Method for producing functional structure

Abstract

A method for producing a functional structure (1) equipped with a functional layer (10), a protective layer (20), and an adhesive layer (30), the method comprising: a laminate forming step for forming a laminate by laminating a protective layer, an adhesive layer forming material, and a functional layer; an integrating step for forming a laminate unit in which the functional layer and the protective layer are integrated via an adhesive layer by softening the adhesive layer forming material to form an adhesive layer; and a hot pressing step for pressing the laminate unit while heating the laminate unit so as to curve the laminate unit convexly from the functional layer toward the protective layer or from the protective layer toward the functional layer. In the integrating step, the adhesive layer forming material is softened at a first temperature lower than the softening temperature of the protective layer (20) to form an adhesive layer. In the hot pressing step, the laminate unit is hot pressed at a second temperature higher than the first temperature.

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] In the functional roof described in JP 2023-167475 A, it is desirable that the precision of the functional roof is high.

[0005] The above problem is not limited to functional roofs provided on the upper surface of a vehicle body, but applies broadly to structures that include a functional layer, a protective layer, and an adhesive layer.

[0006] An object of the present invention is to provide a method for manufacturing a functional structure that can suppress a decrease in the accuracy of the functional structure.

[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 protective layer made of resin and protecting the functional layer; and an adhesive layer adhering the functional layer to the protective layer, the method comprising: a laminate formation process for forming a laminate by stacking the protective layer, an adhesive layer forming material that forms the adhesive layer, and the functional layer; an integration process for softening the adhesive layer forming material in the laminate to form the adhesive layer, thereby forming a laminate unit in which the functional layer and the protective layer are integrated via the adhesive layer; and a heat pressing process for pressing the laminate unit while heating it so that the laminate unit curves convexly from the functional layer toward the protective layer, or from the protective layer toward the functional layer, wherein in the integration process, the adhesive layer forming material is softened at a first temperature lower than the softening temperature of the protective layer to form the adhesive layer, and in the heat pressing process, the laminate unit is heat pressed at a second temperature higher than the first temperature.

[0008] According to this disclosure, it is possible to provide a method for manufacturing a functional structure that can suppress a decrease in the accuracy of the functional structure.

[0009] Fig. 1 is a cross-sectional view schematically showing a functional structure according to an embodiment of the present disclosure; Fig. 2 is a cross-sectional view schematically showing a method for manufacturing the functional structure; Fig. 3 is a cross-sectional view schematically showing a method for manufacturing the functional structure; Fig. 4 is a cross-sectional view schematically showing a method for manufacturing the functional structure; Fig. 6 is a cross-sectional view schematically showing a modified example of the functional structure; Fig. 7 is a cross-sectional view schematically showing a method for manufacturing the functional structure shown in Fig. 6;

[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] 1 is a cross-sectional view schematically illustrating a functional structure according to an embodiment of the present disclosure. The functional structure 1 is preferably used in a vehicle as, for example, a functional roof.

[0012] As shown in FIG. 1 , the functional structure 1 includes a functional layer 10 , a protective layer 20 , an adhesive layer 30 , and a back surface protective material 40 .

[0013] The functional layer 10 has a predetermined function. Examples of the predetermined function include a power generation function, a light control function, a display function, a heat reflective layer, a heat insulating layer, and a low-reflection layer. When the predetermined function is a power generation function, the functional layer 10 is composed of a solar power generation panel (such as a crystalline silicon solar cell, a polycrystalline silicon solar cell, an amorphous silicon solar cell, a copper indium selenide solar cell, a compound semiconductor solar cell, an organic thin-film solar cell, a gallium arsenide solar cell, or a perovskite solar cell). In this case, the functional structure 1 may have multiple functional layers 10. When the predetermined function is a light control function, the functional layer 10 is composed of a light control film (a film capable of adjusting light transmittance by applying a voltage). When the predetermined function is a display function, the functional layer 10 is composed of a display device (such as an LED, an organic EL, or a liquid crystal). As shown in FIG. 1, the functional layer 10 is formed in a generally flat plate shape.

[0014] The protective layer 20 protects the functional layer 10. The protective layer 20 is disposed on one side of the functional layer 10 in the thickness direction of the functional layer 10 (the upper side in FIG. 1 ). The protective layer 20 is made of a resin. The protective layer 20 is preferably made of a resin having optical transparency. The protective layer 20 is made of, for example, polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), or polypropylene (PP).

