Method for manufacturing functional structure

Abstract

A method for manufacturing a functional structure (1) is a method for manufacturing a functional structure comprising a functional layer (10), a sealing layer (20), and a surface protective material (30). This manufacturing method comprises: a laminate formation step for forming a laminate by laminating a surface protective material, a sealing layer formation material for forming a sealing layer, and a functional layer; an integration step for forming a laminate unit (1U) in which the functional layer and the surface protective material are integrated with the sealing layer interposed therebetween by softening the sealing layer formation material in the laminate to form the sealing layer; a cooling step for cooling the laminate unit; and a removal step for removing, after the cooling step, an outside region (29) formed outside a sealing region (21) of the sealing layer that seals the functional layer.

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, and a surface protection material made of resin.

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

[0004] In the functional roof described in JP 2023-167475 A, there is a concern that distortion may occur in the area of ​​the surface of the surface protection material that overlaps with the outer edge of the sealing layer.

[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 sealing layer, and a surface protection material.

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

[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 made of a resin having optical transparency and sealing the functional layer; and a surface protective material made of a resin having optical transparency and protecting the functional layer and the sealing layer, the method comprising: a laminate formation process for forming a laminate by stacking the surface protective material, a sealing layer forming material that forms the sealing layer, and the functional layer; an integration process for softening the sealing layer forming material in the laminate to form the sealing layer, thereby forming a laminate unit in which the functional layer and the surface protective material are integrated via the sealing layer; a cooling process for cooling the laminate unit until the temperature of the sealing layer is at least lower than the softening temperature of the sealing layer forming material; and a removal process for removing an outer region of the sealing layer formed outside the sealing region that seals the functional layer after the cooling process.

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

[0009] Fig. 1 is a plan view 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. Fig. 3 is a cross-sectional view schematically showing a method for manufacturing a functional structure. Fig. 4 is a cross-sectional view schematically showing a method for manufacturing a functional structure. Fig. 5 is a cross-sectional view schematically showing a modified example of the method for manufacturing a 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 equivalent components 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 printing layer 50, a primer layer 60, and a back surface protection material 70.

[0013] As shown in FIG. 1 , in this embodiment, the functional structure 1 has multiple 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, 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). 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 display). 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 a sheet (sealing layer forming material 20f) made of the above resin in a stacked state.

[0015] 2, the sealing layer 20 also seals the wiring material 15 connected to each functional layer 10. As shown in Fig. 1, the wiring material 15 is provided in an area outside the area where the multiple functional layers 10 are provided.

[0016] The surface protection material 30 protects the functional layer 10 and the sealing layer 20. More specifically, the surface protection material 30 protects the surface 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 surface hard coat layer 32 may be provided on the surface of the surface protective material 30. The surface 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 surface hard coat layer 32 is made of a material that is light-transmitting.

[0018] 2, a back hard coat layer 34 may be provided on the back surface of the surface protective material 30. The back hard coat layer 34 is made of a material harder than the material constituting the surface protective material 30, and covers a part of the back surface of the surface protective material 30. The back hard coat layer 34 may be made of the same material as the front hard coat layer 32, or may be made of a different material.

[0019] The back hard coat layer 34 has an intervening portion 34 a and a protruding portion 34 b. The intervening portion 34 a is interposed between the sealing layer 20 and the surface protective material 30. The protruding portion 34 b protrudes outward from the intervening portion 34 a in a direction perpendicular to the thickness of the sealing layer 20.

[0020] The barrier sheet 40 is provided on the surface of the sealing layer 20. 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.

[0021] The barrier layer 42 is made of a material that prevents the transmission of gases and water vapor. The barrier layer 42 is made of a material that is light-transmitting. In this embodiment, the barrier layer is made of a resin material, but it may be made of an inorganic material. The barrier layer 42 covers the entire surface of the sealing layer 20.

[0022] 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.

