Resin structure

Abstract

A resin structure (1) is provided with: a base material layer (10) comprising a light-transmitting resin; a heat-insulation layer (20) provided on a surface of the base material layer (10) and having a function for reflecting heat rays; and a waterproof layer (30) provided on a surface of the heat-insulation layer (20) and having a function for blocking the permeation of moisture. The waterproof layer (30) has a smaller thickness than the thickness of the base material layer (10).

Description

resin structure

[0001] This disclosure relates to resin structures.

[0002] For example, Japanese Patent Application Laid-Open No. 2021-11196 discloses a resin window panel comprising a first resin panel, a hard coat layer provided on the surface of the first resin panel, and a second resin panel provided on the back surface of the first resin panel.

[0003] Japanese Patent Application Laid-Open No. 2021-11196

[0004] The resin window panel described in JP 2021-11196 A preferably has high heat-shielding properties. The heat-shielding layer provided to ensure heat-shielding properties may be vulnerable to moisture. Therefore, it is more desirable for the heat-shielding layer to have a waterproofing function.

[0005] An object of the present invention is to provide a resin structure that can improve heat insulation and waterproofing properties.

[0006] A resin structure according to one aspect of this disclosure comprises a substrate layer made of a light-transmitting resin, a heat-shielding layer provided on the surface of the substrate layer, and a waterproof layer provided on the surface of the heat-shielding layer, wherein the waterproof layer has a thickness smaller than that of the substrate layer.

[0007] According to this disclosure, a resin structure capable of improving heat insulation and waterproofing properties can be provided.

[0008] 1 is a plan view schematically illustrating a resin 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 illustrating a modified example of the resin structure.

[0009] 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.

[0010] Fig. 1 is a diagram schematically illustrating a resin 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 resin structure 1 is preferably used, for example, in the roof of a vehicle.

[0011] As shown in FIGS. 1 and 2 , the resin structure 1 includes a substrate layer 10 , a heat shield layer 20 , a waterproof layer 30 , a hard coat layer 40 , and a back surface protective layer 60 .

[0012] The base layer 10 is made of a light-transmitting resin (such as polycarbonate). The base layer 10 may be colorless or may be lightly colored with an additive or the like.

[0013] The heat shielding layer 20 has the function of reflecting heat rays and infrared rays from sunlight. Examples of the heat shielding layer 20 include a metal-containing film and a multilayer film. The heat shielding layer 20 is provided on the surface of the base material layer 10 via an adhesive layer 5. The heat shielding layer 20 covers the base material layer 10 via the adhesive layer 5. The thickness of the heat shielding layer 20 is smaller than the thickness of the base material layer 10. The heat shielding layer 20 is optically transparent. The heat shielding layer 20 is susceptible to moisture and is deteriorated by ultraviolet rays.

[0014] The waterproof layer 30 is provided on the surface of the heat shielding layer 20 via the adhesive layer 6. The waterproof layer 30 has the function of preventing moisture from penetrating into the heat shielding layer 20. The waterproof layer 30 covers the heat shielding layer 20 via the adhesive layer 6. The waterproof layer 30 is made of polyethylene terephthalate, polycarbonate, or the like. The waterproof layer 30 is light-transmitting. The waterproof layer 30 may be colored. The light transmittance of the base layer 10 is higher than that of the waterproof layer 30. The thickness of the waterproof layer 30 is smaller than that of the base layer 10.

[0015] The hard coat layer 40 is provided on the surface of the waterproof layer 30. The hard coat layer 40 is made of a material harder than the material constituting the waterproof layer 30, and covers the surface of the waterproof layer 30. The hard coat layer 40 is optically transparent. The hard coat layer 40 preferably has the function of protecting the heat shielding layer 20 from ultraviolet rays. The hard coat layer 40 can be, for example, a layer formed by applying a coating agent containing an organic component including an acrylic resin and a silicon-based inorganic component.

[0016] The back surface protective layer 60 is provided on the back surface of the substrate layer 10. The back surface protective layer 60 covers the back surface of the substrate layer 10. The back surface protective layer 60 may be composed of a low-emissivity film (Low-E film). In this case, the low-emissivity film is adhered to the back surface of the substrate layer 10 via an adhesive layer. A hard coat layer may be further provided on the surface of the back surface protective layer 60 opposite the substrate layer 10, covering the back surface protective layer 60. Like the hard coat layer 40, the hard coat layer is made of a material that is harder than the material that constitutes the waterproof layer 30. An example of the hard coat layer is one in which a coating agent containing an organic component including an acrylic resin and a silicon-based inorganic component is applied. The back surface protective layer 60 may be omitted.

[0017] A printed layer 70, such as a black printed layer, is provided on the back surface of the back surface protection layer 60. An adhesive 7 is provided between the printed layer 70 and the vehicle body 2.

