Method for manufacturing mating member, and mating member

Abstract

The present invention relates to a method for manufacturing a mating member, the method comprising: placing a first seal layer that forms a frame on a first transparent plate, applying a liquid first adhesive to an internal space of the frame, sinking one main surface and side surfaces of a sheet member, placing a support plate on both the first adhesive and the first seal layer, curing the first adhesive to form the first adhesive layer, removing the support plate, placing a second seal layer that forms a frame on the first seal layer, applying a liquid second adhesive to an internal space of the frame, placing a second transparent plate, and curing the second adhesive to form the second adhesive layer.

Description

Method for manufacturing a joint member, and joint member

[0001] This disclosure relates to a method for manufacturing a joint member and to a joint member.

[0002] The laminated glass described in Patent Document 1 comprises a first glass plate and a second glass plate facing the first glass plate. The laminated glass also includes a light-adjusting member, an adhesive portion, and a sealing member between the first and second glass plates. The sealing member is installed on the periphery of the first glass plate. The adhesive portion is in contact with the first glass plate, the second glass plate, and the first main surface, second main surface, and side surface of the light-adjusting member. The adhesive portion contains a curable transparent resin. Patent Document 2 contains a description of so-called privacy glass. Patent Documents 3 and 4 contain descriptions of two-component curable polyorganosiloxane compositions.

[0003] International Publication No. 2022 / 039089, International Publication No. 2015 / 088026, Japanese Patent No. 5308564, Japanese Patent No. 5414931

[0004] Thus, when the joining member comprises a first transparent plate, a second transparent plate, a sheet member, an adhesive layer, and a sealing layer, the second transparent plate faces the first transparent plate at a distance. The sheet member is provided between the first and second transparent plates, separated from both the first and second transparent plates. The adhesive layer adheres the first and second transparent plates and encloses the entire sheet member. The sealing layer is provided between the first and second transparent plates and surrounds the adhesive layer.

[0005] In contrast, when forming an adhesive layer by, for example, curing a liquid adhesive, positioning the sheet member has been difficult. This is because the sheet member is placed between the first transparent plate and the second transparent plate, separated from both the first and second transparent plates.

[0006] One embodiment of the present disclosure provides a technology that enables the sheet member to be precisely positioned at a desired location when forming an adhesive layer that encloses the entire sheet member by curing a liquid adhesive in a composite member comprising a sheet member.

[0007] One embodiment of a bonding member according to one embodiment of the present disclosure is as follows: [1A] A bonding member comprising: a first transparent plate; a second transparent plate facing the first transparent plate at a distance from it; a sheet member provided between the first transparent plate and the second transparent plate, spaced apart from both the first and second transparent plates; an adhesive layer that adheres the first transparent plate and the second transparent plate and encloses the entire sheet member; and a seal layer provided between the first transparent plate and the second transparent plate and surrounding the adhesive layer, wherein the adhesive layer has a first adhesive layer and a second adhesive layer in that order from the first transparent plate toward the second transparent plate; the seal layer has a first seal layer and a second seal layer in that order from the first transparent plate toward the second transparent plate; the thickness of the first seal layer is greater than the thickness of the sheet member; and the interface between the first seal layer and the second seal layer and the interface between the first adhesive layer and the second adhesive layer are continuously formed. [2A] The first adhesive layer and the second adhesive layer each have a shear modulus of 1.0 × 10 at 25°C. ３ Pa ~ 2.0 × 10 ５ The bonding member according to [1A], wherein the material is Pa. [3A] The bonding member according to [1A] or [2A], wherein the first adhesive layer and the second adhesive layer each have an average transmittance of 70% or more of light with a wavelength of 300 nm to 700 nm. [4A] The bonding member according to any one of [1A] to [3A], wherein the first seal layer and the second seal layer each have a thickness of 10 μm to 3 mm.

[0008] One embodiment of a method for manufacturing a jointed member according to one embodiment of this disclosure is as follows: [1B] A method for manufacturing a bonded member, comprising: a first transparent plate; a second transparent plate facing the first transparent plate at a distance from it; a sheet member provided between the first and second transparent plates, separated from both the first and second transparent plates; an adhesive layer that adheres the first and second transparent plates and encloses the entire sheet member; and a seal layer provided between the first and second transparent plates and surrounding the adhesive layer, wherein the adhesive layer has a first adhesive layer and a second adhesive layer in that order from the first transparent plate toward the second transparent plate; the seal layer has a first seal layer and a second seal layer in that order from the first transparent plate toward the second transparent plate; the thickness of the first seal layer is greater than the thickness of the sheet member; the interface between the first seal layer and the second seal layer and the interface between the first adhesive layer and the second adhesive layer are continuously formed; and the manufacturing method comprises: setting the first seal layer which forms a frame on the first transparent plate; A method for manufacturing a bonded member, comprising the steps in this order: applying a liquid first adhesive onto the first transparent plate in the internal space of the first seal layer that forms the frame; submerging one main surface and side surface of the sheet member in the first adhesive and placing a support plate, which has been temporarily fixed in advance to the other main surface of the sheet member, on both the first adhesive and the first seal layer; forming the first adhesive layer by curing the first adhesive; removing the support plate from the sheet member, the first adhesive layer and the first seal layer; installing the second seal layer that forms the frame on the first seal layer; applying a liquid second adhesive onto at least one of the first adhesive layer and the other main surface of the sheet member in the internal space of the second seal layer that forms the frame; placing the second transparent plate on both the second adhesive and the second seal layer; and forming the second adhesive layer by curing the second adhesive.[2B] The method for manufacturing a bonded member according to [1B], wherein the support plate comprises a flexible film and a substrate provided on the opposite side of the flexible film from the sheet member with respect to the flexible film, and the removal of the support plate includes removing the substrate and the flexible film in this order. [3B] The method for manufacturing a bonded member according to [2B], wherein the support plate comprises a first adhesive member for bonding the substrate and the flexible film, and the first adhesive member is provided in a frame shape along the periphery of the substrate and is also provided in a part of the area that overlaps with the sheet member in a plan view. [4B] The method for manufacturing a bonded member according to [2B] or [3B], wherein the support plate comprises a second adhesive member for bonding the flexible film and the sheet member, and the second adhesive member is provided in a frame shape along the periphery of the sheet member, forms a space between the sheet member and the flexible film, and prevents the first adhesive from entering the space. [5B] The method for manufacturing a joined member according to any one of [1B] to [4B], wherein the first seal layer forming the frame has an opening in a part of the frame, and when the support plate is placed on both the first adhesive and the first seal layer, the support plate gradually comes into contact with the first adhesive from the opposite side of the first seal layer toward the opening. [6B] The method for manufacturing a joined member according to any one of [1B] to [5B], wherein the second seal layer forming the frame has an opening in a part of the frame, and when the second transparent plate is placed on both the second adhesive and the second seal layer, the second transparent plate gradually comes into contact with the second adhesive from the opposite side of the second seal layer toward the opening. [7B] The method for manufacturing a joined member according to any one of [1B] to [6B], wherein the first adhesive and the second adhesive are each cured at room temperature by mixing a main agent and a curing agent. [8B] The first adhesive and the second adhesive each have a viscosity of 50 × 10 before curing. －３ Pa・s~2000×10 －３A method for manufacturing a bonded member according to any one of [1B] to [7B], wherein the shear modulus at 25°C is 1.0 × 10⁻⁶. [9B] The first adhesive layer and the second adhesive layer each have a shear modulus of 1.0 × 10⁻⁶ at 25°C. ３ Pa ~ 2.0 × 10 ５ A method for manufacturing a bonded member according to any one of [1B] to [8B], wherein the material is Pa. [10B] A method for manufacturing a bonded member according to any one of [1B] to [9B], wherein the first adhesive layer and the second adhesive layer each have an average transmittance of 70% or more of light having a wavelength of 300 nm to 700 nm. [11B] A method for manufacturing a bonded member according to any one of [1B] to [10B], wherein the first seal layer and the second seal layer each have a thickness of 10 μm to 3 mm.

