafter also referred to as "composite interlayer film") is a composite interlayer film 10 comprising a thermoplastic resin sheet 11 and an electrically controllable sheet-like material 12 embedded in the thermoplastic resin sheet 11, as shown in FIG. 1. As described below, the composite interlayer film 10 is sandwiched between a pair of transparent panels 20, 20 and integrated therewith to produce a laminating panel (see FIG. 5). In the present invention, a laminating panel is produced using a composite interlayer film 10 formed by embedding the sheet-like material 12 in the thermoplastic resin sheet 11, thereby preventing air from accumulating at the edges of the composite interlayer film 10 or around the sheet-like material 12 during laminating panel production. This prevents the generation of air bubbles in the laminating panel, thereby providing a laminating panel with a good appearance.

[0011] Furthermore, when the sheet-like material 12 is provided on the interlayer film, misalignment of the components occurs during the production of the laminated panel, and the thermoplastic resin of the thermoplastic resin sheet 11 is easily pushed outward by the sheet-like material 12, resulting in protrusion of the thermoplastic resin. However, in the present invention, by producing the laminated panel using a composite interlayer film 10 that has been prepared in advance, misalignment of the components occurs during the production of the laminated panel, and the thermoplastic resin is prevented from being pushed outward, thereby preventing the thermoplastic resin from protruding to the outside of the laminated panel. This improves the workability of the trimming process to remove unnecessary thermoplastic resin that has protruded to the outside after the laminated panel is produced.

[0012] [Thermoplastic resin sheet] As described above, the composite interlayer film 10 includes a thermoplastic resin sheet 11. The thermoplastic resin sheet may consist of a single sheet, but is preferably formed by integrating multiple sheets. When multiple sheets are used, the multiple sheets may be integrated by being laminated in the thickness direction. When the thermoplastic resin sheet is formed by integrating multiple sheets, it is preferable to place a sheet-like object between the sheets. When the thermoplastic resin sheet is formed from two or more sheets, it becomes easier to embed the sheet-like object inside the thermoplastic resin sheet.

[0013] When the thermoplastic resin sheet is formed from multiple sheets, the number of sheets is not particularly limited as long as it is two or more. However, from a practical standpoint, it is preferably 10 or less, more preferably 8 or less, even more preferably 6 or less, and even more preferably 4 or less. In FIG. 1 , the thermoplastic resin sheet 11 is shown as consisting of two sheets 13 and 14, with the sheet-like object 12 disposed between the sheets 13 and 14. However, this is not necessarily limited to this. The same applies to the following description. When the thermoplastic resin sheet is formed from three or more sheets, the sheet-like object may be disposed between one sheet and two or more stacked sheets. However, from the standpoint of easily embedding the sheet-like object in the thermoplastic resin sheet, it is also preferable to dispose the sheet-like object between two or more stacked sheets and two or more stacked sheets. For example, when four sheets are provided, the sheet-like object may be disposed between one sheet and three sheets. However, as shown in FIG. 2 , it is preferable to dispose the sheet-like object between two sheets 13A, 13B and two sheets 14A, 14B.

[0014] Furthermore, when the thermoplastic resin sheet 11 is formed from multiple sheets, adjacent sheets in the thickness direction may be bonded to each other and integrated. Similarly, the sheets (sheets 13 and 14 in FIG. 1 ) arranged to sandwich the sheet-like member 12 may also be bonded to each other and integrated in areas where the sheet-like member 12 is not provided, and the integrated portions may cover the end faces (i.e., side faces) of the sheet-like member 12. In this manner, the sheet-like member 12 is appropriately embedded between the sheets (sheets 13 and 14 in FIG. 1 ). Note that although the sheets 13 and 14 are shown separately in FIG. 1 , they may be integrated in the composite interlayer film and therefore may be indistinguishable in the thermoplastic resin sheet 11. The same applies to FIGS. 2 to 4 .

[0015] The thermoplastic resin used for the thermoplastic resin sheet (or for each sheet when the thermoplastic resin sheet is formed of a plurality of sheets) is not particularly limited, but examples thereof include polyolefin resins (PO) such as ethylene vinyl acetate copolymer (EVA), polyolefin thermoplastic elastomer (POE), polyurethane thermoplastic elastomer (TPU), polyethylene resin, and polypropylene resin, cyclic olefin resins (COP) such as cyclic olefin copolymer (COC), polyvinyl acetal resins (PVAc) such as polyvinyl butyral resin (PVB), and ionomer resins.

[0016] Among these, ethylene vinyl acetate copolymer (EVA), polyolefin thermoplastic elastomer (POE), polyvinyl acetal resin (PVAc), and ionomer resin are preferred, with polyvinyl acetal resin being more preferred, and polyvinyl butyral resin being even more preferred. The use of these resins tends to improve adhesion to sheet-like materials, and the use of polyvinyl acetal resins tends to improve penetration resistance and the like.

[0017] The above-mentioned thermoplastic resins may be used alone or in combination of two or more types, and the thermoplastic resin sheet may be formed from a mixture of two or more types of thermoplastic resins. Furthermore, when a thermoplastic resin sheet is formed from multiple sheets, the thermoplastic resin used in each sheet may be used alone or in combination of two or more types, and each sheet may be formed from a mixture of two or more types of thermoplastic resins. Furthermore, when a thermoplastic resin sheet is formed from multiple sheets, the thermoplastic resins used in each sheet may be the same or different resins. However, from the viewpoint of facilitating integration of multiple sheets, it is preferable to use the same type of resin. Therefore, when a thermoplastic resin sheet is formed from multiple sheets, it is preferable that all of the thermoplastic resins used in each sheet are ethylene-vinyl acetate copolymer, polyolefin-based thermoplastic elastomer, or polyvinyl acetal-based resin, and more preferably all are polyvinyl acetal-based resin.

[0018] Polyvinyl acetal resins are obtained by acetalizing polyvinyl alcohol with an aldehyde such as n-butyl aldehyde. Polyvinyl alcohol with a saponification degree of 80 to 99.8 mol% is generally used as the polyvinyl alcohol. Therefore, polyvinyl acetal resins usually have an acetal group, a hydroxyl group, and an acetyl group in their side chains. The polyvinyl acetal resin may be an unmodified polyvinyl acetal resin that does not have functional groups other than these in its side chains, or a modified polyvinyl acetal resin that has modifying groups other than these in its side chains.

[0019] Examples of the modifying group include a carboxamido group (-CONHR), an acyl group other than an acetyl group (-COR), and a polyoxyalkylene group. R in each of the carboxamido group and the acyl group is a hydrocarbon group having 2 to 30 carbon atoms, preferably an alkyl group having 3 to 24 carbon atoms, and more preferably an alkyl group having 5 to 20 carbon atoms. Examples of the polyoxyalkylene group include a polyoxyethylene group, a polyoxypropylene group, a polyoxybutylene group, and a group formed from a copolymer of two or more types selected from oxyethylene, oxypropylene, and oxybutylene.