[0023] The printing layer 50 is provided on the back surface of the surface protection material 30. The printing layer 50 is made of a black material (such as ceramic). The printing layer 50 is made of a modified silicone adhesive. The printing layer 50 covers the entire back hard coat layer 34. As shown in FIG. 2 , the printing layer 50 has an overlapping portion 55 that overlaps with the wiring material 15 in the thickness direction of the sealing layer 20 (the vertical direction in FIG. 2 ). In other words, the printing layer 50 has the function of blocking the visibility of the wiring material 15 through the surface protection material 30. The adhesive strength between the printing layer 50 and the back hard coat layer 34 is higher than the adhesive strength between the printing layer 50 and the sealing layer 20.

[0024] The primer layer 60 is provided between the adhesive layer 44 and the overlapping portion 55 of the barrier sheet 40. The primer layer 60 contains a urethane resin, a solvent, etc. The primer layer 60 has the function of increasing the adhesive strength between the adhesive layer 44 and the overlapping portion 55 of the printed layer 50. In other words, the adhesive strength between the adhesive layer 44 and the printed layer 50 via the primer layer 60 is higher than the adhesive strength between the adhesive layer 44 and the printed layer 50 without the primer layer 60.

[0025] The back surface protection material 70 protects the back surface of the sealing layer 20. A barrier sheet (not shown) may be provided between the back surface protection material 70 and the sealing layer 20. The back surface protection material 70 is made of, for example, polycarbonate (PC), ABS resin, PET, or a mixture of these materials.

[0026] 3 to 5, a method for manufacturing the functional structure 1 will be described. This manufacturing method includes a laminate forming step, an integration step, a heat pressing step, a cooling step, and a removal step.

[0027] In the laminate formation step, a laminate 1L (see FIG. 4) is formed by laminating a sealing layer forming material 20f (see FIG. 4) that forms the sealing layer 20 and the functional layer 10. In this embodiment, as shown in FIG. 3, in the laminate formation step, a printing layer 50 is first provided on the surface protection material 30 provided with the front hard coat layer 32 and the back hard coat layer 34, and a primer layer 60 is provided on the printing layer 50 in a portion that overlaps with the sealing region 21 other than the outer region 29. The outer region 29 is a region of the sealing layer 20 formed outside the sealing region 21 that seals the functional layer 10, and is a region that is removed in the removal step.

[0028] 4, the laminate 1L is formed by laminating a barrier sheet 40, a plurality of sealing layer-forming materials 20f constituting the sealing layer 20, the functional layer 10 and wiring material 15 arranged within the plurality of sealing layer-forming materials 20f, and a back surface protective material 70. In this process, the sealing layer-forming materials 20f are laminated so that the sealing layer-forming materials 20f overlap substantially the entire surface protective material 30. In other words, in the laminate-forming process, the sealing layer-forming materials 20f having a shape that overlaps substantially the entire surface protective material 30 are laminated.

[0029] In the integration step, the sealing layer-forming material 20f in the laminate 1L is softened to form the sealing layer 20, thereby forming a laminate unit 1U in which the functional layer 10 and the surface protective material 30 are integrated via the sealing layer 20. More specifically, in the integration step, the sealing layer-forming material 20f is softened to form the sealing layer 20, and the portion of the barrier sheet 40 that does not overlap with the printing layer 50 is adhered to the surface protective material 30, and the portion of the barrier sheet 40 that overlaps with the printing layer 50 is adhered to the printing layer 50 via the primer layer 60, thereby forming the laminate unit 1U. Note that in this embodiment, the sealing layer-forming material 20f is softened by heating the sealing layer-forming material 20f.

[0030] The multilayer unit 1U formed in the integration step has a substantially constant dimension in the thickness direction of the multilayer unit 1U. Here, the "substantially constant" dimension in the thickness direction refers to a case where the thickness of the multilayer unit 1U is less uneven than when the thickness of the multilayer unit 1U has a step as shown in Fig. 2 (a step formed after the removal step described below), and also includes a case where the thickness of the multilayer unit 1U is not strictly constant.

[0031] The heat pressing process is performed after the integration process and before the cooling process. In the heat pressing process, the laminate unit 1U is pressed in the stacking direction of the laminate unit 1U while being heated. In the heat pressing process, the laminate unit 1U is pressed while being heated so that the laminate unit 1U is curved convexly from the functional layer 10 toward the surface protection material 30, or from the surface protection material 30 toward the functional layer 10.