[0009] According to one embodiment of the present disclosure, in a composite member comprising a sheet member, the sheet member can be positioned when an adhesive layer enclosing the entire sheet member is formed by curing a liquid adhesive.

[0010] Figure 1 is a schematic cross-sectional view of a joint member according to one embodiment. Figure 2 is a flowchart of a method for manufacturing a joint member according to one embodiment. Figure 3 is a diagram illustrating a part of the method for manufacturing a joint member according to one embodiment, where Figure 3(A) is a schematic cross-sectional view showing an example of step S101, and Figure 3(B) is a schematic cross-sectional view along the line B-B in Figure 3(A). Figure 4 is a diagram illustrating a part of the method for manufacturing a joint member according to one embodiment, where Figure 4(A) is a schematic cross-sectional view showing an example of step S102, and Figure 4(B) is a schematic cross-sectional view along the line B-B in Figure 4(A). Figure 5 is a diagram illustrating a part of the method for manufacturing a joint member according to one embodiment, where Figure 5(A) is a schematic cross-sectional view showing an example of step S103, Figure 5(B) is a schematic cross-sectional view along the line B-B in Figure 5(A), and Figure 5(C) is a schematic cross-sectional view along the line C-C in Figure 5(A). Figure 6 is a schematic cross-sectional view showing an example of step S104 in one embodiment. Figure 7 is a schematic cross-sectional view showing an example of step S105 in one embodiment. Figure 8 is a schematic cross-sectional view showing an example of step S106 in one embodiment. Figure 9 is a diagram illustrating a part of the manufacturing method of a jointed member according to one embodiment, where Figure 9(A) is a schematic cross-sectional view showing an example of step S107, and Figure 9(B) is a schematic cross-sectional view along the line B-B in Figure 9(A). Figure 10 is a diagram illustrating a part of the manufacturing method of a jointed member according to one embodiment, where Figure 10(A) is a schematic cross-sectional view showing an example of step S108, and Figure 10(B) is a cross-sectional view along the line B-B in Figure 10(A). Figure 11 is a schematic cross-sectional view showing an example of step S109 in one embodiment. Figure 12 is a schematic cross-sectional view showing an example of step S110 in one embodiment.

[0011] The embodiments for implementing this disclosure will be described below with reference to the drawings. In each drawing, identical or similar components will be denoted by the same reference numeral, and their descriptions may be omitted. In the specification, the "~" indicating a numerical range means that the numerical values ​​before and after it are included as the lower and upper limits. The numerical range includes rounded ranges. In the specification, the X-axis direction, Y-axis direction, and Z-axis direction are perpendicular to each other. The X-axis direction includes the positive X-axis direction and the negative X-axis direction, which is the opposite direction to the positive X-axis direction. The Y-axis direction includes the positive Y-axis direction and the negative Y-axis direction, which is the opposite direction to the positive Y-axis direction. The Z-axis direction includes the positive Z-axis direction and the negative Z-axis direction, which is the opposite direction to the positive Z-axis direction.

[0012] Referring to Figure 1, a bonding member 1 according to one embodiment will be described. The bonding member 1 comprises a first transparent plate 10, a second transparent plate 20, a sheet member 30, an adhesive layer 40, and a sealing layer 50. The second transparent plate 20 faces the first transparent plate 10 with a gap between them. The sheet member 30 is provided between the first transparent plate 10 and the second transparent plate 20, spaced apart from both the first and second transparent plates 20. The adhesive layer 40 adheres the first transparent plate 10 and the second transparent plate 20 and encloses the entire sheet member 30. The sealing layer 50 is provided between the first transparent plate 10 and the second transparent plate 20 and surrounds the adhesive layer 40.

[0013] The joining member 1 is plate-shaped. In Figure 1, the joining member 1 is flat, but it may also be curved. The joining member 1 is installed, for example, in the window of a vehicle. The vehicle is typically an automobile, but it may also be a railway vehicle. When the joining member 1 is installed in the window of an automobile, the joining member 1 is usually a curved plate that is convex toward the outside of the vehicle. When the image of a head-up display (HUD) is projected onto the window of an automobile, the thickness of the joining member 1 may gradually decrease from the bottom to the top of the automobile. The joining member 1 may also be installed in the windows of buildings, showcases, transparent partitions, ships, or aircraft.