[0020] The ionomer resin is not particularly limited, and various ionomer resins can be used. Specific examples include ethylene-based ionomers, styrene-based ionomers, perfluorocarbon-based ionomers, telechelic ionomers, and polyurethane ionomers. Among these, ethylene-based ionomers are preferred because they improve the mechanical strength, durability, transparency, and other properties of the laminated glass and provide excellent adhesion to glass. Examples of ethylene-based ionomers include ethylene and (meth)acrylate ion copolymers.

[0021] In the thermoplastic resin sheet (or each sheet if formed from multiple sheets), the thermoplastic resin may be the main component, and its content may be 50% by mass or more, preferably 70% by mass or more, and more preferably 80% by mass or more, based on the total amount of the thermoplastic resin sheet (or each sheet if formed from multiple sheets).

[0022] The thermoplastic resin sheet (or each sheet when formed from multiple sheets) may also contain a plasticizer. When the thermoplastic resin sheet contains a plasticizer, it becomes flexible, thereby improving the flexibility of the laminated panel and penetrating resistance. It also tends to improve adhesion to sheet-like materials and transparent panels. Examples of plasticizers include organic ester plasticizers such as monobasic organic acid esters and polybasic organic acid esters. The content of the plasticizer in the thermoplastic resin sheet (or each sheet when formed from multiple sheets) is, from the viewpoints of flexibility, penetrating resistance, adhesiveness, etc., for example, 10 to 100 parts by mass, preferably 20 to 80 parts by mass, more preferably 25 to 65 parts by mass, per 100 parts by mass of the thermoplastic resin.

[0023] The thermoplastic resin sheet (or each sheet when formed from multiple sheets) may be substantially free of plasticizer. By substantially not containing a plasticizer, the thermoplastic resin sheet can prevent the sheet-like material from being eroded by the plasticizer. Note that "substantially free of plasticizer" means that the content of plasticizer in the thermoplastic resin sheet (or each sheet when formed from multiple sheets) is less than 10 parts by mass, preferably 5 parts by mass or less, more preferably 3 parts by mass or less, and even more preferably 0 parts by mass.

[0024] Furthermore, the thermoplastic resin sheet may contain additives other than plasticizers, such as colorants such as dyes and pigments, fillers, infrared absorbers, ultraviolet absorbers, antioxidants, light stabilizers, fluorescent brighteners, crystal nucleating agents, dispersants, metal carboxylates, and heat-shielding materials, as needed.

[0025] The compressibility of the thermoplastic resin sheet when held at 90°C and a pressure of 0.08 MPa for 5 minutes is preferably 3% to 90%. When the compressibility is within this range, the thermoplastic resin sheet flows appropriately during thermocompression bonding, making it easier to embed a sheet-like material in the thermoplastic resin sheet without leaving any air in the thermoplastic resin sheet. Furthermore, by allowing the thermoplastic resin sheet to flow appropriately during thermocompression bonding, the thickness of the resulting composite interlayer film can be made uniform. Furthermore, when manufacturing a laminated panel, the thermoplastic resin constituting the thermoplastic resin sheet can be prevented from protruding outside the laminated panel. More preferably, the compressibility is 4% to 80%. The compressibility is calculated as the rate of thickness change when the temperature is raised to 90°C at a pressure of 0.08 MPa and a rate of 6°C / min using the compression mode of a dynamic viscoelasticity analyzer RSA-G2, and then held for 5 minutes. It is calculated as (thickness at the start of the holding time - thickness after 5 minutes of holding time) / (thickness at the start of the holding time) x 100. The compression ratio can be adjusted by the type and amount of the resin constituting the thermoplastic resin sheet, the type and amount of the plasticizer, and the like.

[0026] When the thermoplastic resin sheet is formed from multiple sheets, the thickness of each sheet is preferably 100 μm or more, more preferably 200 μm or more, and even more preferably 300 μm or more, and is preferably 1000 μm or less, more preferably 800 μm or less, and even more preferably 500 μm or less. By making the thickness of each sheet equal to or greater than these lower limits, it becomes easier to embed a sheet-like material inside the thermoplastic resin sheet. Furthermore, by making the thickness equal to or less than the upper limits, it is possible to prevent the thickness of the composite interlayer film from becoming thicker than necessary.

[0027] <Sheet-Like Material> The sheet-like material used in the present invention is electrically controllable. Sheet-like materials generally have an electrical circuit, and their operation can be switched by the flow of current or by changing the amount of current flow. Specific examples of sheet-like materials include electrically controllable films and substrates such as electrically controllable flexible printed circuit boards. More specifically, examples include films or flexible printed circuit boards equipped with devices such as dimmers, coils, antennas, piezo elements, LED elements, batteries, sensors such as touch sensors, switches, memories, processors, and integrated circuits such as communication ICs. These devices may be provided singly or in combination on each sheet-like material. The antenna may be, for example, capable of receiving power from an external device in a non-contact manner. In this case, it may be an electromagnetic induction type or a magnetic resonance type. The antenna is generally composed of a coil. The antenna may be formed, for example, by printing, from a metal material such as a metal paste.

[0028] A flexible printed circuit board is generally a substrate on which wiring is printed and a device is mounted on a base material. A resin substrate is used as the substrate. Examples of resin substrates include, but are not limited to, polyester resin substrates such as polyethylene terephthalate and polyethylene naphthalate, and polyimide resin substrates. The resin substrate in a flexible printed circuit board has flexibility and may not be clearly distinguishable from a resin film. The wiring may be formed from a metal material such as a metal paste, or may be formed from a metal oxide or a conductive material other than a metal or metal oxide.

[0029] The electrically controllable film may include at least a substrate film and a device provided on the substrate film, or may include a film in which the device is disposed between two substrate films. Examples of the substrate film include various resin films such as polyester resin films such as polyethylene terephthalate and polyethylene naphthalate, acrylic resin films, cellulose derivative films such as triacetyl cellulose (TAC), polyethersulfone (PES) resin films, and polyimide resin films.

[0030] In addition, in the electrically controllable film, an electrode layer may be provided on the device-side surface of the substrate film. The electrode layer may be made of any conventionally known electrode material, but is preferably a transparent electrode layer. Specific examples of the electrode material include an indium tin oxide (ITO) conductive film, a tin oxide conductive film, a zinc oxide conductive film, and a polymer conductive film.

[0031] An example of an electrically controllable film is a light-controlling film, which is a device that is a light-controlling body. The light-controlling film includes two substrate films and a light-controlling body (light-controlling layer) disposed between the two substrate films. Examples of light-controlling films include a polymer-dispersed liquid crystal (PDLC) film, an electrochromic film, a suspended particle device (SPD) film, and an electrophoretic film device.

