Method for manufacturing functional structure

Abstract

This method for manufacturing a functional structure (1) comprises: an adhesion step for adhering a barrier sheet (40) to a surface protection material (30) while pushing out air bubbles between the surface protection material (30) and the barrier sheet (40); a laminate formation step for forming a laminate on the barrier sheet (40) adhered to the surface protection material (30) by laminating a plurality of sealing layer formation materials constituting a sealing layer and functional layers arranged in the plurality of sealing layer formation materials; and an integration step for forming the sealing layer for sealing the functional layers by softening the plurality of sealing layer formation materials by heating the laminate.

Description

Manufacturing method of functional structure

[0001] This disclosure relates to a method for manufacturing a functional structure.

[0002] Conventionally, functional roofs (such as photovoltaic panels and dimming roofs) provided on the upper surface of a vehicle body have been known. For example, Japanese Patent Application Laid-Open No. 2023-167475 discloses a functional roof including a functional layer, a sealing layer, a front barrier sheet, and a surface protection material.

[0003] Japanese Patent Application Laid-Open No. 2023-167475

[0004] Since the barrier sheet has the function of preventing the permeation of gases such as air, there is a concern that air bubbles may remain between the surface protection material and the front barrier sheet when manufacturing the functional roof described in JP 2023-167475 A.

[0005] The above problem is not limited to functional roofs provided on the upper surface of a vehicle body, but applies broadly to devices including a functional layer, a sealing layer, a barrier sheet, and a surface protection material.

[0006] An object of the present invention is to provide a method for producing a functional structure that can suppress the formation of air bubbles between a surface protection material and a barrier sheet.

[0007] A method for manufacturing a functional structure according to one aspect of this disclosure is a method for manufacturing a functional structure comprising: a functional layer having a predetermined function; a sealing layer that seals the functional layer; a surface protective material made of a light-transmitting resin that protects the surface of the sealing layer; and a barrier sheet made of a light-transmitting resin that is provided between the sealing layer and the surface protective material, the method comprising: an adhesion step of adhering the barrier sheet to the surface protective material while pushing out any air bubbles between the surface protective material and the barrier sheet; a laminate formation step of forming a laminate by stacking multiple sheets of sealing layer-forming material that constitute the sealing layer and the functional layer disposed within the multiple sealing layer-forming materials on the barrier sheet adhered to the surface protective material; and an integration step of forming the sealing layer that seals the functional layer by heating the laminate to soften the multiple sealing layer-forming materials.

[0008] According to this disclosure, it is possible to provide a method for manufacturing a functional structure that can suppress the formation of air bubbles between a surface protection material and a barrier sheet.

[0009] It is a plan view schematically showing a functional structure according to an embodiment of the present disclosure. It is a cross-sectional view taken along the line II-II in FIG. It is a cross-sectional view schematically showing a method for manufacturing the functional structure. It is a cross-sectional view schematically showing a method for manufacturing the functional structure.

[0010] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described with reference to the accompanying drawings, in which the same or corresponding elements are designated by the same reference numerals.

[0011] Fig. 1 is a diagram schematically showing a functional structure according to an embodiment of the present disclosure. Fig. 2 is a cross-sectional view taken along line II-II in Fig. 1. The functional structure 1 is preferably used in a vehicle as, for example, a functional roof.

[0012] As shown in Figures 1 and 2, the functional structure 1 comprises at least one functional layer 10, a sealing layer 20, a surface protection material 30, a barrier sheet 40, a back surface protection material 50, and a back barrier sheet 60.

[0013] As shown in FIG. 1, in this embodiment, the functional structure 1 has a plurality of functional layers 10. Each functional layer 10 has a predetermined function. Examples of the predetermined function include a power generation function, a light control function, and a display function. If the predetermined function is a power generation function, the functional layer 10 is composed of a solar power generation panel. If the predetermined function is a light control function, the functional layer 10 is composed of a light control film (a film whose light transmittance can be adjusted by applying a voltage). If the predetermined function is a display function, the functional layer 10 is composed of a display device (LED, organic EL, liquid crystal, etc.). As shown in FIG. 2, the functional layer 10 is formed in a generally flat plate shape.

[0014] The sealing layer 20 seals the functional layer 10. More specifically, the sealing layer 20 seals the entire area of ​​each main surface and end surface of the functional layer 10. The sealing layer 20 is made of a light-transmitting resin. The sealing layer 20 is made of, for example, ethylene vinyl acetate (EVA), polyolefin, silicone, or ionomer. The sealing layer 20 is formed by heating sheets (sealing layer-forming materials) made of the above resin in a stacked state.