[0014] The first transparent plate 10 and the second transparent plate 20 may be installed on either the inside or outside of the vehicle. The first transparent plate 10 may be installed on the inside and the second transparent plate 20 on the outside. Alternatively, the first transparent plate 10 may be installed on the outside and the second transparent plate 20 on the inside. In Figure 1, the first transparent plate 10 and the second transparent plate 20 are flat plates, but they may also be curved plates. The shape of the first transparent plate 10 and the second transparent plate 20 as viewed from the outside or inside of the vehicle, i.e., the shape in plan view, is rectangular, but they may also be trapezoidal or triangular, and are not particularly limited.

[0015] In this embodiment, the first transparent plate 10 and the second transparent plate 20 are preferably glass plates. Glass plates have superior scratch resistance compared to resin plates. The first transparent plate 10 and the second transparent plate 20 may be made of the same glass or different glass. As the glass, soda-lime glass, aluminosilicate glass, borosilicate glass, alkali-free glass, or quartz glass can be used.

[0016] Methods for manufacturing glass sheets include, for example, the float process, fusion process, roll-out process, or down-draw process. Methods for bending glass sheets include gravity forming, press forming, or roller forming. Glass sheets are bent at approximately 550°C to 770°C. Glass sheets may also be physically strengthened (e.g., air-cooled strengthening) or chemically strengthened.

[0017] The first transparent plate 10 and the second transparent plate 20 may be made of resin. Suitable resins include polycarbonate resin, acrylic resin, polystyrene resin, aromatic polyester resin, polyester resin, polyarylate resin, polycondensate of halogenated bisphenol A and ethylene glycol, acrylic urethane resin, or halogenated aryl group-containing acrylic resin. Among these, polycarbonate resin is preferred from the viewpoint of lightness and flexibility. Two or more types of resin may be used in combination. Furthermore, one of the first transparent plate 10 and the second transparent plate 20 may be made of glass, and the other of the two may be made of resin.

[0018] The first transparent plate 10 and the second transparent plate 20 are usually colorless, but any transparent material is acceptable, and they may be colored. In the case of colored materials, they may be so-called privacy glass, particularly those with a dark color such as gray. Privacy glass is described in detail, for example, in Patent Document 2, and its contents can be referenced herein.

[0019] The first transparent plate 10 and the second transparent plate 20 each have, for example, a thickness of 0.1 mm to 10 mm. From the viewpoint of resistance to impact from flying stones, the thickness is preferably 0.1 mm or more, more preferably 0.3 mm or more, even more preferably 0.5 mm or more, even more preferably 0.7 mm or more, particularly preferably 1.1 mm or more, and most preferably 1.6 mm or more. From the viewpoint of weight reduction, the thickness is preferably 10 mm or less, more preferably 3.0 mm or less, even more preferably 2.6 mm or less, and even more preferably 2.1 mm or less.

[0020] The first transparent plate 10 and the second transparent plate 20 may have the same thickness or different thicknesses. From the viewpoint of achieving both weight reduction and resistance to flying stone impact, it is preferable that the transparent plate on the outside of the vehicle has a greater thickness than the transparent plate on the inside of the vehicle. The absolute value of the difference between the thickness of the first transparent plate 10 and the thickness of the second transparent plate 20 is preferably 0.3 mm to 1.5 mm, and more preferably 0.5 mm to 1.3 mm. Here, the absolute value of the above difference in thickness is preferably 0.3 mm or more, more preferably 0.5 mm or more, and preferably 1.5 mm or less, and more preferably 1.3 mm or less.

[0021] A functional film (not shown) may be provided on at least one of the two main surfaces 11 and 12 of the first transparent plate 10 and the two main surfaces 21 and 22 of the second transparent plate 20. The functional film may provide properties such as water repellency, hydrophilicity, or light shielding (e.g., light shielding from visible light, ultraviolet light, or infrared light). Multiple functional films having different functions may be provided. The multiple functional films may be laminated or spaced apart.

[0022] The sheet member 30 is, for example, a light-adjusting film. The light-adjusting film is a photochromic film, an electrochromic film, or an electrokinetic film. The light-adjusting film switches the visible light transmittance of the bonding member 1. The difference in visible light transmittance before and after switching is preferably 3% or more, more preferably 35% or more, even more preferably 50% or more, and particularly preferably 80% or more. There is no particular upper limit to the difference in visible light transmittance before and after switching, but it may be, for example, 90% or less. The visible light transmittance is measured in accordance with JIS R3212:2015.

[0023] The dimming film has a dimming element. The dimming element includes, for example, a suspended particle device (SPD), a twisted nematic liquid crystal (TNLC), a polymer dispersed liquid crystal (PDLC), a polymer network liquid crystal (PNLC), or a guest-host liquid crystal (GHLC).

[0024] When the dimming element includes TNLC, PDLC, PNLC, or GHLC, stress applied to the dimming film tends to cause uneven distribution of liquid crystals and color unevenness. This tendency is particularly pronounced when the dimming element includes GHLC. When the dimming element includes GHLC, the inside of the dimming element is liquid, which allows for a fast switching speed of light transmittance, but also makes it prone to uneven distribution of liquid crystals. In contrast, according to this embodiment, as will be described later, the stress applied to the sheet member 30 can be reduced, thus effectively suppressing color unevenness in the dimming film.

[0025] The dimming film comprises, for example, a first substrate (not shown), a first conductive layer, a dimming element, a second conductive layer, and a second substrate in this order. The first and second substrates are made of, for example, a transparent resin. The first and second substrates each have a thickness of, for example, 5 μm to 500 μm, preferably 10 μm to 400 μm, and more preferably 50 μm to 350 μm. Here, from the viewpoint of suppressing the occurrence of color unevenness, for example, a thickness of 5 μm or more is preferred, 10 μm or more is more preferred, and 50 μm or more is even more preferred. From the viewpoint of conforming to the shape of glass, for example, a thickness of 500 μm or less is preferred, 400 μm or less is more preferred, and 350 μm or less is even more preferred.

[0026] The first conductive layer and the second conductive layer apply a voltage to the dimming element. The first and second conductive layers are composed of, for example, transparent conductive oxide (TCO). The first and second conductive layers may also be composed of a transparent conductive polymer. The first and second conductive layers may be composed of a laminated film of a metal layer and a dielectric layer, silver nanowires, or a silver or copper metal mesh. The first and second conductive layers each have a thickness of, for example, 200 nm to 2 μm.