[0032] In a polymer-dispersed liquid crystal (PDLC) film, the light-controlling layer is composed of polymer-dispersed liquid crystals. Examples of polymer-dispersed liquid crystals include network-type liquid crystals, in which a network structure is formed by polymers in the liquid crystal layer (light-controlling layer). In an SPD film, the light-controlling layer is composed of a layer containing a resin matrix and a light-controlling suspension dispersed in the resin matrix. Furthermore, in the case of an electrochromic film, the light-controlling layer may contain an electrochromic material. The electrochromic material is not limited to any compound having electrochromic properties, and may be any of inorganic compounds, organic compounds, and mixed-valence complexes. An electrophoretic film device, for example, has an electrophoretic section between substrates having two electrode layers. The electrophoretic section includes, for example, electrophoretic particles and a dispersant that disperses the electrophoretic particles.

[0033] Specific preferred examples of the sheet-like material include flexible printed circuit boards and light-control films that include at least one of the various devices described above. Flexible printed circuit boards may be called flexible hybrid electronics (FHEs), which combine electronic components such as sensors, batteries, and antennas with integrated circuits such as memories, processors, and communication ICs. Flexible printed circuit boards equipped with near-field communication (NFC) devices that include an antenna and an integrated circuit may also be used.

[0034] In one embodiment, the composite interlayer film may be in a form other than that in which two or more light control films are arranged in the thickness direction. Also, in one embodiment, the composite interlayer film may be in a form that does not contain a light control film.

[0035] Furthermore, the composite interlayer film 10 may have one sheet-like material 12 as shown in Figures 1 and 2, or two or more sheet-like materials 12 as shown in Figures 3 and 4. When a plurality of sheet-like materials 12 are provided, the number is not particularly limited, but from the viewpoint of workability and the viewpoint of properly embedding the sheet-like materials 12 in the thermoplastic resin sheet 11, it is, for example, 10 or less, preferably 5 or less, and more preferably 3 or less.

[0036] When two or more sheet-like materials 12 are provided, the multiple sheet-like materials 12 may be provided along the thickness direction as shown in Fig. 3. When multiple sheet-like materials 12 are provided along the thickness direction, the number of sheet-like materials arranged along the thickness direction is not particularly limited, but is 3 or less from the viewpoint of preventing the composite interlayer film 10 from becoming too thick.

[0037] Alternatively, two or more sheet-like materials 12 may be arranged along the surface direction, as shown in FIG. 4 . As shown in FIG. 4 , the multiple sheet-like materials 12 arranged along the surface direction often have different thicknesses, which can easily cause air to accumulate between the two sheet-like materials 12. However, in the present invention, as described above, by embedding each sheet-like material 12 within the thermoplastic resin sheet 11 before integrating it with the transparent panel, air is less likely to accumulate between the two sheet-like materials 12, 12, etc. When the thermoplastic resin sheet 11 is formed from multiple sheets, the two or more sheet-like materials 12 are preferably positioned between the same sheets 13 and 14, as shown in FIGS. 3 and 4 . Positioning two or more sheet-like materials 12 between the same sheets 13 and 14 facilitates the production of a composite interlayer film. While FIGS. 3 and 4 show an example in which two sheets form the thermoplastic resin sheet 11, the number of sheets is not limited, as described above.

[0038] The sheet-like object 12 is smaller than the thermoplastic resin sheet 11, and when the composite interlayer film 10 is viewed in the thickness direction, the outline (peripheral edge 12S) of the sheet-like object 12 is arranged inside the outline (peripheral edge 11S) of the thermoplastic resin sheet 11. As a result, not only both surfaces but also the end faces of the sheet-like object 12 are covered by the thermoplastic resin sheet 11, and the sheet-like object 12 is embedded in the thermoplastic resin sheet 11. When the thermoplastic resin sheet 11 is formed from multiple sheets as described above, the sheet-like object 12 is preferably arranged between the sheets that form the thermoplastic resin sheet 11 (between sheets 13 and 14 in FIG. 1 ). 1 , the sheet-like material 12 is smaller than each of the sheets 13, 14 disposed therebetween, and when viewed in the thickness direction of the composite interlayer film 10, the outline of the sheet-like material 12 (i.e., peripheral edge 12S) is preferably positioned inside the outlines of each of the sheets 13, 14 disposed therebetween (i.e., peripheral edge 13S, 14S). More preferably, the peripheral edge 12S of the sheet-like material 12 is positioned inside the peripheral edges of all of the sheets that form the thermoplastic resin sheet 11.

[0039] Therefore, the peripheral edge 12S of the sheet-like material 12 is preferably positioned inside the peripheral edge 11S of the thermoplastic resin sheet 11 (i.e., the peripheral edges 13S, 14S of the sheets 13, 14 between which the sheet-like material 12 is positioned) over the entire periphery. The peripheral edge 12S of the sheet-like material 12 is preferably positioned inward from the peripheral edge 11S (i.e., the peripheral edges 13S, 14S) at a distance L of 8 mm or more, and more preferably at a distance L of 10 mm or more. Positioning the sheet-like material 12 on the inner periphery at a distance L of 8 mm or more allows the sheet-like material 10 to be properly embedded in the thermoplastic resin sheet 11. Furthermore, it is easier to prevent the thermoplastic resin constituting the thermoplastic resin sheet 11 from protruding outside the lamination panel.

[0040] Here, as described above, the distance L between the peripheral edge portion 12S and the peripheral edge portion 11S (i.e., the peripheral edge portions 13S and 14S) is preferably 8 mm or more, and more preferably 10 mm or more. There is no particular upper limit to the distance L, but it may be, for example, 1000 mm or less, or may be 500 mm or less. Note that the distance L refers to the shortest distance between the peripheral edge portion 12S and the peripheral edge portion 11S. Therefore, the peripheral edge portion 12S of the sheet-like material 12 is preferably positioned inward from the peripheral edge portion 11S by a distance of 8 mm or more, and more preferably by a distance of 10 mm or more, throughout the entire periphery.

[0041] Furthermore, as shown in Figures 3 and 4, when two or more sheet-like materials 12 are provided in the composite interlayer film, the peripheral portion 12S of each sheet-like material 12 is provided inside the peripheral portion 11S (i.e., peripheral portions 13S, 14S) of the thermoplastic resin sheet, and the distance L between each sheet-like material 12 is as described above.

