Adhesive sheet, article and method for producing article

1 . An adhesive sheet comprising:

a first face; and

a second face,

wherein:

the first face and the second face are opposite to each other,

the first face includes a thermally expandable thermosetting adhesive layer A containing a thermosetting resin and an expansion agent,

the second face includes a thermally expandable thermosetting adhesive layer B containing a thermosetting resin and an expansion agent and having a different composition from a composition of the thermally expandable thermosetting adhesive layer A,

the thermally expandable thermosetting adhesive layer B is laminated on one face of the thermally expandable thermosetting adhesive layer A directly or through another layer,

the first face has a higher shear adhesive strength than a shear adhesive strength of the second face,

the thermally expandable thermosetting adhesive layer A and the thermally expandable thermosetting adhesive layer B each have a thickness direction expansion rate of 130% or more after heating at 150° C. for 60 minutes, and

the shear adhesive strength of the second face of the adhesive sheet before thermal expansion is less than 0.5 MPa.

2 . The adhesive sheet according to claim 1 , wherein the shear adhesive strength of the first face of the adhesive sheet is 0.2 MPa or more.

3 . The adhesive sheet according to claim 1 , wherein the thermally expandable thermosetting adhesive layer A contains a thermosetting resin with a viscosity of 3,000,000 mPa·sec or less at 25° C. in an amount of 10% by mass or more in an entire resin component of the thermally expandable thermosetting adhesive layer A.

4 . The adhesive sheet according to claim 3 , wherein the thermally expandable thermosetting adhesive layer A contains a thermosetting resin with a viscosity of 3,000,000 mPa·sec or less at 25° C. in an amount of 10% by mass or more and 50% by mass or less in an entire resin component of the thermally expandable thermosetting adhesive layer A.

5 . The adhesive sheet according to claim 1 , wherein the thermally expandable thermosetting adhesive layer B contains a thermosetting resin with a viscosity of 3,000,000 mPa·sec or less at 25° C. in an amount of 40% by mass or less in an entire resin component of the thermally expandable thermosetting adhesive layer B.

6 . The adhesive sheet according to claim 5 , wherein the thermally expandable thermosetting adhesive layer B contains a thermosetting resin with a viscosity of 3,000,000 mPa·sec or less at 25° C. in an amount of 20% by mass or less in an entire resin component of the thermally expandable thermosetting adhesive layer B.

7 . The adhesive sheet according to claim 1 , wherein the thermally expandable thermosetting adhesive layer A and the thermally expandable thermosetting adhesive layer B each have a glass transition temperature of 80° C. or higher after heating at 150° C. for 60 minutes.

8 . An article comprising:

a first adherend; and

a second adherend that is formed with a cavity,

wherein:

the first adherend is disposed in the cavity of the second adherend,

an expanded product of the adhesive sheet according to claim 1 is disposed between the first adherend and the second adherend in the cavity, and

one of the first adherend and the second adherend is bonded to the thermally expandable thermosetting adhesive layer A after expansion and an other of the first adherend and the second adherend is bonded to the thermally expandable thermosetting adhesive layer B after expansion.

9 . An article comprising:

a first adherend;

a third adherend;

a fourth adherend; and

a cavity between the third adherend and the fourth adherend,

wherein

the first adherend is disposed in the cavity, and

an expanded product of the adhesive sheet according to claim 1 is disposed between the first adherend and the third adherend and between the first adherend and the fourth adherend in the cavity respectively, and

at least one of the first adherend, and the third adherend and the fourth adherend is bonded to the thermally expandable thermosetting adhesive layer A after expansion and another of the first adherend, and the third adherend and the fourth adherend is bonded to the thermally expandable thermosetting adhesive layer B after expansion.

10 . A method for producing an article, the method comprising:

a step 1A of bonding a face of the thermally expandable thermosetting adhesive layer A side of the adhesive sheet according to claim 1 to a surface of a first adherend or a surface of a cavity formed in a second adherend;

a step 2A of inserting the first adherend into the cavity; and

a step 3A of heating the adhesive sheet to expand and cure the thermally expandable thermosetting adhesive layer A and the thermally expandable thermosetting adhesive layer B and to bond the first adherend and the second adherend together through an expanded product of the adhesive sheet.

11 . A method for producing an article, the method comprising:

a step 1B of bonding a face of a thermally expandable thermosetting adhesive layer A side of the adhesive sheet according to claim 1 to a surface of a first adherend or a surface of a cavity formed by a third adherend and a fourth adherend;

a step 2B of inserting the first adherend into the cavity; and

a step 3B of heating the adhesive sheet to expand and cure a thermally expandable thermosetting adhesive layer A and the thermally expandable thermosetting adhesive layer B and to bond the first adherend with the third adherend and the fourth adherend together through an expanded product of the adhesive sheet.