[0027] Note that the sheet member 30 is not limited to a dimming film. For example, the sheet member 30 may be a solar cell film or an organic light-emitting diode (OLED) sheet. The organic EL sheet may be for illumination or image display. The bonding member 1 may be equipped with wiring (not shown) that electrically connects the outside of the bonding member 1 to the sheet member 30. The wiring passes between the first adhesive layer 41 and the second adhesive layer 42, and between the first seal layer 51 and the second seal layer 52, as described later, and is brought out to the outside of the bonding member 1. The sheet member 30 may be a screen sheet. The screen sheet displays an image projected by a projector. The image may be a still image or a moving image. If the sheet member is a screen sheet, the wiring (not shown) that electrically connects the outside of the bonding member 1 to the sheet member 30 is not necessary.

[0028] The thickness of the sheet member 30 is, for example, 0.05 mm to 2.9 mm, preferably 0.05 mm to 2.0 mm, and more preferably 0.1 mm to 1.0 mm. Here, the above thickness is preferably 0.05 mm or more, more preferably 0.1 mm or more, and preferably 2.9 mm or less, more preferably 2.0 mm or less, and even more preferably 1.0 mm or less. The sheet member 30 preferably has a longest distance between any two points on the periphery of the sheet member 30 of 50 mm to 3000 mm.

[0029] The adhesive layer 40 has a first adhesive layer 41 and a second adhesive layer 42 in this order from the first transparent plate 10 toward the second transparent plate 20. The first adhesive layer 41 is formed by curing a liquid first adhesive. The second adhesive layer 42 is formed by curing a liquid second adhesive. The first adhesive and the second adhesive preferably have the same composition, but may have different compositions. The first adhesive and the second adhesive can use, for example, a resin composition of acrylate, silicone, acrylic-modified silicone, urethane, urethane acrylate, epoxy, epoxy acrylate, acrylamide, or methacrylamide.

[0030] The first adhesive and the second adhesive may be any of thermosetting type, photocuring type, or reaction curing type, but preferably the reaction curing type. The reaction curing type adhesive cures at room temperature by mixing a main agent and a curing agent, so it can suppress the generation of stress due to temperature change. In this specification, room temperature is 15°C to 35°C. Also, the reaction curing type adhesive cures without irradiating ultraviolet rays, so it can suppress the deterioration of the sheet member 30 due to ultraviolet ray irradiation. As the reaction curing type adhesive, for example, a two-component curable polyorganosiloxane composition described in Patent Document 3 or 4 can be used.

[0031] The first adhesive and the second adhesive each preferably have a viscosity before curing of 50×10 －３ Pa·s to 2000×10 －３ Pa·s. Here, from the viewpoint of good shape retention during coating and ensuring the coating amount, the viscosity before curing is 50×10 －３Preferably, it is Pa·s or more, and more preferably 500×10 －３ Pa·s or more. On the other hand, from the viewpoint of the shape workability after coating, the viscosity before curing is preferably 2000×10 －３ Pa·s or less, and more preferably 1200×10 －３ Pa·s or less.

[0032] The first adhesive and the second adhesive may contain additives such as an elastomer, high refractive inorganic nanoparticles, an antioxidant, a curing agent, a plasticizer, a filler, an ultraviolet stabilizer, a color toner, a reinforcing agent, an antifoaming agent, a surfactant, or a rust inhibitor. These additives are selected so as not to deteriorate the sheet member 30.

[0033] The first adhesive layer 41 and the second adhesive layer 42 preferably have a shear modulus of elasticity at 25°C of 2.0×10 ５ Pa or less, and more preferably 1.0×10 ３ Pa to 2.0×10 ５ Pa. Here, the shear modulus of elasticity is preferably 2.0×10 ５ Pa or less, more preferably 1.9×10 ５ Pa or less, and even more preferably 1.8×10 ５ Pa or less. The first adhesive layer 41 is moderately soft, and the first adhesive layer 41 can be deformed according to the difference in thermal expansion between the first transparent plate 10 and the sheet member 30. Also, the second adhesive layer 42 is moderately soft, and the second adhesive layer 42 can be deformed according to the difference in thermal expansion between the second transparent plate 20 and the sheet member 30. Therefore, it is possible to suppress the stress caused by the difference in thermal expansion from being applied to the sheet member 30.

[0034] The first adhesive layer 41 and the second adhesive layer 42 preferably have a shear modulus of elasticity at 25°C of 1.0×10 ３ Pa or more, more preferably 5.0×10 ３ Pa or more, and even more preferably 1.0×10 ４ Pa or more. The first adhesive layer 41 and the second adhesive layer 42 are moderately hard, the rigidity of the combined member 1 is high, and the handling property of the combined member 1 is good.

[0035] Further, the first adhesive layer 41 and the second adhesive layer 42 preferably have a loss factor (tan δ) of 0.1 to 1.0 at 25°C. Here, from the viewpoint of high adhesive strength, the loss factor is preferably 0.1 or more, and from the viewpoint of reducing shear peeling, the loss factor is preferably 1.0 or less.

[0036] In this specification, the shear modulus and tan δ are measured using a device for measuring dynamic viscoelasticity by the shear method, for example, MCR301 manufactured by Anton Paar. The measurement frequency is, for example, 1 kHz.

[0037] The first adhesive layer 41 and the second adhesive layer 42 preferably have an average transmittance of 70% or more, more preferably 80% or more, for light having a wavelength of 300 nm to 700 nm. The average transmittance is measured in accordance with JIS K7361-1:1997. The average transmittance is measured at the portion where the thickness of the first adhesive layer 41 is maximum or the portion where the thickness of the second adhesive layer 42 is maximum. The upper limit of the average transmittance is not particularly limited, and the higher the better, but it may be, for example, 100% or 99% or less.

[0038] The first adhesive layer 41 and the second adhesive layer 42 preferably have a yellowness of 30 or less, more preferably 20 or less, measured in accordance with JIS K7373:2006. The yellowness is measured at the portion where the thickness of the first adhesive layer 41 is maximum or the portion where the thickness of the second adhesive layer 42 is maximum. The value obtained by dividing the yellowness of the first adhesive layer 41 by the maximum thickness (μm) of the first adhesive layer 41 and the value obtained by dividing the yellowness of the second adhesive layer 42 by the maximum thickness (μm) of the second adhesive layer 42 are each preferably －１ 0.04 μm or less, and more preferably －１ 0.03 μm or less.