[0015] The adhesive layer 30 adheres the functional layer 10 to the protective layer 20. In this embodiment, the adhesive layer 30 seals the functional layer 10. More specifically, the adhesive layer 30 seals the entire main surface and end surfaces of the functional layer 10. The adhesive layer 30 is preferably made of a light-transmitting resin. The adhesive layer 30 may be made of, for example, ethylene vinyl acetate (EVA), polyolefin, silicone, ionomer, or epoxy-based resin. The adhesive layer 30 is formed by heating multiple sheets (adhesive layer-forming materials) made of the above resin in a stacked state. The adhesive layer-forming material may be a single sheet, or may be a coated paste-like adhesive instead of a sheet. The resin material forming the adhesive layer 30 is selected from materials having a softening temperature lower than that of the protective layer 20.

[0016] 1 , the functional structure 1 is curved convexly from the functional layer 10 toward the protective layer 20. Note that the functional structure 1 may also be curved convexly from the protective layer 20 toward the functional layer 10.

[0017] The back surface protective material 40 protects the surface 30S of the adhesive layer 30 opposite to the side on which the protective layer 20 is provided. The thickness of the back surface protective material 40 may be smaller than the thickness of the protective layer 20. The back surface protective material 40 is made of, for example, polycarbonate (PC), ABS resin, or a mixture of these. The back surface protective material 40 may be omitted.

[0018] Next, a method for manufacturing the functional structure 1 will be described with reference to Figures 2 and 3. This manufacturing method includes a laminate forming step, an integration step, and a heat pressing step.

[0019] In the laminate formation process, the laminate 1L (see FIG. 2) is formed by laminating the protective layer 20, the adhesive layer forming material 30f that forms the adhesive layer 30, and the functional layer 10. In the laminate formation process in this embodiment, the functional layer 10 is disposed between the adhesive layer forming materials 30f. In the laminate formation process, for example, the laminate 1L is formed by laminating the protective layer 20, the adhesive layer forming material 30f, and the functional layer 10 on the plate-like member 101.

[0020] In the integration process, the adhesive layer-forming material 30f in the laminate 1L is softened to form the adhesive layer 30, thereby forming a laminate unit 1U (see FIG. 3 ) in which the functional layer 10 and the protective layer 20 are integrated via the adhesive layer 30. In the integration process of this embodiment, the adhesive layer-forming material 30f is softened to form the adhesive layer 30 having a shape that seals the functional layer 10. In the integration process, the adhesive layer-forming material 30f is softened at a first temperature (e.g., about 130° C.) that is lower than the softening temperature of the protective layer 20, to form the adhesive layer 30.

[0021] 3, in the integration step, for example, the laminate 1L is placed on a heated plate-like member 101, and in a state where the laminate 1L is covered with a rubber sheet 102, the space between the plate-like member 101 and the sheet 102 is evacuated to integrate the laminate unit 1U. The plate-like member 101 may also be a rubber sheet.

[0022] In the heat pressing process, the multilayer unit 1U is pressed while being heated so that the multilayer unit 1U is curved convexly from the functional layer 10 toward the protective layer 20. In the heat pressing process, the multilayer unit 1U is heat pressed at a second temperature (for example, about 150°C to 160°C) higher than the first temperature. The second temperature is set to about the softening temperature of the material forming the protective layer 20.

[0023] As described above, in the manufacturing method of the functional structure 1 in this embodiment, the adhesive layer 30 is formed by softening the adhesive layer-forming material 30f at a first temperature lower than the softening temperature of the protective layer 20 in the integration step, thereby suppressing softening of the protective layer 20 in the integration step. Therefore, it is possible to suppress a decrease in the precision of the functional structure 1 while ensuring the adhesive strength between the functional layer 10 and the protective layer 20. The precision of the functional structure 1 refers to the precision with which the functional structure 1 obtained by hot pressing has a desired shape, and a state in which there is little dimensional distortion or warpage relative to the desired shape is a state in which a decrease in the precision of the functional structure is suppressed.

[0024] Modifications of the above embodiment will now be described.

[0025] 4, the adhesive layer 30 may be disposed only between the functional layer 10 and the protective layer 20. In this example, the integration step uses a bonding apparatus shown in Fig. 5. The bonding apparatus includes a conveying roller 103, a heating roller 104, and a support roller 105.

[0026] The conveying roller 103 conveys the flat protective layer 20 downstream in the conveying direction (the direction indicated by the arrow in FIG. 5 ). The heating roller 104 presses the functional layer 10 against the protective layer 20 while heating the functional layer 10. The heating roller 104 is heated by a heat source (not shown). The temperature of the heating roller 104 is controlled by a control unit (not shown). The support roller 105 sends the protective layer 20 downstream in the conveying direction together with the heating roller 104. The support roller 105 may also be heated.