[0015] 2, the sealing layer 20 has a front surface S1 and a back surface S2. The front surface S1 is provided on one side of the functional layer 10 in the thickness direction of the functional layer 10 (the upper side in FIG. 2), and is constituted by one main surface of the sealing layer 20. The back surface S2 is provided on the other side of the functional layer 10 in the thickness direction of the functional layer 10 (the lower side in FIG. 2), and is constituted by the other main surface of the sealing layer 20.

[0016] The surface protection material 30 protects the surface S1 of the sealing layer 20. The surface protection material 30 is provided on one side (the upper side in FIG. 2 ) of the sealing layer 20 via a barrier sheet 40. The surface protection material 30 is made of a light-transmitting resin. The surface protection material 30 is made of, for example, polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), or polypropylene (PP).

[0017] 1 and 2, a hard coat layer 32 may be provided on the surface of the surface protective material 30. The hard coat layer 32 is made of a material that is harder than the material that constitutes the surface protective material 30, and covers the surface of the surface protective material 30. The hard coat layer 32 is made of a material that is optically transparent.

[0018] 1 and 2 , a shielding portion 34 may be provided on the back surface of the surface protection material 30. The shielding portion 34 is made of a black material (ceramic, etc.). In this embodiment, the shielding portion 34 is provided on the back surface of a portion of the surface protection material 30 that protrudes outward from a portion that overlaps with the sealing layer 20 in the thickness direction.

[0019] The barrier sheet 40 is provided between the sealing layer 20 and the surface protection material 30. The barrier sheet 40 is formed in a film shape (thin film shape). As shown in FIG. 2 , the barrier sheet 40 has a barrier layer 42 and an adhesive layer 44.

[0020] The barrier layer 42 is made of a material (such as a resin material) that prevents the transmission of gases and water vapor. The barrier layer 42 is made of a material that is optically transparent. The barrier layer 42 covers the entire surface S1 of the sealing layer 20.

[0021] The adhesive layer 44 is provided on the surface of the barrier layer 42. The adhesive layer 44 adheres the barrier layer 42 to the rear surface of the surface protection material 30. The adhesive layer 44 is made of a light-transmitting material (synthetic resin, etc.). The adhesive layer 44 has no adhesive strength at room temperature and can be deformed integrally with the barrier layer 42. The adhesive layer 44 acquires adhesive strength when heated to a predetermined temperature.

[0022] The back surface protective material 50 protects the back surface S2 of the sealing layer 20. The back surface protective material 50 is provided on the other side (the lower side in FIG. 2 ) of the sealing layer 20 via a back barrier sheet 60. The outer shape of the back surface protective material 50 in a planar view is formed to be approximately the same as the outer shape of the back surface S2 of the sealing layer 20 in a planar view. The thickness of the back surface protective material 50 may be the same as or smaller than the thickness of the surface protective material 30. The bending rigidity of the back surface protective material 50 may be the same as or different from the bending rigidity of the surface protective material 30. In this embodiment, the thickness of the surface protective material 30 is greater than the thickness of the back surface protective material 50, and therefore the bending rigidity of the surface protective material 30 is higher than the bending rigidity of the back surface protective material 50. When the functional layer 10 is made of a light-controlling film, the back surface protective material 50 is made of a light-transmitting material. The back surface protective material 50 is made of, for example, polycarbonate (PC), ABS resin, or a mixture thereof.

[0023] The back barrier sheet 60 is provided between the sealing layer 20 and the back surface protection material 50. The configuration of the back barrier sheet 60 is basically the same as that of the barrier sheet 40. That is, the back barrier sheet 60 has a back barrier layer 62 made of a material (such as a resin material) that prevents the transmission of gases and water vapor, and an adhesive layer 64. The back barrier layer 62 may be made of a material that is optically transparent or not optically transparent. The back barrier sheet 60 may be omitted together with the back surface protection material 50.

[0024] Next, a method for manufacturing the functional structure 1 will be described with reference to Figures 3 and 4. This manufacturing method includes a bonding step, a laminate forming step, an integration step, and a heat pressing step.

[0025] In the bonding process, the barrier sheet 40 is bonded to the surface protection material 30 while pushing out any air bubbles between the surface protection material 30 and the barrier sheet 40. More specifically, in the bonding process, the barrier sheet 40 is heated to soften the adhesive layer 44, and the barrier sheet 40 is bonded to the surface protection material 30 formed in a flat plate shape by a pressing roller 103 so as to push out any air bubbles between the adhesive layer 44 and the surface protection material 30.