[0039] The adhesive layer 40 may contain a coloring agent, an infrared absorber, an ultraviolet absorber, or a light-emitting agent. Of the first adhesive layer 41 and the second adhesive layer 42, the adhesive layer on the outside of the vehicle relative to the sheet member 30 preferably contains an ultraviolet absorber. The ultraviolet absorber suppresses the deterioration of the sheet member 30 due to ultraviolet rays. The adhesive layer 40 may also have a colored layer containing a coloring agent. The colored layer is, for example, called a shade band. The coloring agent is not particularly limited, but for example, carbon black.

[0040] The sealing layer 50 has a first sealing layer 51 and a second sealing layer 52 in this order, extending from the first transparent plate 10 toward the second transparent plate 20. The first sealing layer 51 is provided along at least a portion of the periphery of the surface of the first transparent plate 10 facing the second transparent plate 20 (the main surface 12 of the first transparent plate 10), and restricts the outflow of the first adhesive. That is, the first sealing layer 51 forms a frame on the surface of the first transparent plate 10 facing the second transparent plate 20. The second sealing layer 52 is provided on top of the first sealing layer 51 after the first adhesive has cured, and restricts the outflow of the second adhesive. The second sealing layer 52 is provided along at least a portion of the periphery of the surface of the second transparent plate 20 facing the first transparent plate 10 (the main surface 21 of the second transparent plate 20). That is, the second sealing layer 52 forms a frame following the first sealing layer 51.

[0041] The first seal layer 51 and the second seal layer 52 are each formed of, for example, a transparent resin. Note that the first seal layer 51 and the second seal layer 52 can be concealed by a light-shielding layer (not shown), and therefore may be formed of an opaque resin. The light-shielding layer is provided along at least a portion of the periphery of the first transparent plate 10 or the second transparent plate 20. The shear modulus of the first seal layer 51 and the second seal layer 52 at 25°C is preferably equal to or greater than the shear modulus of the first adhesive layer 41 and the second adhesive layer at 25°C.

[0042] The first seal layer 51 and the second seal layer 52 each preferably have a thickness of 10 μm to 3 mm. From the viewpoint of ensuring sufficient space between the first transparent plate 10 and the second transparent plate 20 and suitably accommodating the sheet member 30 between them, the above thickness is preferably 10 μm or more, and more preferably 100 μm or more. On the other hand, from the viewpoint of increasing the rigidity of the joining member 1 and improving the handling of the joining member 1, the above thickness is preferably 3 mm or less, and more preferably 1.5 mm or less.

[0043] The thickness of the first sealing layer 51 is greater than the thickness of the sheet member 30. Therefore, even if one main surface 31 and one side surface 33 of the sheet member 30 are submerged in the first adhesive, a gap can be formed between the sheet member 30 and the first transparent plate 10 for the first adhesive, and thus the hardened first adhesive layer 41, to penetrate. By filling the gap between the sheet member 30 and the first transparent plate 10, the first adhesive layer 41 can be deformed in accordance with the difference in thermal expansion between the sheet member 30 and the first transparent plate 10, thereby suppressing the stress caused by the difference in thermal expansion from being applied to the sheet member 30. As a result, for example, color unevenness in the dimming film can be suitably suppressed.

[0044] One main surface 31 of the sheet member 30 and the side surface 33 connected thereto are covered with a first adhesive layer 41. On the other hand, the other main surface 32 of the sheet member 30 is covered with a second adhesive layer 42. By filling the gap between the sheet member 30 and the second transparent plate 20, the second adhesive layer 42 can be deformed in accordance with the difference in thermal expansion between the sheet member 30 and the second transparent plate 20, thereby suppressing the stress on the sheet member 30 caused by the difference in thermal expansion. As a result, for example, color unevenness in the dimming film can be suitably suppressed.

[0045] The interface 53 between the first seal layer 51 and the second seal layer 52, and the interface 43 between the first adhesive layer 41 and the second adhesive layer 42 are formed continuously. That is, there is no step between the interfaces 53 and 43, and a single surface is formed. This is because, in step S104, which will be described later, when the support plate 60 is placed on the first seal layer 51 as shown in Figure 6, the support plate 60 levels the liquid level of the first adhesive 41A, making it the same height as the top surface of the first seal layer 51.

[0046] A method for manufacturing the joint member 1 according to one embodiment will be described with reference to Figures 2 to 12. As shown in Figure 2, the method for manufacturing the joint member 1 has steps S101 to S110. Note that the order of steps S101 to S110 is not limited to the order shown in Figure 2. However, since the support plate 60 needs to be temporarily fixed to the other main surface 32 of the sheet member 30 before submerging one main surface 31 of the sheet member 30 in the first adhesive, step S103 is performed before step S104. Otherwise, the order of each step can be changed as appropriate. For example, step S103 may be performed before step S101, or after step S101 and before step S102. Steps S101 to S110 are performed by a human, but may also be performed by a machine.

[0047] Step S101 is the installation of the first seal layer 51, which includes installing the first seal layer 51 on the first transparent plate 10, as shown in Figures 3(A) and (B). The first transparent plate 10 is installed with the surface of the first transparent plate 10 facing the second transparent plate 20 (the main surface 12 of the first transparent plate 10) facing upward. The first seal layer 51 is provided along at least a portion (only a portion in Figure 3(B)) of the periphery of the main surface 12 of the first transparent plate 10, forming a frame. The first seal layer 51 forms a frame, and it is preferable that a part of the frame has an opening 51a. The first seal layer 51 preferably has an adhesive layer (not shown) that is adhered to the first transparent plate 10 in order to suppress misalignment with respect to the first transparent plate 10.