[0042] An electrode wire 15 may also be connected to the sheet-like material 12. The electrode wire 15 is an extraction electrode that electrically connects the outside of the composite interlayer film to the sheet-like material 12. The electrode wire 15 may be, for example, a cable such as a flexible flat cable. The electrode wire 15 connected to the sheet-like material 12 may be one or more. Power may be supplied to the device of the sheet-like material 12 from the outside via the electrode wire 15. Therefore, the electrode wire 15 may extend from the sheet-like material 12 to the peripheral edge 11S of the thermoplastic resin sheet 11. For example, when the thermoplastic resin sheet 11 is formed of two or more sheets, the electrode wire 15 may be disposed between the sheet 13 and the sheet 14, with the sheet-like material 12 disposed therebetween, as shown in FIG. 1 . The extraction electrode (electrode wire 15) may be omitted. In this case, power may be supplied to the sheet-like material 12 by means other than the extraction electrode. For example, if an antenna is provided on the sheet-like material 12, power may be supplied via the antenna.

[0043] Furthermore, in the composite interlayer film 10, a joint (not shown) may be present at the peripheral edge 11S of the thermoplastic resin sheet 11, or a joint (not shown) may be present inside the thermoplastic resin sheet 11. Examples of the joint include connectors such as FPC connectors, ZIF connectors, floating connectors, interlocking connectors, and flip-lock connectors, as well as conductive parts via anisotropic conductive films, etc. The connectors may be attached to the thermoplastic resin sheet 11 by known methods such as soldering, interlocking, and insertion. The connectors may be connected to electrode wires 15 extended to predetermined locations on the thermoplastic resin sheet 11. The joints provided inside the thermoplastic resin sheet 11 may connect electrode wires 15, such as flexible flat cables, to each other. The joints provided inside the thermoplastic resin sheet 11 are preferably conductive parts via anisotropic conductive films, etc.

[0044] As described above, the sheet-like material 12 is provided with devices and the like, and generally has a thickness that varies depending on the position. In the present invention, the sheet-like material 12 is embedded inside the thermoplastic resin sheet 11 before being integrated with the transparent panel, so that even if the thickness of the sheet-like material 12 varies depending on the position, air can be prevented from accumulating at the position where the thickness changes.

[0045] As described above, the thickness of the sheet-like material 12 may vary depending on the position, but preferably includes a portion having a thickness of at least 100 μm or more, more preferably a portion having a thickness of 200 μm or more, and even more preferably a portion having a thickness of 300 μm or more. By including a portion having a thickness of 100 μm or more, the sheet-like material 12 can appropriately mount devices and the like on the sheet-like material 12. Furthermore, in the case of a flexible printed circuit board, the sheet-like material 12 tends to be relatively thick and may include a portion having a thickness of 500 μm or more. As the thickness of the sheet-like material 12 increases, the thermoplastic resin constituting the thermoplastic resin sheet 11 tends to be extruded to the outside, causing the thermoplastic resin to protrude. However, in the present invention, by embedding the sheet-like material 12 in the thermoplastic resin sheet 11 in advance as described above, such protrusion of the thermoplastic resin can be prevented.

[0046] Furthermore, the thickness of the thickest portion (maximum thickness) of the sheet-like material 12 is preferably 1500 μm or less, more preferably 1000 μm or less, and even more preferably 800 μm or less. If the maximum thickness is 1500 μm or less, air is less likely to accumulate. Furthermore, thickness differences are less likely to occur in the resulting composite interlayer film. When the sheet-like material is an electrically controllable film, it tends to be relatively thin, and for example, the maximum thickness may be less than 500 μm. Note that the thickness of the sheet-like material 12 refers to the thickness of each sheet-like material 12 when multiple sheet-like materials 12 are provided. When multiple sheet-like materials 12 are provided, it is desirable that at least one sheet-like material 12 has the above thickness, but it is preferable that all of the sheet-like materials 12 have the above thickness.

[0047] Furthermore, the size of the sheet-like material 12 is not particularly limited, but it is preferable that it occupy, for example, 0.2% to 99% of the thermoplastic resin sheet 11 when viewed in the thickness direction. By occupying 0.2% or more, various functions can be imparted to the sheet-like material. Furthermore, by making it 99% or less, it becomes easier to embed the sheet-like material 12 in the thermoplastic resin sheet 11. From these viewpoints, the above-mentioned occupied area is preferably 1% to 99% or less, more preferably 3% to 95% or less, and even more preferably 5% to 90% or less.

[0048] The sheet-like material 12 may be sized to occupy a large portion of the thermoplastic resin sheet 11. For example, the sheet-like material 12 may occupy 30% to 99% of the area of ​​the thermoplastic resin sheet 11, 40% to 95% of the area, or 50% to 90% of the area. Note that the sheet-like material 12 becomes relatively large as described above when an electrically controllable film such as a light-controlling film is used. Because the electrically controllable film occupies a large area but is relatively thin, it is easily embedded appropriately in the thermoplastic resin sheet 11. Alternatively, the sheet-like material 12 may be sized not to occupy a large portion of the thermoplastic resin sheet 11. For example, the sheet-like material 12 may occupy 0.2% to less than 50% of the area of ​​the thermoplastic resin sheet 11, 1% to 35% of the area, 3% to 35% of the area, or 5% to 25% of the area. Note that the area occupied by the sheet-like material 12 becomes relatively small as described above when a flexible printed circuit board is used. Although flexible printed circuit boards are often relatively thick, they occupy a small area and can therefore be appropriately embedded in the thermoplastic resin sheet 11. Note that the size (occupied area) of the sheet-like material referred to here means the size of each sheet-like material when multiple sheet-like materials are provided.

[0049] The surface 10A of the composite interlayer film 10 may preferably have irregularities. The surface 10A of the composite interlayer film 10 is usually the bonding surface with the transparent panel, and by having irregularities, air is less likely to accumulate between the composite interlayer film 10 and the transparent panel when bonding them together. This allows the composite interlayer film 10 to be bonded to the transparent panel without forming air bubbles between the film and the transparent panel. Furthermore, blocking resistance is improved, and self-adhesion can be prevented even when multiple composite interlayer films 10 are stacked and stored.

[0050] The surface roughness (Rz) of the surface 10A of the composite interlayer film 10 is, for example, 1 μm or more and 120 μm or less. When the surface roughness (Rz) is within this range, the composite interlayer film can be bonded to the transparent panel with good workability, with almost no air bubbles forming between the transparent panel and the composite interlayer film. Furthermore, blocking resistance is also improved. From these perspectives, the surface roughness (Rz) is preferably 3 μm or more and 100 μm or less, more preferably 5 μm or more and 80 μm or less, and even more preferably 10 μm or more and 70 μm or less. While it is preferable that only one surface 10A of the composite interlayer film 10 has the above surface roughness (Rz), it is preferable that both surfaces 10A, 10A have the above surface roughness (Rz). Note that, as shown in Figures 1 to 4, the surface of the thermoplastic resin sheet 11 typically becomes the surface 10A of the composite interlayer film 10. The surface roughness (Rz) is a ten-point average roughness measured in accordance with JIS B0601:1994.