[0026] 3, a bonding apparatus 100 including a pressure roller 103 is used in the bonding step of this embodiment. The bonding apparatus 100 includes a transport roller 101, a supply roller 102, the pressure roller 103, a support roller 104, and a tension roller 105.

[0027] The transport rollers 101 transport the flat surface protection material 30 downstream in the transport direction (the direction indicated by the arrow in FIG. 3 ). The supply rollers 102 hold the barrier sheet 40 wound in a roll. The pressure roller 103 heats the barrier sheet 40 and presses it against the flat surface protection material 30. The pressure roller 103 is heated by a heat source (not shown). The temperature of the pressure roller 103 is controlled by a control unit (not shown). That is, the pressure roller 103 is composed of a heated roller. The support roller 104 sends the surface protection material 30 downstream in the transport direction together with the pressure roller 103. The support roller 104 may also be heated. The tension roller 105 is disposed between the supply roller 102 and the pressure roller 103.

[0028] In the laminate formation step, a laminate is formed by laminating a plurality of sealing layer-forming materials constituting the sealing layer 20 and functional layers 10 arranged within the plurality of sealing layer-forming materials on a barrier sheet 40 adhered to a surface protective material 30. More specifically, in the laminate formation step, as shown in Fig. 4, a laminate is formed by laminating a plurality of sealing layer-forming materials constituting the sealing layer 20 and functional layers 10 arranged within the plurality of sealing layer-forming materials, a back barrier sheet 60, and a back surface protective material 50 on the barrier sheet 40 adhered to a surface protective material 30 provided with a shielding portion 34. Note that in the laminate formation step, a hard coat layer 32 may be provided on the surface protective material 30 before the formation of the laminate.

[0029] Furthermore, in the above-mentioned adhesion step, the back barrier sheet 60 may be adhered to the back surface protective material 50 while squeezing out any air bubbles between the back surface protective material 50 and the back barrier sheet 60. In this case, in the laminate formation step, multiple sealing layer-forming materials and functional layers 10 arranged within the multiple sealing layer-forming materials, and the back surface protective material 50 to which the back barrier sheet 60 is adhered are laminated on the barrier sheet 40 adhered to the surface protective material 30.

[0030] In the integration process, the laminate is heated to soften the multiple sheets of sealing layer-forming material, thereby forming a sealing layer 20 that seals the functional layer 10. As shown in Fig. 3, in the integration process, for example, the laminate is placed on a heated plate-like member 201 and covered with a rubber sheet 202, and the space between the plate-like member 201 and the sheet 202 is evacuated to integrate the laminate.

[0031] The heat pressing step is performed after the integration step. In the heat pressing step, the laminate is pressed in the stacking direction of the laminate while being heated. In the heat pressing step, the hard coat layer 32, the surface protective material 30, the barrier sheet 40, the sealing layer 20, the back barrier sheet 60, and the back surface protective material 50 are pressed while being heated so that the hard coat layer 32, the surface protective material 30, the barrier sheet 40, the sealing layer 20, the back barrier sheet 60, and the back surface protective material 50 are convexly curved from the back surface protective material 50 toward the surface protective material 30 or from the surface protective material 30 toward the back surface protective material 50.

[0032] As described above, in the manufacturing method of the functional structure 1 in this embodiment, in the bonding process, the barrier sheet 40 is bonded to the surface protection material 30 while pushing out any air bubbles between the surface protection material 30 and the barrier sheet 40, thereby suppressing the remaining air bubbles between the surface protection material 30 and the barrier sheet 40.

[0033] Furthermore, in the bonding process, since the surface protection material 30 is formed in a flat plate shape, the occurrence of wrinkles in the barrier sheet 40 when the barrier sheet 40 is bonded to the surface protection material 30 is suppressed compared to when the barrier sheet 40 is bonded to a curved surface protection material 30.

[0034] It will be appreciated by those skilled in the art that the exemplary embodiments described above are examples of the following aspects.

[0035] [Aspect 1] A method for manufacturing a functional structure including a functional layer having a predetermined function, a sealing layer that seals the functional layer, a surface protective material made of a light-transmitting resin and protecting a surface of the sealing layer, and a barrier sheet made of a light-transmitting resin and provided between the sealing layer and the surface protective material, the method comprising: an adhesion step of adhering the barrier sheet to the surface protective material while pushing out any air bubbles between the surface protective material and the barrier sheet; a laminate formation step of forming a laminate by stacking, on the barrier sheet adhered to the surface protective material, a plurality of sealing layer-forming materials that constitute the sealing layer and the functional layer disposed within the plurality of sealing layer-forming materials; and an integration step of heating the laminate to soften the plurality of sealing layer-forming materials, thereby forming the sealing layer that seals the functional layer.