[0048] Step S102 is the application of the first adhesive, which, as shown in Figures 4(A) and (B), includes applying a liquid first adhesive 41A onto the first transparent plate 10 in the internal space (inside) of the first seal layer 51 that forms the frame. The first adhesive 41A is applied to the main surface 12 of the first transparent plate 10. As shown in Figure 4(B), it is preferable that the first adhesive 41A is applied such that the thickness of the first adhesive 41A decreases as you move from the opposite side of the opening 51a of the first seal layer 51 toward the opening 51a. This suppresses the trapping of air bubbles in step S104, which will be described later. When applying the first adhesive, it is necessary to apply a sufficient amount to fill the internal space when the sheet member 30 is submerged, so that after the subsequent steps S104 to S106, the interface between the first seal layer 51 and the second seal layer 52 and the interface between the first adhesive layer 41 and the second adhesive layer 42 are continuously formed.

[0049] Step S103 involves bonding the sheet member 30 and the support plate 60, but prior to step S104, it includes bonding the sheet member 30 and the support plate 60 in advance, as shown in Figure 5(A). The support plate 60 preferably has a substrate 61 and a flexible film 62. The support plate 60 may have only one of the substrate 61 and the flexible film 62, but having both allows for both limiting the deformation of the sheet member 30 and making it easy to remove the support plate 60 from the sheet member 30. It is preferable to perform step S103 before step S102. Performing step S102 after step S103 shortens the time from the completion of step S102 to the start of step S104, and suppresses the curing of the first adhesive 41A until step S104 is started.

[0050] The substrate 61 restricts the deformation of the flexible film 62, and consequently, the deformation of the sheet member 30. The substrate 61 is provided on the side of the flexible film 62 opposite to the sheet member 30. That is, the substrate 61 is located on the main surface of the flexible film 62 opposite to the sheet member 30 side. Therefore, the substrate 61 does not come into contact with the first adhesive 41A and thus the first adhesive layer 41, and the substrate 61 can be easily removed in step S106, which will be described later.

[0051] The substrate 61 has greater bending rigidity than the flexible film 62. In this embodiment, the substrate 61 is a glass plate, but it may be a ceramic plate, a resin plate, or a metal plate. The substrate 61 may be transparent or opaque. In this embodiment, the substrate 61 is flat, but it may be curved. The thickness of the substrate 61 is, for example, 0.5 mm to 3 mm.

[0052] In step S104, described later, it is preferable that the substrate 61 overlaps the entire first transparent plate 10 in a plan view. A plan view means directly viewing the main surfaces 11 and 12 of the first transparent plate 10. In the region that overlaps the entire first transparent plate 10 in a plan view, the deformation of the flexible film 62 can be restricted and the liquid level of the first adhesive layer 41 can be leveled. As a result, the interface 53 between the first seal layer 51 and the second seal layer 52, and the interface 43 between the first adhesive layer 41 and the second adhesive layer 42 are continuously formed. Note that the substrate 61 may be larger than the first transparent plate 10.

[0053] The flexible film 62 is in contact with the first adhesive 41A and thus the first adhesive layer 41, and therefore has flexibility to facilitate peeling from the first adhesive layer 41. By gradually peeling the flexible film 62 from the first adhesive layer 41 while bending it, the force required for peeling can be reduced. Consequently, the flexible film 62 can be easily removed.

[0054] The flexible film 62 is formed of, for example, a resin. The resin is not particularly limited, but for example, PTFE (tetrafluoroethylene resin). The flexible film 62 may be transparent or opaque. It is preferable that the flexible film 62 is larger than the substrate 61 in order to limit contact between the first adhesive 41A and the substrate 61. The thickness of the flexible film 62 is, for example, 0.05 mm to 0.5 mm.

[0055] As shown in Figure 5(A), the support plate 60 preferably has a first adhesive member 63. The first adhesive member 63 adheres the substrate 61 and the flexible film 62. Preferably, the contact surface of the first adhesive member 63 with the flexible film 62 has a higher adhesive strength than the contact surface with the substrate 61. When removing the substrate 61 from the flexible film 62, the first adhesive member 63 can remain on the flexible film 62. Examples of the first adhesive member 63 include double-sided tape.

[0056] As shown in Figure 5(B), the first adhesive member 63 is provided in a frame shape along the periphery of the substrate 61, and is also provided in a part of the area that overlaps with the sheet member 30 in a plan view. This limits the deformation of the flexible film 62, and consequently the deformation of the sheet member 30. Since the first adhesive member 63 is not provided on the entire surface of one side of the substrate 61, the substrate 61 can be easily removed from the flexible film 62.

[0057] As shown in Figure 5(A), the support plate 60 preferably has a second adhesive member 64. The second adhesive member 64 adheres the sheet member 30 and the flexible film 62. Preferably, the contact surface of the second adhesive member 64 with the flexible film 62 has a higher adhesive strength than the contact surface with the sheet member 30. The second adhesive member 64 can be removed from the sheet member 30 together with the flexible film 62. Examples of the second adhesive member 64 include double-sided tape.

[0058] As shown in Figure 5(C), the second adhesive member 64 is provided in a frame shape along the periphery of the sheet member 30, and as shown in Figure 5(A), it forms a space between the sheet member 30 and the flexible film 62, preventing the first adhesive 41A from entering this space. This limits contact between the first adhesive 41A and the flexible film 62, and allows the flexible film 62 to be easily removed in step S106, which will be described later. Although not shown, the second adhesive member 64 may also be provided in the central part of the sheet member 30.

[0059] Step S104 involves installing the support plate 60, which, as shown in Figure 6, includes installing the support plate 60 on both the first adhesive 41A and the first seal layer 51 in a direction such that the temporarily fixed sheet member 30 sinks into the first adhesive 41A. Specifically, step S104 includes sinking one main surface 31 and side surface 33 of the sheet member 30 into the first adhesive 41A, and placing the support plate 60, which has been temporarily fixed to the other main surface 32 of the sheet member 30, on both the first adhesive 41A and the first seal layer 51. As a result, the first adhesive 41A and the first seal layer 51 become a flat surface without any steps, and the interface 53 between the first seal layer 51 and the second seal layer 52, and the interface 43 between the first adhesive layer 41 and the second adhesive layer 42 are continuously formed. The first sealing layer 51 has a thickness greater than the thickness of the sheet member 30 in order to form a gap between the sheet member 30 and the first transparent plate 10 for the first adhesive 41A to enter. The support plate 60 levels the liquid level of the first adhesive 41A so that it is at the same height as the top surface of the first sealing layer 51.