[0051] The composite interlayer film 10 preferably has a contour shape that matches the shape of the transparent panel that will be integrated with the composite interlayer film 10. Therefore, for example, if the contour of the transparent panel is rectangular, the contour of the composite interlayer film 10 should also be rectangular. Furthermore, if the transparent panel is partially curved to match, for example, the side glass or windshield of an automobile, the contour of the composite interlayer film 10 should also be partially curved to correspond to that curve.

[0052] The thickness of the composite interlayer film 10 is preferably 1000 μm or more. When the thickness of the composite interlayer film 10 is 1000 μm or more, the sheet-like object 12 can be properly embedded in the thermoplastic resin sheet 11. Furthermore, when the thickness is 1000 μm or more, air generally tends to accumulate at the edges of the composite interlayer film or around the sheet-like object. However, in the present invention, air accumulation can be prevented by using a composite interlayer film 10 that is pre-integrated as described above. From these perspectives, the thickness of the composite interlayer film 10 is more preferably 1200 μm or more, and even more preferably 1500 μm or more. Furthermore, the thickness of the composite interlayer film 10 is, for example, 3000 μm or less, preferably 2500 μm or less, and more preferably 2100 μm or less. By setting the thickness of the composite interlayer film 10 to the above upper limit or less, the thickness of the laminated panel can be prevented from becoming unnecessarily thick.

[0053] <Method for Manufacturing Composite Interlayer Film> The composite interlayer film of the present invention is obtained by stacking multiple sheets to form a thermoplastic resin sheet, placing a sheet-like object between the sheets, and integrating the resulting laminate. This allows the sheet-like object to be embedded within the thermoplastic resin sheet formed from the multiple sheets. The laminate may be integrated by thermocompression bonding. Integration by thermocompression bonding allows the sheet-like object to be appropriately embedded within the thermoplastic resin sheet. Here, the heating temperature during thermocompression bonding is, for example, 30°C to 130°C, preferably 40°C to 100°C. Furthermore, the pressure (gauge pressure) during thermocompression bonding is, for example, 0.01 MPa to 17 MPa, preferably 1 MPa to 8 MPa. Negative pressure bonding may also be used, for example, at a gauge pressure of approximately -780 mbar. By performing thermocompression bonding at the above temperatures and pressures, the sheet-like object can be embedded within the thermoplastic resin sheet without leaving air around the sheet-like object or at the edges of the thermoplastic resin sheet. Furthermore, the thickness of the resulting composite interlayer film can be made uniform.The thermocompression bonding can be carried out by, for example, press molding, roll molding, vacuum laminator, or the like.

[0054] During thermocompression bonding, a release sheet may be placed on one or both sides of the laminate to prevent the thermoplastic resin sheet from sticking to a molding machine (e.g., a press plate, etc.). The release sheet is not particularly limited, but may be a resin sheet or a film whose at least one surface has been subjected to a release treatment with a silicone release agent, etc. The resin sheet may be a rubber sheet made of EPDM, etc.

[0055] When the thermoplastic resin sheet is formed of two sheets, the sheet-like material may be disposed between one sheet and another. When the thermoplastic resin sheet is formed of three or more sheets, the sheet-like material may be disposed between two or more overlapping sheets and one sheet, or between two or more overlapping sheets and two or more overlapping sheets. When the composite interlayer film has electrode wires connected to the sheet-like material, the electrode wires may be disposed between the sheets while connected to the sheet-like material.

[0056] Each sheet for forming the thermoplastic resin sheet preferably has a contour shape that matches the shape of the transparent panel to which the composite interlayer film will be integrated. Furthermore, each sheet for forming the thermoplastic resin sheet may be cut to have a contour shape that matches the shape of the transparent panel. Therefore, if the contour shape of the transparent panel is rectangular, each sheet for forming the thermoplastic resin sheet may be cut into a rectangular shape before being laminated. Furthermore, for example, if the contour of the transparent panel is partially curved, each sheet for forming the thermoplastic resin sheet may be processed to have a partially curved contour as well.

[0057] As described above, when electrode wires are provided in a composite interlayer film, the electrode wires extend to the peripheral edge of the thermoplastic resin sheet, and in some cases, connectors are also attached. Therefore, when attempting to cut the composite interlayer film into a desired contour shape after production, it becomes necessary to cut the electrode wires as well, but it is difficult to efficiently cut the electrode wires together with the thermoplastic resin sheet. Furthermore, the attachment of connectors makes cutting even more difficult. On the other hand, as described above, if each sheet is cut into a desired contour shape before being integrated with a sheet-like material or electrode wires, there is no need to cut the composite interlayer film having electrode wires or attached connectors, and a composite interlayer film having a desired contour shape can be easily obtained.

[0058] In this production method, it is preferable that the surface of the obtained composite interlayer film be adjusted during the above-mentioned thermocompression bonding so that it has the desired unevenness. That is, it is preferable that one or both surfaces of the composite interlayer film after thermocompression bonding be adjusted so that it has the above-mentioned surface roughness (Rz).

[0059] One method for adjusting the desired unevenness as described above is, for example, to pre-form unevenness on the surface of one or both surfaces 10A of the composite interlayer film 10, among the multiple sheets used to form the thermoplastic resin sheet, so that the surface has a surface roughness (Rz) greater than the desired surface roughness (Rz). The unevenness may be formed on the surface of the sheet by a known method, such as embossing. Furthermore, when the sheet is molded by extrusion, the unevenness may be formed by appropriately adjusting the extrusion conditions. Generally, the heating and pressure applied during thermocompression bonding reduces the unevenness pre-formed on the sheet, thereby reducing the surface roughness (Rz). However, by pre-forming large unevenness on each sheet so as to achieve a relatively large surface roughness (Rz), the surface of the thermoplastic resin sheet can maintain the desired surface roughness (Rz) even when the unevenness is reduced.

[0060] Another method is to provide a release sheet to be used during thermocompression bonding with a textured surface, then place the sheet so that the textured surface is in contact with the sheet to form the thermoplastic resin sheet, and transfer the textured surface of the release sheet to the surface of the thermoplastic resin sheet during thermocompression bonding. The textured surface of the release sheet may be provided by a known method, for example, by embossing.

[0061] <Method of using composite interlayer film> The composite interlayer film of the present invention is used to manufacture a laminated panel. Specifically, it is sandwiched between two transparent panels and integrated with them to manufacture a laminated panel. In the present invention, by manufacturing a laminated panel using the above-mentioned composite interlayer film, it is possible to obtain a laminated panel with a good appearance in which foaming in the composite interlayer film is suppressed.

[0062] The method for producing the laminated panel is not particularly limited, but any general method for producing laminated glass will do. For example, as shown in Fig. 5, a composite interlayer film 10 is placed between a pair of transparent panels 20, 20, and the panels are thermocompression-bonded together by applying pressure and heat in an autoclave or the like. The heating temperature during thermocompression bonding is, for example, 60°C or higher and 180°C or lower, preferably 80°C or higher and 160°C or lower. The pressure (gauge pressure) during thermocompression bonding is, for example, 1 MPa or higher and 18 MPa or lower, preferably 3 MPa or higher and 15 MPa or lower.