[0036] In this manufacturing method for this functional structure, the barrier sheet is bonded to the surface protection material while pushing out any air bubbles between the surface protection material and the barrier sheet during the bonding process, thereby preventing any air bubbles from remaining between the surface protection material and the barrier sheet.

[0037] [Aspect 2] The method for producing a functional structure according to Aspect 1, wherein the barrier sheet used in the bonding step has a barrier layer and an adhesive layer provided on the surface of the barrier layer, and in the bonding step, the barrier sheet is heated to soften the adhesive layer, and the barrier sheet is bonded to the surface protection material by a pressing roller so as to push out any air bubbles between the adhesive layer and the surface protection material.

[0038] In this embodiment, the pressing roller effectively presses out the air bubbles and adheres the barrier sheet to the surface protection material.

[0039] [Aspect 3] The method for producing a functional structure according to Aspect 1 or 2, further comprising, after the integration step, a heat pressing step of pressing the laminate in a lamination direction of the laminate while heating the laminate.

[0040] [Aspect 4] The method for producing a functional structure according to Aspect 3, wherein in the heat pressing step, the surface protective material, the barrier sheet, and the sealing layer are pressed while being heated so that the surface protective material, the barrier sheet, and the sealing layer are convexly curved from the sealing layer toward the surface protective material or from the surface protective material toward the sealing layer.

[0041] [Aspect 5] The method for manufacturing a functional structure according to any one of Aspects 1 to 4, wherein the functional structure further comprises a back surface protective material that protects the back surface of the sealing layer, and a back barrier sheet that is provided between the sealing layer and the back surface protective material, and in the bonding step, the back barrier sheet is bonded to the back surface protective material while pushing out any air bubbles between the back surface protective material and the back barrier sheet.

[0042] It should be noted that the embodiments disclosed herein are illustrative in all respects and should not be considered limiting. The scope of the present invention is defined by the claims rather than the description of the above embodiments, and further includes all modifications within the meaning and scope of the claims.

[0043] REFERENCE SIGNS LIST 1 functional structure 10 functional layer 20 sealing layer 30 surface protective material 32 hard coat layer 34 shielding portion 40 barrier sheet 42 barrier layer 44 adhesive layer 50 back surface protective material 60 back barrier sheet 100 laminating device 101 transport roller 102 supply roller 103 pressing roller 104 support roller 105 tension roller 201 plate-like member 202 sheet S1 front surface S2 back surface

Claims

1. A method for producing a functional structure comprising a functional layer having a predetermined function, a sealing layer that seals the functional layer, a surface protective material made of a light-transmitting resin and protecting a surface of the sealing layer, and a barrier sheet made of a light-transmitting resin and provided between the sealing layer and the surface protective material, the method comprising: a bonding step of bonding the barrier sheet to the surface protective material while pushing out any air bubbles between the surface protective material and the barrier sheet; a laminate formation step of forming a laminate by stacking a plurality of sealing layer-forming materials that constitute the sealing layer and the functional layer disposed within the plurality of sealing layer-forming materials on the barrier sheet bonded to the surface protective material; and an integration step of forming the sealing layer that seals the functional layer by heating the laminate to soften the plurality of sealing layer-forming materials.

2. A method for manufacturing a functional structure as described in claim 1, wherein the barrier sheet used in the bonding step has a barrier layer and an adhesive layer provided on the surface of the barrier layer, and in the bonding step, the barrier sheet is heated to soften the adhesive layer, while the barrier sheet is bonded to the surface protection material by a pressing roller so as to push out any air bubbles between the adhesive layer and the surface protection material.

3. A method for producing a functional structure according to claim 1 or 2, further comprising a heat pressing step of pressing the laminate in a lamination direction of the laminate while heating the laminate after the integration step.

4. A method for manufacturing a functional structure as described in claim 3, wherein in the heat pressing process, the surface protective material, the barrier sheet and the sealing layer are pressed while being heated so that the surface protective material, the barrier sheet and the sealing layer are convexly curved from the sealing layer toward the surface protective material or from the surface protective material toward the sealing layer.

5. A method for manufacturing a functional structure as described in claim 1, wherein the functional structure further comprises a back surface protective material that protects the back surface of the sealing layer, and a back barrier sheet that is provided between the sealing layer and the back surface protective material, and in the bonding process, the back barrier sheet is bonded to the back surface protective material while pushing out any air bubbles between the back surface protective material and the back barrier sheet.

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