Method for manufacturing a transparent antenna, and laminate

Abstract

To provide a transparent antenna manufacturing method capable of obtaining a transparent antenna by a simple method.SOLUTION: A transparent antenna manufacturing method includes a lamination step for laminating a laminate A on a support member 20 in a state in which a transparent resin layer 11 is positioned on the support member 20 side more than a conductive member 13 in the laminate A including the transparent resin layer 11 and the conductive member 13 arranged on the transparent resin layer 11. The transparent resin layer 11 includes at least one kind selected from a group consisting of a polymerizable composition and a cured product thereof. The polymerizable composition contains an elastomer, a polymerizable compound, and a polymerization initiator. The conductive member 13 has a patterned portion.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a transparent antenna, a laminate, and the like.

Background Art

[0002] Antennas for receiving radio waves are installed in image display devices (for example, image display devices in various electronic devices such as personal computers, navigation systems, mobile phones, watches, electronic dictionaries, etc.), components of automobiles, buildings, and the like. For example, there are cases where an image display device incorporating an antenna is used. In recent years, in order to cope with miniaturization, thinning, and diversification of shapes of image display devices and ensure the likelihood of design, a transparent antenna with low visibility (hereinafter also referred to as a "transparent antenna") is proposed to be arranged on an image display unit for displaying an image (see, for example, Patent Document 1 below).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Regarding the method for manufacturing a transparent antenna, from the viewpoint of improving manufacturing efficiency, it is required to obtain a transparent antenna by a simple method.

[0005] One aspect of the present disclosure aims to provide a method for manufacturing a transparent antenna capable of obtaining a transparent antenna by a simple method. Another aspect of the present disclosure aims to provide a laminate capable of obtaining a transparent antenna by a simple method.

Means for Solving the Problems

[0006] The present disclosure relates to the following [1] to [8] and the like in some aspects. [1] A method for manufacturing a transparent antenna, comprising a lamination step of laminating a laminate on a support member, wherein the laminate comprises a transparent resin layer and a conductive member disposed on the transparent resin layer, and the transparent resin layer is positioned on the support member side of the conductive member, the transparent resin layer comprises at least one selected from the group consisting of polymerizable compositions and cured products thereof, the polymerizable composition comprises an elastomer, a polymerizable compound, and a polymerization initiator, and the conductive member has a patterned portion. [2] A method for manufacturing a transparent antenna according to [1], wherein the conductive member contains copper. [3] The method for manufacturing a transparent antenna according to [1] or [2], wherein the thickness of the conductive member is 5 μm or less. [4] A laminate comprising a transparent resin layer and a conductive member disposed on the transparent resin layer, wherein the transparent resin layer contains at least one selected from the group consisting of polymerizable compositions and cured products thereof, the polymerizable composition contains an elastomer, a polymerizable compound, and a polymerization initiator, and the conductive member has a patterned portion. [5] The laminate according to [4], further comprising a layer disposed on the opposite side of the conductive member, with the transparent resin layer in between. [6] The laminate according to [4] or [5], further comprising a layer disposed on the opposite side of the transparent resin layer with respect to the conductive member. [7] The laminate according to any one of [4] to [6], wherein the conductive member contains copper. [8] The laminate according to any one of [4] to [7], wherein the thickness of the conductive member is 5 μm or less.

[0007] One possible method for manufacturing a transparent antenna is to prepare a laminate comprising a support member, a polymerizable composition layer placed on the support member, and a conductive member placed on the polymerizable composition layer, and then pattern the conductive member to obtain a transparent antenna. Alternatively, the aforementioned laminate comprising the support member, polymerizable composition layer, and conductive member can be obtained by sequentially forming the polymerizable composition layer and the conductive member on the support member. However, in these cases, each component must be formed on the support member and the conductive member must be patterned each time a transparent antenna is manufactured, which can complicate the manufacturing process. On the other hand, according to one aspect of the present disclosure, a laminate comprising a transparent resin layer and a conductive member having a patterned portion is prepared in advance, and then the laminate is laminated onto the support member. This eliminates the need to form each component on the support member each time a transparent antenna is manufactured, allowing for a simple method to obtain a transparent antenna. Similarly, according to another aspect of the present disclosure, a laminate comprising a transparent resin layer and a conductive member having a patterned portion is laminated onto the support member. This eliminates the need to form each component on the support member each time a transparent antenna is manufactured, allowing for a simple method to obtain a transparent antenna. [Effects of the Invention]

[0008] According to one aspect of this disclosure, a method for manufacturing a transparent antenna can be provided that allows for obtaining a transparent antenna by a simple method. According to another aspect of this disclosure, a laminate can be provided that allows for obtaining a transparent antenna by a simple method. [Brief explanation of the drawing]

[0009] [Figure 1] This is a schematic cross-sectional view showing an example of a laminate. [Figure 2] This is a schematic cross-sectional view illustrating an example of a method for manufacturing a laminate. [Figure 3] This is a schematic cross-sectional view showing an example of a manufacturing method for a transparent antenna. [Modes for carrying out the invention]

[0010] The embodiments of this disclosure will be described in detail below. However, this disclosure is not limited to the embodiments described below.