[0060] When placing the support plate 60 on both the first adhesive 41A and the first sealing layer 51, it is preferable that the support plate 60 gradually comes into contact with the first adhesive 41A from the opposite side of the opening 51a of the first sealing layer 51 toward the opening 51a. This suppresses the trapping of air bubbles and allows the first adhesive 41A to flow toward the opening 51a of the first sealing layer 51, filling the space between the support plate 60 and the first transparent plate 10 with the first adhesive 41A. Excess first adhesive 41A may leak out from the opening 51a of the first sealing layer 51 to prevent a rise in pressure. To prevent the leaked first adhesive 41A from contaminating the first transparent plate 10, etc., a protective sheet (not shown) may be peelably provided on the first transparent plate 10, etc., in advance. The protective sheet is removed after step S104, preferably after step S109.

[0061] Step S104 may be performed in a reduced-pressure atmosphere to suppress the inclusion of air bubbles.

[0062] Step S105 includes forming a first adhesive layer 41 by curing the first adhesive 41A, as shown in Figure 7. If the first adhesive 41A is a reaction-curing type, it hardens at room temperature by mixing the main agent and the hardener, thus suppressing the generation of stress due to temperature changes. Also, if the first adhesive 41A is a reaction-curing type, it hardens without irradiation with ultraviolet light, thus suppressing the deterioration of the sheet member 30 due to irradiation with ultraviolet light. Step S105 may be carried out at room temperature and atmospheric pressure, or in an atmospheric environment. In this specification, atmospheric pressure is 86 × 10⁻⁶. ３ Pa ~ 106 x 10 ３ It is Pa.

[0063] Step S106 includes removing the support plate 60 from the sheet member 30, the first adhesive layer 41, and the first sealing layer 51, as shown in Figure 8. Removing the support plate 60 preferably includes removing the substrate 61 and the flexible film 62 in that order. Since the substrate 61 does not come into contact with the first adhesive 41A, it can be removed without bending.

[0064] After removing the substrate 61, the first adhesive member 63 remaining on the flexible film 62 may be removed before removing the flexible film 62. Unlike the substrate 61, the flexible film 62 is in contact with the first adhesive layer 41 and is therefore flexible to facilitate peeling from the first adhesive layer 41. By gradually peeling the flexible film 62 from the first adhesive layer 41 while bending it, the force required for peeling can be reduced. Therefore, the flexible film 62 can be easily removed.

[0065] Step S107 includes installing a second seal layer 52 on top of the first seal layer 51, as shown in Figures 9(A) and (B). The second seal layer 52 forms a frame, preferably having an opening 52a in part of the frame. The second seal layer 52 preferably has an adhesive layer (not shown) that is bonded to the first seal layer 51 in order to suppress misalignment with the first seal layer 51. Although not shown, a part of the second seal layer 52 may be installed on top of the first adhesive layer 41.

[0066] Step S108 includes applying a liquid second adhesive 42A to at least one of the first adhesive layer 41 and the other main surface 32 of the sheet member 30 in the internal space (inside) of the second seal layer 52, as shown in Figures 10(A) and (B). The second adhesive 42A may be applied to the other main surface 32 of the sheet member 30, or to both the first adhesive layer 41 and the other main surface 32 of the sheet member 30. As shown in Figure 10(B), it is preferable that the second adhesive 42A is applied such that the thickness of the second adhesive 42A decreases as you move from the opposite side of the opening 52a of the second seal layer 52 toward the opening 52a. This suppresses the trapping of air bubbles in step S109, which will be described later.

[0067] Step S109 includes installing the second transparent plate 20, as shown in Figure 11. Specifically, step S109 includes placing the second transparent plate 20 on top of both the second adhesive 42A and the second sealing layer 52. The second transparent plate 20 levels the liquid level of the second adhesive 42A and aligns it with the top surface of the second sealing layer 52.

[0068] When placing the second transparent plate 20 on both the second adhesive 42A and the second sealing layer 52, it is preferable that the second transparent plate 20 gradually comes into contact with the second adhesive 42A from the opposite side of the opening 52a of the second sealing layer 52 toward the opening 52a. This suppresses the trapping of air bubbles, allows the second adhesive 42A to flow toward the opening 52a of the second sealing layer 52, and fills the space between the second transparent plate 20 and the first adhesive layer 41 with the second adhesive 42A. Excess second adhesive 42A may leak out from the opening 52a of the second sealing layer 52 to prevent the pressure from rising. To prevent the leaked second adhesive 42A from contaminating the second transparent plate 20, etc., a protective sheet (not shown) may be peelably provided on the second transparent plate 20, etc. beforehand. The protective sheet is removed after step S109.

[0069] Step S109 may be performed in a reduced-pressure atmosphere to suppress the inclusion of air bubbles.

[0070] Step S110 includes forming a second adhesive layer 42 by curing the second adhesive 42A, as shown in Figure 12. If the second adhesive 42A is a reaction-curing type, it hardens at room temperature by mixing the main agent and the hardener, thus suppressing the generation of stress due to temperature changes. Also, if the second adhesive 42A is a reaction-curing type, it hardens without irradiation with ultraviolet light, thus suppressing the deterioration of the sheet member 30 due to irradiation with ultraviolet light. Step S110 may be carried out at room temperature and atmospheric pressure, or in an atmospheric environment.

[0071] According to this embodiment, the seal layer 50 is divided into a first seal layer 51 and a second seal layer 52, and a support plate 60 is placed on the first seal layer 51 before installing the second seal layer 52. The support plate 60 forms a gap between the sheet member 30 and the first transparent plate 10 into which the first adhesive 41A can enter, and also positions the sheet member 30 in the desired position. The support plate 60 also levels the liquid level of the first adhesive 41A so that it is at the same height as the top surface of the first seal layer 51. The support plate 60 is removed after the first adhesive 41A has hardened, that is, after the first adhesive layer 41 has been formed. Then, the second seal layer 52 is installed on the first seal layer 51, and the second adhesive layer 42 is formed on the first adhesive layer 41. This allows the entire sheet member 30 to be covered with the adhesive layer 40. Therefore, when the adhesive layer 40 that covers the entire sheet member 30 is formed by hardening a liquid adhesive, the sheet member 30 can be positioned with high precision.