[0018] As described above, the resin structure 1 in this embodiment includes the heat shield layer 20 and the waterproof layer 30. When the heat shield layer 20 is made of a material that is susceptible to moisture, the provision of the waterproof layer 30 on the surface of the heat shield layer 20 ensures heat shielding properties and waterproofing of the heat shield layer 20. Furthermore, because the thickness of the waterproof layer 30 is smaller than the thickness of the substrate layer 10, infrared rays that pass through the waterproof layer 30 and are reflected by the heat shield layer 20 are prevented from accumulating in the waterproof layer 30, which would otherwise result in a decrease in heat shielding properties. Furthermore, the hard coat layer 40 can prevent the waterproof layer 30 from being damaged. Furthermore, when the hard coat layer 40 has the function of protecting the heat shield layer 20 from ultraviolet rays, the hard coat layer 40 can prevent the waterproof layer 30 and the heat shield layer 20 from being deteriorated by ultraviolet rays.

[0019] Furthermore, since the base material layer 10 is colorless or light in color, it can be recycled together with light-colored polycarbonate materials used in building materials, etc. During recycling, the heat shield layer 20, waterproof layer 30, hard coat layer 40, printed layer 70, etc. can be removed using a peeling device.

[0020] As shown in FIG. 3 , the resin structure 1 may further include a functional layer 50 provided within the base material layer 10 .

[0021] The functional layer 50 has a predetermined function. Examples of the predetermined function include a power generation function, a light control function, a display function, etc. In the example shown in FIG. 3 , a light control layer is used as the functional layer 50. Specifically, the functional layer 50 has a light control element 52 capable of controlling light, and a sealing layer 54 that seals the light control element 52. The light control element 52 may be an element that obtains a power generation function, a light control function, a display function, etc. by passing electricity through it.

[0022] It will be appreciated by those skilled in the art that the exemplary embodiments described above are examples of the following aspects.

[0023] [Aspect 1] A resin structure comprising: a substrate layer made of a light-transmitting resin; a heat-shielding layer provided on the surface of the substrate layer and having a function of reflecting heat rays; and a waterproof layer provided on the surface of the heat-shielding layer and having a function of blocking the penetration of moisture, wherein the waterproof layer has a thickness smaller than that of the substrate layer.

[0024] In this resin structure, the heat-shielding layer and the waterproof layer ensure heat-shielding and waterproofing properties. Furthermore, since the thickness of the waterproof layer is smaller than the thickness of the base layer, heat accumulation in the waterproof layer due to infrared rays that pass through the waterproof layer and are reflected by the heat-shielding layer and accumulate in the waterproof layer, i.e., a decrease in heat-shielding properties, is suppressed.

[0025] [Embodiment 2] The resin structure according to embodiment 1, further comprising a hard coat layer provided on the surface of the waterproof layer and having a higher hardness than the waterproof layer.

[0026] In this manner, the waterproof layer is effectively protected.

[0027] [Aspect 3] The resin structure according to aspect 1 or 2, wherein the substrate layer has a higher light transmittance than the waterproof layer.

[0028] In this embodiment, the light transmittance of the base layer, which has a thickness greater than that of the waterproof layer, is higher than that of the waterproof layer, making it suitable for recycling.

[0029] [Embodiment 4] The resin structure according to any one of embodiments 1 to 3, further comprising a functional layer provided within the base material layer, the functional layer having an element.

[0030] [Embodiment 5] The resin structure according to any one of embodiments 1 to 4, further comprising a back surface protection layer provided on the back surface of the base material layer.

[0031] 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.

[0032] REFERENCE SIGNS LIST 1 resin structure 2 body 5 adhesive layer 6 adhesive layer 10 substrate layer 20 heat-shielding layer 30 waterproof layer 40 hard coat layer 50 functional layer 52 light-modulating element 54 sealing layer 60 back surface protective layer

Claims

1. A resin structure comprising: a base layer made of a light-transmitting resin; a heat-shielding layer provided on the surface of the base layer and having the function of reflecting heat rays; and a waterproof layer provided on the surface of the heat-shielding layer and having the function of blocking the penetration of moisture, wherein the waterproof layer has a thickness smaller than that of the base layer.

2. The resin structure according to claim 1, further comprising a hard coat layer provided on the surface of the waterproof layer and having a higher hardness than the waterproof layer.

3. The resin structure according to claim 1, wherein the light transmittance of the base material layer is higher than the light transmittance of the waterproof layer.

4. The resin structure according to claim 1, further comprising a functional layer provided within the base material layer, the functional layer having an element.

5. The resin structure according to claim 1, further comprising a back surface protection layer provided on the back surface of the base material layer.

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