[0027] In the integration process in this example, the functional layer 10 is pressed against the protective layer 20 by a heating roller 104, while the adhesive layer forming material 30f is heated through the functional layer 10, thereby softening the adhesive layer forming material 30f and forming the adhesive layer 30.

[0028] <Second Modification> As shown in FIG. 6 , the functional structure 1 may further include another functional layer 12 and another adhesive layer 32 .

[0029] The other functional layer 12 is disposed on the side of the protective layer 20 opposite to the side on which the functional layer 10 is disposed (the upper side in FIG. 6 ). The other functional layer 12 may have the same function as the functional layer 10, or may have a different function. The thickness of the other functional layer 12 may be the same as or different from the thickness of the functional layer 10.

[0030] Another adhesive layer 32 bonds the other functional layer 12 to the protective layer 20 .

[0031] In this example, the protective layer 20 functions as a support layer that supports the functional layer 10 and other functional layers 12 .

[0032] 7, the integration step in this example uses a bonding device similar to that in the first modified example. In this example, the support roller 105, like the heating roller 104, presses the other functional layer 12 against the protective layer 20 while heating the other functional layer 12.

[0033] That is, in the integration process, a pair of heating rollers 104 and support rollers 105 clamp the laminate 1L from both sides in the stacking direction, pressing the functional layer 10 and the other functional layers 12 toward the protective layer 20 while heating the adhesive layer forming material 30f through the functional layer 10 and heating the other adhesive layer forming material 32f through the other functional layers 12, thereby softening the adhesive layer forming material 30f and the other adhesive layer forming material 32f and forming the adhesive layer 30 and the other adhesive layer 32.

[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 comprising: a functional layer having a predetermined function; a protective layer made of resin and protecting the functional layer; and an adhesive layer adhering the functional layer to the protective layer, the method comprising: a laminate formation step of forming a laminate by laminating the protective layer, an adhesive layer-forming material that forms the adhesive layer, and the functional layer; an integration step of softening the adhesive layer-forming material in the laminate to form the adhesive layer, thereby forming a laminate unit in which the functional layer and the protective layer are integrated via the adhesive layer; and a heat-pressing step of pressing the laminate unit while heating it so that the laminate unit is convexly curved from the functional layer toward the protective layer, or from the protective layer toward the functional layer, wherein in the integration step, the adhesive layer-forming material is softened at a first temperature that is lower than the softening temperature of the protective layer to form the adhesive layer; and in the heat-pressing step, the laminate unit is heat-pressed at a second temperature that is higher than the first temperature.

[0036] In this method for manufacturing a functional structure, the adhesive layer is formed by softening the adhesive layer-forming material at a first temperature lower than the softening temperature of the protective layer in the integration step, thereby suppressing softening of the protective layer in the integration step, thereby achieving both effective adhesion between the functional layer and the protective layer by the adhesive layer and reduced precision of the functional structure.

[0037] [Aspect 2] The method for manufacturing a functional structure described in Aspect 1, wherein in the laminate formation process, the functional layer is placed between the adhesive layer forming materials, and in the integration process, the adhesive layer having a shape that seals the functional layer is formed by softening the adhesive layer forming materials.

[0038] In this embodiment, the functional layer is sealed by the adhesive layer, and therefore the functional layer is effectively protected.

[0039] [Aspect 3] A method for manufacturing a functional structure according to Aspect 1, wherein in the laminate formation process, the adhesive layer forming material is placed between the functional layer and the protective layer, and in the integration process, the adhesive layer forming material is softened by heating the adhesive layer forming material through the functional layer while pressing the functional layer against the protective layer with a heating roller, thereby forming the adhesive layer.

[0040] [Aspect 4] The method for manufacturing a functional structure according to Aspect 1, wherein the functional structure comprises another functional layer having a predetermined function and another adhesive layer that adheres the other functional layer to the protective layer, wherein in the laminate formation step, the laminate is formed by stacking the other functional layer, another adhesive layer-forming material that forms the other adhesive layer, the protective layer, the adhesive layer-forming material, and the functional layer in this order, and in the integration step, a pair of heating rollers that hold the laminate from both sides in the stacking direction press the functional layer and the other functional layer toward the protective layer while heating the adhesive layer-forming material via the functional layer and heating the other adhesive layer-forming material via the other functional layer, thereby softening the adhesive layer-forming material and the other adhesive layer-forming material to form the adhesive layer and the other adhesive layer.