[0032] The cooling process is performed after the heat pressing process and before the removing process. In the cooling process, the laminate unit 1U formed in the heat pressing process is cooled. In the cooling process, the laminate unit 1U may be cooled using a cooling device (not shown), or the laminate unit 1U may be cooled by natural heat dissipation. In the cooling process, the laminate unit 1U is cooled until the temperature of the sealing layer 20 becomes lower than the softening temperature of the sealing layer forming material 20f or the heating temperature in the heat pressing process. In the cooling process, it is preferable that the laminate unit 1U is cooled until the sealing layer 20 and the surface protection material 30 are completely solidified. However, the cooling process may be completed before the sealing layer 20 and the surface protection material 30 are completely solidified.

[0033] The removal process is performed after the cooling process. In the removal process, an outer region 29 formed outside the sealing region 21 of the sealing layer 20 that seals the functional layer 10 is removed. As shown in FIG. 5 , the outer region 29 refers to the region of the sealing layer 20 that does not overlap with the primer layer 60, i.e., the region outside the dashed-dotted line L in FIG. 5 . In this embodiment, the removal process also removes an outer portion 79 of the back surface protective material 70 that overlaps with the outer region 29. In the removal process, the sealing layer 20 and the back surface protective material 70 are cut at the portion of the dashed-dotted line L by, for example, NC processing, and the outer region 29 and the outer portion 79 are peeled off from the printing layer 50. The removal of the outer region 29 and the outer portion 79 may be performed by trimming.

[0034] As described above, in the manufacturing method of the functional structure 1 in this embodiment, in the lamination step, the sealing layer forming material 20f having a shape that overlaps with almost the entire area of ​​the surface protection material 30 is laminated, and the laminate unit 1U is cooled before the removal step while the thickness of the sealing layer 20 is substantially constant, so that the occurrence of distortion is suppressed in the boundary between the part of the surface protection material 30 that overlaps with the sealing region 21 and the part that overlaps with the outer region 29, i.e., in the part of the surface of the surface protection material 30 that overlaps with the outer edge of the sealing layer 20. Therefore, a decrease in the surface precision of the surface protection material 30 is suppressed.

[0035] Furthermore, since the removal process is the final process in the manufacturing method of the functional structure 1, distortion of the surface protection material 30 is prevented from occurring when the functional structure 1 is heated, etc. after the surface precision of the surface protection material 30 is ensured in the removal process.

[0036] 6, in the laminate formation step, the barrier sheet 40 may be laminated so as to have a shape that covers the entire sealing layer-forming material 20f, i.e., both the sealing region 21 and the outer region 29. In this case, in the removal step, the outer barrier layer 49 of the barrier sheet 40 that covers the outer region 29 is removed together with the outer region 29. Note that, because the adhesive strength between the adhesive layer 44 and the printing layer 50 of the barrier sheet 40 is not particularly high, the outer barrier layer 49 can be easily removed in the removal step.

[0037] It will be appreciated by those skilled in the art that the exemplary embodiments described above are examples of the following aspects.

[0038] [Aspect 1] A method for manufacturing a functional structure including a functional layer having a predetermined function, a sealing layer made of a light-transmitting resin and sealing the functional layer, and a surface protective material made of a light-transmitting resin and protecting the functional layer and the sealing layer, the method comprising: a laminate formation step of forming a laminate by stacking the surface protective material, a sealing layer-forming material that forms the sealing layer, and the functional layer; an integration step of softening the sealing layer-forming material in the laminate to form the sealing layer, thereby forming a laminate unit in which the functional layer and the surface protective material are integrated via the sealing layer; a cooling step of cooling the laminate unit until the temperature of the sealing layer becomes lower than at least the softening temperature of the sealing layer-forming material; and a removal step of removing an outer region of the sealing layer that is formed outside the sealing region that seals the functional layer.

[0039] In this manufacturing method for this functional structure, the laminate unit is cooled before the removal step, which prevents distortion from occurring at the boundary between the portion of the surface protection material that overlaps the sealing region and the portion that overlaps the outer region, i.e., the portion of the surface of the surface protection material that overlaps the outer edge of the sealing layer, thereby preventing a decrease in the surface precision of the surface protection material.