[0063] <Laminated Panel> The present invention also provides a laminated panel manufactured from the above-mentioned composite interlayer film. The laminated panel includes a composite interlayer film and two transparent panels, with the composite interlayer film sandwiched between the two transparent panels. In the laminated panel, the two transparent panels are bonded together via the above-mentioned composite interlayer film.

[0064] Examples of the transparent panel include glass plates. The glass plates may be either inorganic or organic glass, with inorganic glass being preferred. Examples of inorganic glass include, but are not limited to, clear glass, clear float glass, float glass plates, tempered glass, colored glass, polished glass plates, patterned glass plates, wired glass plates, lined glass plates, ultraviolet-absorbing glass plates, infrared-reflecting glass plates, infrared-absorbing glass plates, and green glass. Examples of organic glass include what is generally called resin glass, and include, but are not limited to, organic glass plates such as polycarbonate plates, polymethyl methacrylate plates, and polyester plates. The two transparent panels may be made of the same material or different materials. For example, one may be inorganic glass and the other organic glass. It is preferred that both of the two transparent panels be inorganic glass or organic glass, but it is more preferred that both be inorganic glass.

[0065] The thickness of each of the transparent panels is not particularly limited, but is preferably 0.5 mm to 3.2 mm, more preferably 0.7 mm to 2.7 mm, and even more preferably 1.0 mm to 2.6 mm. By keeping the thickness within the above range, it is possible to impart a certain level of mechanical strength to the laminated panel while keeping the overall thickness of the laminated panel at a certain level or less.

[0066] The composite interlayer film and laminated panel of the present invention can be used as window glass for vehicles such as automobiles, aircraft, ships, and other vehicles, as well as for buildings, etc., but are preferably used for buildings and automobiles. Furthermore, the interlayer film structure and laminated panel of the present invention are particularly preferably used for automobiles. When used in automobiles, they may be used for any window glass, such as windshield, side glass, rear glass, or roof glass.

[0067] Generally, a laminated panel is held by fitting its peripheral portion into a holding portion provided around the periphery of the laminated panel, and the sheet-like material may be placed in such a peripheral portion. Since the peripheral portion is held by the holding portion and is covered by the holding portion and cannot be seen from the outside, providing the sheet-like material in the peripheral portion can prevent the sheet-like material from blocking visibility or degrading the design.

[0068] The laminated panel may be provided with a shielding portion that shields a portion of the laminated panel. The shielding portion is not particularly limited, but is preferably provided on one of the transparent panels. The shielding portion may be provided on either surface of the transparent panel, but is preferably provided on the surface facing the composite interlayer film. Furthermore, when a shielding portion is provided on one of a pair of transparent panels and the laminated panel is a windowpane, the shielding portion is preferably provided on the transparent panel facing the exterior (the exterior side in an automobile). The shielding portion is not particularly limited as long as it has light-blocking properties, but is preferably colored with a colorant such as a pigment or dye, and is more preferably a black shielding portion colored black. The shielding portion may be formed on the transparent panel by printing or the like. The shielding portion is preferably a black printed portion, also known as black ceramic. Black ceramic is generally formed from black ceramic. The shielding portion is generally provided on the periphery of the transparent panel to prevent obstruction of visibility. When a shielding portion is provided, the sheet-like material is preferably disposed in a position overlapping the shielding portion when the laminating panel is viewed in the thickness direction, thereby preventing the sheet-like material from blocking the view or impairing the design.

[0069] The present invention will be explained in more detail by way of examples, but the present invention is not limited to these examples in any way.

[0070] <Evaluation> The laminated panels obtained in each example and comparative example were evaluated according to the following evaluation criteria. 1. Appearance (air at edge) The edge of the composite interlayer film was visually observed and evaluated according to the following criteria. A: No air bubbles at the edge. B: Air bubbles were observed on some edge edges. C: Air bubbles were observed around almost the entire edge.

[0071] 2. Appearance (air around the sheet-like object) The area around the sheet-like object provided on the composite interlayer film was visually observed and evaluated according to the following criteria: A: No air bubbles around the sheet-like object. B: One air bubble was found around the sheet-like object. C: Multiple air bubbles were found around the sheet-like object.

[0072] 3. Trim workability The workability of trimming was evaluated using the following evaluation criteria. A: In the laminated panels, there was no protrusion of thermoplastic resin, making trimming almost unnecessary. B: In the laminated panels, misalignment occurred between the thermoplastic resin sheet and the transparent panel, causing thermoplastic resin to protrude. Depending on the thickness of the composite interlayer film, trimming of the peripheral edges was possible, but electrode wires were required, making it complicated. C: In the laminated panels, misalignment occurred between the thermoplastic resin sheet and the transparent panel, causing thermoplastic resin to protrude. There was a large amount of thermoplastic resin protruding, making trimming difficult, and electrode wires made trimming extremely complicated.

[0073] 4. Air bubbles inside the film (film / transparent panel interface) The interface between the composite interlayer film and the transparent panel was observed and evaluated according to the following evaluation criteria: A: No air bubbles were present at the interface between the composite interlayer film and the transparent panel. B: Air bubbles were present at the interface between the composite interlayer film and the transparent panel.

[0074] The methods for measuring the various physical properties in the examples and comparative examples are as follows. (Compressibility) This is the compressibility measured by the method described in the specification when the sample was held at 90°C and a pressure of 0.08 MPa for 5 minutes. (Surface roughness (Rz)) The surface roughness (Rz) was determined by measuring the ten-point average roughness in accordance with JIS B0601:1994.