[0011] In this specification, numerical ranges indicated using "~" represent a range that includes the numbers before and after "~" as the minimum and maximum values, respectively. "A or greater" in a numerical range means A and the range greater than A. "A or less" in a numerical range means A and the range less than A. In numerical ranges described stepwise in this specification, the upper or lower limit of a numerical range in one step can be arbitrarily combined with the upper or lower limit of a numerical range in another step. "A or B" means that either A or B is included, or both are included. Unless otherwise specified, the materials exemplified in this specification can be used individually or in combination of two or more. The term "layer" includes not only structural shapes formed on the entire surface when observed as a plan view, but also structural shapes formed on only a part of it. The term "process" includes not only independent processes, but also processes that cannot be clearly distinguished from other processes, as long as the intended function of the process is achieved. "(meth)acrylic" means at least one of acrylic and its corresponding methacrylic. The same applies to other similar expressions such as "(meth)acryloyl".

[0012] The method for manufacturing a transparent antenna according to this embodiment includes a lamination step of laminating a laminate (hereinafter referred to as "laminated laminate A") on a support member such that the transparent resin layer is located on the support member side of the conductive member. In the method for manufacturing a transparent antenna according to this embodiment, the transparent resin layer contains at least one selected from the group consisting of polymerizable compositions and cured products thereof, the polymerizable composition contains an elastomer, a polymerizable compound, and a polymerization initiator, and the conductive member has a patterned portion.

[0013] According to the manufacturing method of the transparent antenna of this embodiment, by preparing the laminate A in advance and then stacking the laminate A on a support member, it is not necessary to form each component on the support member each time a transparent antenna is manufactured, and a transparent antenna can be obtained by a simple method.

[0014] The laminate according to this embodiment may have the laminate A described above, or may be the laminate A described above. That is, the laminate according to this embodiment comprises a transparent resin layer and a conductive member disposed on the transparent resin layer, wherein the transparent resin layer contains at least one selected from the group consisting of polymerizable compositions and cured products thereof, the polymerizable composition contains an elastomer, a polymerizable compound, and a polymerization initiator, and the conductive member has a patterned portion. The laminate according to this embodiment can be used in the method for manufacturing a transparent antenna according to this embodiment. According to the laminate according to this embodiment, by laminating laminate A on a support member, it is not necessary to form each member on the support member each time a transparent antenna is manufactured, and a transparent antenna can be obtained by a simple method.

[0015] Laminate A has a structure obtained by laminating a transparent resin layer and a conductive member in that order. In laminate A, the transparent resin layer and the conductive member may be in contact with each other.

[0016] The transparent resin layer comprises at least one selected from the group consisting of polymerizable compositions and their cured products, and the polymerizable composition comprises an elastomer, a polymerizable compound, and a polymerization initiator. The transparent resin layer may comprise at least one selected from the group consisting of curable compositions and their cured products, and may have at least one selected from the group consisting of an uncured portion and a cured portion. The transparent resin layer may be a transparent substrate.

[0017] Examples of the elastomer include styrenic elastomers, olefinic elastomers, urethane elastomers, polyester elastomers, polyamide elastomers, silicone elastomers, and the like. Examples of the styrenic elastomer include styrene-butadiene random copolymers, styrene-butadiene-styrene block copolymers, styrene-butylene-butadiene-styrene block copolymers, styrene-isoprene-styrene block copolymers, styrene-ethylene-butylene-styrene block copolymers, styrene-ethylene-propylene-styrene block copolymers, and hydrogenated copolymers thereof.

[0018] As the polymerizable compound, a compound that polymerizes by heating, irradiation with active light (such as ultraviolet rays), or the like can be used. Examples of the polymerizable compound include (meth)acrylic compounds (compounds having a (meth)acryloyl group), epoxy compounds (compounds having an epoxy group), maleimide compounds, vinyl ether compounds, allyl compounds, styrene compounds, (meth)acrylamide compounds, nadimide compounds, natural rubber, isoprene rubber, butyl rubber, nitrile rubber, butadiene rubber, styrene-butadiene rubber, acrylonitrile-butadiene rubber, carboxylated nitrile rubber, oxetane compounds, lactone compounds, and the like. The polymerizable compound may contain a (meth)acrylic compound (compound having a (meth)acryloyl group) and may contain an epoxy compound (compound having an epoxy group). As the (meth)acrylic compound, a compound having no epoxy group may be used. As the epoxy compound, a compound having no (meth)acryloyl group may be used.

[0019] As the polymerization initiator, it is possible to use a compound that initiates polymerization by heating, irradiation with active light rays (such as ultraviolet rays), etc. Examples include thermal polymerization initiators and photoinitiators (excluding compounds corresponding to thermal polymerization initiators). Examples of thermal polymerization initiators include ketone peroxides, peroxyketals, hydroperoxides, dialkyl peroxides, diacyl peroxides, peroxicarbonates, peroxy esters, acid anhydrides, azo compounds, etc. Examples of photoinitiators include acylphosphine oxide compounds, acetophenone compounds, anthraquinone compounds, benzophenone compounds, imidazole compounds, acridine compounds, oxime ester compounds, etc.