[0040] Aspect 2 is a method for producing a functional structure according to Aspect 1, wherein the functional structure further comprises a barrier sheet covering the surface of the sealing layer, a printing layer provided on the outer edge of the back surface of the surface protective material, and a primer layer provided between the barrier sheet and the printing layer, and wherein the laminate forming step comprises providing the printing layer on the surface protective material and providing the primer layer on a portion of the printing layer that overlaps with the sealing region other than the outer region, and then laminating the barrier sheet, the sealing layer forming material, and the functional layer to form the laminate, and wherein the integration step comprises softening the sealing layer forming material to form the sealing layer, adhering a portion of the barrier sheet that does not overlap with the printing layer to the surface protective material, and adhering a portion of the barrier sheet that overlaps with the printing layer to the printing layer via the primer layer, thereby forming the laminate unit.

[0041] In this embodiment, the outer region of the sealing layer can be easily removed in the removal process while protecting the sealing layer with the barrier sheet and ensuring the adhesive strength between the barrier sheet and the printing layer with the primer layer.

[0042] [Aspect 3] The method for manufacturing a functional structure according to Aspect 1 or 2 further comprises a heat pressing step, after the integration step and before the removal step, of pressing the laminate unit while heating it so that the laminate unit curves convexly from the functional layer towards the surface protection material, or from the surface protection material towards the functional layer.

[0043] [Aspect 4] The method for producing a functional structure according to any one of Aspects 1 to 3, wherein in the cooling step, the laminate unit is cooled to a temperature at which the sealing layer and the surface protection material are solidified.

[0044] In this embodiment, the sealing layer and the surface protection material are solidified in the cooling step, which improves the accuracy of removing the outer region in the removing step.

[0045] 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.

[0046] 1 functional structure, 1L laminate, 1U laminate unit, 10 functional layer, 15 wiring material, 20 sealing layer, 20f sealing layer forming material, 21 sealing region, 29 outer region, 30 surface protective material, 32 front hard coat layer, 34 rear hard coat layer, 40 barrier sheet, 42 barrier layer, 44 adhesive layer, 50 printing layer, 55 overlapping portion, 60 primer layer, 70 rear surface protective material, 79 outer portion.

Claims

1. A method for manufacturing a functional structure comprising a functional layer having a predetermined function, a sealing layer made of a light-transmitting resin and sealing the functional layer, and a surface protective material made of a light-transmitting resin and protecting the functional layer and the sealing layer, the method comprising: a laminate formation process for forming a laminate by stacking the surface protective material, a sealing layer-forming material that forms the sealing layer, and the functional layer; an integration process for softening the sealing layer-forming material in the laminate to form the sealing layer, thereby forming a laminate unit in which the functional layer and the surface protective material are integrated via the sealing layer; a cooling process for cooling the laminate unit until the temperature of the sealing layer is at least lower than the softening temperature of the sealing layer-forming material; and a removal process for removing an outer region of the sealing layer that is formed outside the sealing region that seals the functional layer, after the cooling process.

2. A method for manufacturing a functional structure as described in claim 1, wherein the functional structure further comprises a barrier sheet covering the surface of the sealing layer, a printing layer provided on the outer edge of the back surface of the surface protection material, and a primer layer provided between the barrier sheet and the printing layer, and wherein in the laminate formation process, the printing layer is provided on the surface protection material, and the primer layer is provided on a portion of the printing layer that overlaps with the sealing area other than the outer area, and then the barrier sheet, the sealing layer forming material, and the functional layer are laminated together to form the laminate, and in the integration process, the sealing layer is formed by softening the sealing layer forming material, and the portion of the barrier sheet that does not overlap with the printing layer is adhered to the surface protection material, and the portion of the barrier sheet that overlaps with the printing layer is adhered to the printing layer via the primer layer, thereby forming the laminate unit.

3. A method for manufacturing a functional structure as described in claim 1 or 2, further comprising a heat pressing process after the integration process and before the removal process, in which the laminate unit is pressed while heated so that the laminate unit is convexly curved from the functional layer toward the surface protection material, or from the surface protection material toward the functional layer.

4. The method for manufacturing a functional structure according to claim 1, wherein in the cooling step, the laminate unit is cooled to a temperature at which the sealing layer and the surface protection material are solidified.

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