[0075] (Thermoplastic resin sheet) PVB: Resin sheet made of polyvinyl butyral resin, containing plasticizer, plasticizer content: 40 parts by mass (relative to 100 parts by mass of polyvinyl butyral resin), compression rate 4.8%, PVB sheet, surface roughness (Rz) 40 μm EVA: Resin sheet made of ethylene vinyl acetate copolymer (trade name: S-LEC EN Film, manufactured by Sekisui Chemical Co., Ltd.), compression rate 76.5%, EVA sheet POE: Resin sheet made of polyolefin thermoplastic elastomer (trade name: PHOTOCAP (registered trademark) 35521P HLT, manufactured by Specialized Technology Resources, Inc.), compression rate 18.1%, POE sheet Ionomer: Ethylene and methacrylate ion copolymer sheet containing metal ions (trade name: SentryGlas Plus, manufactured by DuPont), compression ratio 12.0%, ionomer sheet

[0076] (Sheet-like material) TCL: A film (TCL film) obtained by screen printing a conductive paste made of silver nanowires onto a 125 μm thick PET film. PDLC: Polymer dispersed liquid crystal (PDLC) film, product name: LCG-Smart film, manufactured by Gauzy. NFC: A flexible printed board (NFC board) obtained by screen printing an antenna and wiring onto a 125 μm thick PET film using a metal paste, and then mounting various electronic elements using a surface mount machine. Size: 40 mm x 40 mm. Touch: A flexible printed board (touch sensor board) obtained by screen printing wiring onto a 125 μm thick PET film using a metal paste, and then mounting various electronic elements using a surface mount machine. Size: 25 mm x 100 mm. (Transparent panel) A 2.1 mm thick clear glass plate

[0077] [Example 1] (Preparation of composite interlayer film) Four PVB sheets with a thickness of 380 μm were prepared. The PVB sheets were pre-cut to fit the shape of the side glass (area 0.45 m ２). The TCL film used was 10 mm smaller than the PVB sheet over its entire periphery. As shown in Table 1, a laminate was obtained by laminating a PVB sheet, a PVB sheet, a TCL film, a PVB sheet, and a PVB sheet in this order. The TCL film was positioned so that its peripheral edge was located 10 mm inward from the peripheral edge of each PVB sheet over its entire periphery. The electrode wires (flexible flat cables) connected to the TCL film were also positioned between the PVB sheets, in the same position as the TCL film. Release sheets were placed on both sides of the resulting laminate, and the laminate was heated and decompressed by vacuum forming at a temperature of 70°C and a gauge pressure of -780 mbar. The four PVB sheets were integrated by thermocompression bonding to form a single thermoplastic resin sheet, within which the TCL film was embedded, to obtain a composite interlayer film. The resulting composite interlayer film had the configuration shown in Figure 2. The release sheet used in the thermocompression bonding was an EPDM rubber sheet, and the surface on the laminate side was embossed so that the surface roughness (Rz) of the composite interlayer film was 40 μm.

[0078] (Preparation of Laminated Panel) A composite interlayer film and another transparent panel were superimposed on a transparent panel, and these were integrated using an autoclave at 140°C and 15 MPa (gauge pressure) to obtain a laminated panel. The obtained laminated panel was evaluated based on the above evaluation criteria.

[0079] [Examples 2 and 3] The same procedure as in Example 1 was carried out, except that the sheets for forming the thermoplastic resin sheet were changed as shown in Table 1. [Example 4] Two ionomer sheets with a thickness of 900 μm were prepared. As shown in Table 1, the ionomer sheet, TCL film, and ionomer sheet were laminated in this order to obtain a laminate. Otherwise, a composite interlayer film was obtained in the same manner as in Example 1.

[0080] [Example 5] One PVB sheet with a thickness of 380 μm and two PVB sheets with a thickness of 760 μm were prepared. As shown in Table 1, a PVB sheet (380 μm), a TCL film, a PVB sheet (760 μm), and a PVB sheet (760 μm) were laminated in this order to obtain a laminate. Otherwise, a composite interlayer film was obtained in the same manner as in Example 1.

[0081] Example 6 The same procedure as in Example 5 was carried out, except that a PDLC film was used as the sheet material instead of a TLC film. The electrode wires connected to the PDLC film were placed in the same position between the PVB sheets as the PDLC film.

[0082] [Example 7] A PDLC film and a touch sensor substrate were prepared as sheet-like materials. Three PVB sheets with a thickness of 760 μm were also prepared, and the PVB sheet, PDLC film, touch sensor substrate, PVB sheet, and PVB sheet were laminated in this order as shown in Table 1 to obtain a laminate. A composite interlayer film was obtained in the same manner as in Example 6. The obtained composite interlayer film had the same configuration as that shown in FIG. 3, except for the number of sheets.

[0083] Example 8 A TCL film and a touch sensor substrate were prepared as sheet-like materials, and the same procedure as in Example 7 was carried out, except that the TCL film was used instead of the PDLC film. Note that the electrode wires connected to the TCL film were arranged in the same position between the PVB sheets as the TCL film.

[0084] Example 9 A TCL film and an NFC substrate were prepared as sheet-like materials, and the same procedure as in Example 8 was carried out except that the NFC substrate was used instead of the touch sensor substrate.

[0085] [Example 10] The same procedure as in Example 9 was carried out, except that a release film was used in which the surface on the laminate side was embossed so that the surface roughness (Rz) of the composite interlayer film was 10 μm.

[0086] [Example 11] The same procedure as in Example 9 was carried out, except that a release film was used in which the surface on the laminate side was embossed so that the surface roughness (Rz) of the composite interlayer film was 100 μm.

[0087] [Example 12] The same procedure as in Example 9 was carried out, except that a release film was used in which the surface on the laminate side was embossed so that the surface roughness (Rz) of the composite interlayer film was 120 μm.

[0088] Example 13 The same procedure as in Example 9 was carried out, except that a release film that was not embossed was used.

[0089] [Comparative Example 1] (Preparation of Laminated Panel) Four PVB sheets with a thickness of 380 μm were prepared. The PVB sheets were pre-cut to the shape of the side glass. A TCL film having the same contour as the PVB sheet was used. A PVB sheet, a PVB sheet, a TCL film, a PVB sheet, and a PVB sheet were laminated in this order on one transparent panel, and the other transparent panel was further laminated on top of this to obtain a laminate. At this time, the peripheral edge of the TCL film was positioned so as to coincide with the peripheral edge of each PVB sheet over the entire periphery. In addition, the electrode wires connected to the TCL film were positioned between the PVB sheets in the same position as the TCL film. The obtained laminate was pre-pressed by vacuum forming at a temperature of 70 ° C. and a gauge pressure of -780 mbar, and then fully pressed using an autoclave at 140 ° C. and 15 MPa (gauge pressure), and the respective constituent materials were integrated by thermocompression to obtain a laminated panel.

[0090] Comparative Example 2 Comparative Example 2 was carried out in the same manner as in Comparative Example 1, except that a TCL film was used that was 5 mm smaller than the PVB sheet over its entire periphery, and the peripheral edge of the TCL film in the laminate was adjusted to be positioned 5 mm inward from the peripheral edge of each PVB sheet over its entire periphery.

[0091] Comparative Example 3 Comparative Example 3 was carried out in the same manner as in Comparative Example 1, except that a TCL film was used that was 5 mm smaller than the PVB sheet over its entire periphery, and the peripheral edge of the TCL film in the laminate was adjusted to be positioned 10 mm inward from the peripheral edge of each PVB sheet over its entire periphery.

[0092] [Comparative Example 4] One PVB sheet with a thickness of 380 μm and two PVB sheets with a thickness of 760 μm were prepared. As shown in Table 2, a PVB sheet (380 μm), a TCL film, a PVB sheet (760 μm), and a PVB sheet (760 μm) were laminated in this order on one transparent panel, and the other transparent panel was then laminated on top of this to obtain a laminate. Otherwise, a laminate panel was obtained in the same manner as in Comparative Example 1.