[0041] [Aspect 5] A method for manufacturing a functional structure comprising a first functional layer having a predetermined first function, a second functional layer having a predetermined second function, a support layer made of resin and supporting the first functional layer and the second functional layer, a first adhesive layer adhering the first functional layer to the support layer, and a second adhesive layer adhering the second functional layer to the support layer, comprising: a laminate formation step of forming a laminate by laminating the first functional layer, a first adhesive layer-forming material that forms the first adhesive layer, the support layer, a second adhesive layer-forming material that forms the second adhesive layer, and the second functional layer in this order; and an integration step of softening the first adhesive layer-forming material to form the first adhesive layer and softening the second adhesive layer-forming material to form the second adhesive layer, thereby forming a laminate unit in which the first functional layer and the support layer are integrated via the first adhesive layer and the second functional layer and the support layer are integrated via the second adhesive layer. a heat pressing process in which the laminate unit is heated and pressed so that the laminate unit is convexly curved from the first functional layer toward the second functional layer, or from the second functional layer toward the first functional layer, wherein in the integration process, the first adhesive layer forming material and the second adhesive layer forming material are softened at a first temperature lower than the softening temperature of the support layer to form the first adhesive layer and the second adhesive layer, and in the heat pressing process, the laminate unit is heat pressed at a second temperature higher than the first temperature.

[0042] [Aspect 6] In the integration process, a pair of heating rollers sandwiching the laminate from both sides in the stacking direction of the laminate press the first functional layer and the second functional layer toward the support layer while heating the first adhesive layer forming material through the first functional layer and heating the second adhesive layer forming material through the second functional layer, thereby softening the first adhesive layer forming material and the second adhesive layer forming material to form the first adhesive layer and the second adhesive layer, in the method for manufacturing a functional structure described in Aspect 5.

[0043] 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, not by the description of the above embodiments, and further includes all modifications within the meaning and scope of the claims.

[0044] 1 functional structure, 1L laminate, 1U laminate unit, 10 functional layer, 12 other functional layer, 20 protective layer, 30 adhesive layer, 32 other adhesive layer, 40 back surface protective material, 101 plate-shaped member, 102 sheet, 103 conveying roller, 104 heating roller, 105 support roller.

Claims

1. A method for manufacturing a functional structure comprising a functional layer having a predetermined function, a protective layer made of resin and protecting the functional layer, and an adhesive layer adhering the functional layer to the protective layer, the method comprising: a laminate formation step of forming a laminate by laminating the protective layer, an adhesive layer-forming material that forms the adhesive layer, and the functional layer; an integration step of softening the adhesive layer-forming material in the laminate to form the adhesive layer, thereby forming a laminate unit in which the functional layer and the protective layer are integrated via the adhesive layer; and a heat pressing step of pressing the laminate unit while heating it so that the laminate unit is curved convexly from the functional layer toward the protective layer, or from the protective layer toward the functional layer; wherein in the integration step, the adhesive layer-forming material is softened at a first temperature that is lower than the softening temperature of the protective layer to form the adhesive layer, and in the heat pressing step, the laminate unit is heat pressed at a second temperature that is higher than the first temperature.

2. A method for manufacturing a functional structure as described in claim 1, wherein in the laminate formation process, the functional layer is placed between the adhesive layer forming materials, and in the integration process, the adhesive layer having a shape that seals the functional layer is formed by softening the adhesive layer forming materials.

3. A method for manufacturing a functional structure as described in claim 1, wherein in the laminate formation process, the adhesive layer forming material is placed between the functional layer and the protective layer, and in the integration process, the adhesive layer forming material is softened by heating the adhesive layer forming material through the functional layer while pressing the functional layer against the protective layer with a heating roller, thereby forming the adhesive layer.

4. A method for manufacturing a functional structure as described in claim 1, wherein the functional structure comprises another functional layer having a predetermined function and another adhesive layer that adheres the other functional layer to the protective layer, and wherein in the laminate formation process, the laminate is formed by stacking the other functional layer, another adhesive layer forming material that forms the other adhesive layer, the protective layer, the adhesive layer forming material, and the functional layer in this order, and in the integration process, a pair of heating rollers that hold the laminate from both sides in the stacking direction press the functional layer and the other functional layer toward the protective layer while heating the adhesive layer forming material via the functional layer and heating the other adhesive layer forming material via the other functional layer, thereby softening the adhesive layer forming material and the other adhesive layer forming material to form the adhesive layer and the other adhesive layer.

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