[0072] The manufacturing method of the joint member and the joint member relating to this disclosure have been described above, but this disclosure is not limited to the embodiments described above. Various changes, modifications, substitutions, additions, deletions, and combinations are possible within the scope described in the claims. These also naturally fall within the technical scope of this disclosure.

[0073] Although the present invention has been described in detail and with reference to specific embodiments, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention. This application is based on Japanese Patent Application No. 2024-163332 filed on September 20, 2024, the contents of which are incorporated herein by reference.

[0074] 1 Joining member 10 First transparent plate 20 Second transparent plate 30 Sheet member 40 Adhesive layer 41 First adhesive layer 41A First adhesive 42 Second adhesive layer 42A Second adhesive 50 Sealing layer 51 First sealing layer 52 Second sealing layer 60 Support plate

Claims

1. A method for manufacturing a bonded member, comprising: a first transparent plate; a second transparent plate facing the first transparent plate at a distance from it; a sheet member provided between the first and second transparent plates, separated from both the first and second transparent plates; an adhesive layer that adheres the first and second transparent plates and encloses the entire sheet member; and a seal layer provided between the first and second transparent plates and surrounding the adhesive layer, wherein the adhesive layer has a first adhesive layer and a second adhesive layer in that order from the first transparent plate toward the second transparent plate; the seal layer has a first seal layer and a second seal layer in that order from the first transparent plate toward the second transparent plate; the thickness of the first seal layer is greater than the thickness of the sheet member; the interface between the first seal layer and the second seal layer and the interface between the first adhesive layer and the second adhesive layer are continuously formed; and the manufacturing method comprises: setting the first seal layer which forms a frame on the first transparent plate; A method for manufacturing a bonded member, comprising the steps in this order: applying a liquid first adhesive onto the first transparent plate in the internal space of the first seal layer that forms the frame; submerging one main surface and side surface of the sheet member in the first adhesive and placing a support plate, which has been temporarily fixed in advance to the other main surface of the sheet member, on both the first adhesive and the first seal layer; forming the first adhesive layer by curing the first adhesive; removing the support plate from the sheet member, the first adhesive layer and the first seal layer; installing the second seal layer that forms the frame on the first seal layer; applying a liquid second adhesive onto at least one of the first adhesive layer and the other main surface of the sheet member in the internal space of the second seal layer that forms the frame; placing the second transparent plate on both the second adhesive and the second seal layer; and forming the second adhesive layer by curing the second adhesive.

2. The method for manufacturing a bonding member according to claim 1, wherein the support plate comprises a flexible film and a substrate provided on the opposite side of the flexible film from the sheet member with respect to the flexible film, and the removal of the support plate includes removing the substrate and the flexible film in that order.

3. The method for manufacturing a bonding member according to claim 2, wherein the support plate has a first adhesive member for bonding the substrate and the flexible film, and the first adhesive member is provided in a frame shape along the periphery of the substrate and is also provided in a part of the area that overlaps with the sheet member in a plan view.

4. The method for manufacturing a bonded member according to claim 2, wherein the support plate has a second adhesive member for bonding the flexible film and the sheet member, the second adhesive member is provided in a frame shape along the periphery of the sheet member, and forms a space between the sheet member and the flexible film, preventing the first adhesive from entering the space.

5. The method for manufacturing a jointed member according to claim 1, wherein the first seal layer forming the frame has an opening in a part of the frame, and when the support plate is placed on both the first adhesive and the first seal layer, the support plate gradually comes into contact with the first adhesive from the opposite side of the first seal layer toward the opening.

6. The method for manufacturing a bonded member according to claim 1, wherein the second seal layer forming the frame has an opening in a part of the frame, and when the second transparent plate is placed on both the second adhesive and the second seal layer, the second transparent plate gradually comes into contact with the second adhesive from the side of the second seal layer away from the opening toward the opening.

7. A method for manufacturing a bonded member according to any one of claims 1 to 6, comprising curing the first adhesive and the second adhesive at room temperature by mixing a main agent and a curing agent, respectively.

8. The first adhesive and the second adhesive each have a viscosity of 50 × 10 before curing. －３ Pa・s~2000×10 －３ A method for manufacturing a bonding member according to any one of claims 1 to 6, wherein the material is Pa·s.

9. The first adhesive layer and the second adhesive layer each have a shear modulus of 1.0 × 10⁻⁶ at 25°C. ３ Pa ~ 2.0 × 10 ５ A method for manufacturing a bonding member according to any one of claims 1 to 6, wherein the material is Pa.

10. The method for manufacturing a bonded member according to any one of claims 1 to 6, wherein the first adhesive layer and the second adhesive layer each have an average transmittance of 70% or more of light having a wavelength of 300 nm to 700 nm.

11. The method for manufacturing a bonding member according to any one of claims 1 to 6, wherein the first sealing layer and the second sealing layer each have a thickness of 10 μm to 3 mm.

12. A bonding member comprising: a first transparent plate; a second transparent plate facing the first transparent plate at a distance from it; a sheet member provided between the first and second transparent plates, spaced apart from both the first and second transparent plates; an adhesive layer that adheres the first and second transparent plates together and encloses the entire sheet member; and a sealing layer provided between the first and second transparent plates and surrounding the adhesive layer, wherein the adhesive layer has a first adhesive layer and a second adhesive layer in that order from the first transparent plate toward the second transparent plate; the sealing layer has a first sealing layer and a second sealing layer in that order from the first transparent plate toward the second transparent plate; the thickness of the first sealing layer is greater than the thickness of the sheet member; and the interface between the first sealing layer and the second sealing layer and the interface between the first adhesive layer and the second adhesive layer are continuously formed.

13. The first adhesive layer and the second adhesive layer each have a shear modulus of 1.0 × 10⁻⁶ at 25°C. ３ Pa ~ 2.0 × 10 ５ The joining member according to claim 12, wherein the material is Pa.

14. The bonding member according to claim 12 or 13, wherein the first adhesive layer and the second adhesive layer each have an average transmittance of 70% or more of light with a wavelength of 300 nm to 700 nm.

15. The bonding member according to claim 12 or 13, wherein the first sealing layer and the second sealing layer each have a thickness of 10 μm to 3 mm.

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