[0093] Comparative Example 5 was carried out in the same manner as in Comparative Example 4, except that a PDLC film was used instead of a TLC film as the sheet material. Note that the electrode wires connected to the PDLC film were arranged in the same position between the PVB sheets as the PDLC film.

[0094] [Comparative Example 6] A PDLC film and a touch sensor substrate were prepared as sheet-like materials. Three 760 μm-thick PVB sheets were also prepared, and the PVB sheet, PDLC film, touch sensor substrate, PVB sheet, and PVB sheet were laminated in this order on one transparent panel as shown in Table 2, and the other transparent panel was then laminated on top of this to obtain a laminate. Otherwise, a laminate panel was obtained in the same manner as in Comparative Example 5.

[0095] Comparative Example 7 A TCL film and a touch sensor substrate were prepared as sheet-like materials, and the same procedure as in Comparative Example 6 was carried out, except that the TCL film was used instead of the PDLC film. The electrode wires connected to the TCL film were arranged in the same position between the PVB sheets as the TCL film.

[0096] Comparative Example 8 A TCL film and an NFC substrate were prepared as sheet-like materials, and the same procedure as in Comparative Example 7 was carried out except that the NFC substrate was used instead of the touch sensor substrate.

[0097]

[0098]

[0099] *The constituent materials in Tables 1 and 2 indicate that the laminate was obtained by layering them in order from top to bottom. *The distance L in Tables 1 and 2 indicates the shortest distance between the periphery of the sheet-like material and the periphery of the thermoplastic resin sheet in the composite interlayer film. *The total thickness after lamination indicates the thickness of the laminate before thermocompression bonding, and the total thickness after integration indicates the thickness of the composite interlayer film.

[0100] In each example, the sheet-like material was made smaller than the thermoplastic resin sheet and positioned on the inner periphery of the thermoplastic resin sheet, thereby enabling it to be embedded in the thermoplastic resin sheet in the composite interlayer film. Furthermore, by sandwiching the composite interlayer film having the sheet-like material embedded in the thermoplastic resin sheet between a pair of transparent panels and integrating them to obtain a laminated panel, the generation of air bubbles around the edges of the composite interlayer film or the sheet-like material was prevented, resulting in a laminated panel with a good appearance. Furthermore, protrusion of the thermoplastic resin was prevented, improving the workability of trimming.

[0101] In contrast, in each comparative example, the sheet-like material and the thermoplastic resin sheet were not integrated in advance, but rather, the sheet-like material and the thermoplastic resin sheet were integrated together with the transparent panel during the production of the laminated panel. As a result, in each comparative example, air bubbles occurred at the edge of the composite interlayer film or around the sheet-like material, making it impossible to obtain a laminated panel with a good appearance. Furthermore, when the distance L between the peripheral edge of the sheet-like material and the peripheral edge of the thermoplastic resin sheet was reduced as shown in Comparative Examples 1 and 2, or when a relatively thick flexible printed circuit board was used as shown in Comparative Examples 6 to 8, the thermoplastic resin protruded, reducing the workability of the trimming process.

[0102] REFERENCE SIGNS LIST 10 Composite interlayer film for laminated panel 10A Surface 11 Thermoplastic resin sheet 12 Sheet-like object 13, 14, 13A, 13B, 14A, 14B Sheets 11S, 12S, 13S, 14S Peripheral edge portion 20 Transparent panel L Distance

Claims

1. A composite interlayer for laminated panels, which is sandwiched between a pair of transparent panels and integrated with them to manufacture a laminated panel, The invention comprises a thermoplastic resin sheet and a sheet-like material embedded in the thermoplastic resin sheet and electrically controllable, The aforementioned thermoplastic resin sheet is formed by laminating and integrating multiple sheets in the thickness direction. The sheet-like material is placed between adjacent sheets among the plurality of sheets. The adjacent sheets, arranged to sandwich the aforementioned sheet-like material, are bonded together and integrated in the portion where the sheet-like material is not provided, and the end face of the sheet-like material is covered by the integrated portion. A composite interlayer for laminated panels, wherein the ten-point average roughness (Rz) of the surface of the composite interlayer for laminated panels, measured in accordance with JIS B0601:1994, is between 1 μm and 100 μm.

2. The composite interlayer film for a laminated panel according to Claim 1, wherein the peripheral edge of the sheet-like material is positioned inward from the peripheral edge of the thermoplastic resin sheet.

3. The composite interlayer film for a laminated panel according to claim 2, wherein the peripheral edge of the sheet-like material is positioned inward over its entire circumference compared to the peripheral edge of the thermoplastic resin sheet.

4. The composite interlayer film for a laminated panel according to any one of claims 1 to 3, further comprising electrode wires connected to the sheet-like material, wherein the electrode wires are arranged between sheets constituting the thermoplastic resin sheet while connected to the sheet-like material.

5. The electrode wire extends from the sheet-like material to the peripheral edge of the thermoplastic resin sheet, The composite interlayer film for a laminated panel according to claim 4, wherein a joint exists at the peripheral edge of the thermoplastic resin sheet, and the joint is connected to the electrode wire.

6. The composite interlayer film for laminated panels according to any one of claims 1 to 3, wherein the content of the plasticizer in the thermoplastic resin sheet is less than 10 parts by mass per 100 parts by mass of the thermoplastic resin.

7. The composite interlayer film for laminated panels according to claim 6, wherein the content of the plasticizer is 5 parts by mass or less per 100 parts by mass of thermoplastic resin.

8. The composite interlayer film for laminated panels according to claim 6, wherein the content of the plasticizer is 3 parts by mass or less per 100 parts by mass of thermoplastic resin.

9. The composite interlayer film for laminated panels according to claim 6, wherein the content of the plasticizer is 0 parts by mass per 100 parts by mass of thermoplastic resin.

10. A method for manufacturing a composite interlayer film for a laminated panel according to any one of claims 1 to 3, comprising laminating a plurality of sheets for forming the thermoplastic resin sheet and integrating the laminate obtained by arranging the sheet-like material between the sheets.

11. The manufacturing method according to claim 10, wherein the laminates are integrated by thermocompression bonding.

12. The composite interlayer for a laminated panel according to any one of claims 1 to 3, and a pair of transparent panels, A laminated panel in which the composite interlayer for the laminated panel is placed between the pair of transparent panels, and the pair of transparent panels are integrated via the composite interlayer for the laminated panel.

13. The joining panel is provided with a shielding portion that shields a part of the joining panel, The laminated panel according to claim 12, wherein the sheet-like material is positioned to overlap the shielding portion when the laminated panel is viewed in the thickness direction.