[0020] The polymerizable composition may contain additives other than the elastomer, polymerizable compound, and polymerization initiator. Examples of such additives include curing accelerators, antioxidants, ultraviolet absorbers, visible light absorbers, colorants, plasticizers, stabilizers, fillers, organic solvents, etc.

[0021] From the perspective of facilitating thinning of the transparent antenna, the thickness of the transparent resin layer may be 1000 μm or less, 800 μm or less, 500 μm or less, 300 μm or less, 250 μm or less, 200 μm or less, 150 μm or less, or 100 μm or less. From the perspective of facilitating improvement of antenna characteristics, the thickness of the transparent resin layer may be 1 μm or more, 5 μm or more, 10 μm or more, 20 μm or more, 30 μm or more, 50 μm or more, 80 μm or more, or 100 μm or more. From these perspectives, the thickness of the transparent resin layer may be 1 to 1000 μm, 10 to 500 μm, 20 to 200 μm, or 50 to 200 μm.

[0022] The conductive member is disposed on the transparent resin layer. The conductive member has a patterned portion, and in the conductive member having a patterned portion (hereinafter referred to as "patterned conductive member"), part or all of the conductive member may be patterned. Examples of the shape of the patterned portion include mesh shape, spiral shape, etc. The patterned (for example, mesh-shaped) conductive member may be composed of a wire (for example, a metal wire). The conductive member may be a single layer.

[0023] Examples of materials that make up conductive components include metal materials, carbon materials (e.g., graphene), and conductive polymers. Examples of metal materials include copper, silver, and gold. Conductive components may contain copper from the viewpoint of easily obtaining excellent conductivity and easily reducing manufacturing costs.

[0024] The thickness of the conductive member may be 50 μm or less, 45 μm or less, 40 μm or less, 35 μm or less, 30 μm or less, 25 μm or less, 20 μm or less, 18 μm or less, 15 μm or less, 10 μm or less, 8 μm or less, 5 μm or less, 3 μm or less, or 2 μm or less, from the viewpoint of preventing chipping of the conductive member. The thickness of the conductive member may be 0.1 μm or more, 0.3 μm or more, 0.5 μm or more, 0.8 μm or more, 1 μm or more, 1.2 μm or more, 1.5 μm or more, 2 μm or more, 3 μm or more, 5 μm or more, 8 μm or more, 10 μm or more, 15 μm or more, 18 μm or more, or 20 μm or more, from the viewpoint of easily obtaining excellent elongation. From these perspectives, the thickness of the conductive member may be 0.1 to 50 μm, 0.1 to 30 μm, 0.1 to 20 μm, 0.1 to 10 μm, 0.5 to 5 μm, or 1 to 3 μm.

[0025] The laminate according to this embodiment may include components other than the transparent resin layer and the conductive member. The laminate according to this embodiment may include a first layer positioned on the opposite side of the transparent resin layer from the conductive member, a second layer positioned on the opposite side of the transparent resin layer from the conductive member, and a component positioned between the transparent resin layer and the conductive member. The laminate according to this embodiment can protect the transparent resin layer by including the first layer. The laminate according to this embodiment can protect the conductive member by including the second layer.

[0026] Examples of constituent materials for the first and second layers include polyester (polyethylene terephthalate (PET), polybutylene terephthalate, polyethylene naphthalate, etc.), polyolefin (polyethylene, polypropylene, cycloolefin polymer, etc.), polycarbonate, polyamide, polyimide, polyamide-imide, polyetherimide, polyether sulfide, polyethersulfone, polyether ketone, polyphenylene ether, and polyphenylene sulfide. The constituent materials for the first and second layers may be the same or different. At least one selected from the group consisting of the first and second layers may be a transparent substrate.

[0027] The thicknesses of the first and second layers may be 1 to 200 μm, 10 to 100 μm, or 20 to 50 μm. The thicknesses of the first and second layers may be the same or different.

[0028] Figure 1 is a schematic cross-sectional view showing an example of a laminate. The laminate 10 in Figure 1 comprises a transparent resin layer 11, a conductive member 13, and a base film 15. The laminate 10 has a structure obtained by laminating the base film 15, the transparent resin layer 11, and the conductive member 13 in this order. The transparent resin layer 11 is formed from a polymerizable composition containing an elastomer, a polymerizable compound, and a polymerization initiator. The conductive member 13 has a patterned portion. The transparent resin layer 11 and the conductive member 13 constitute laminate A. The base film 15 is positioned on the opposite side of the conductive member 13, with the transparent resin layer 11 in between.

[0029] The method for manufacturing the laminate according to this embodiment may include a step A1 of patterning at least a portion of a conductive member (for example, a solid conductive member) placed on a transparent resin layer before patterning, and a step A2 of forming the conductive member in a pattern on the transparent resin layer. In step A1, at least a portion of the conductive member may be patterned by etching at least a portion of the conductive member using a patterned resist layer as a mask. The method for manufacturing the laminate according to this embodiment may include a step of removing the patterned resist layer after step A1.

[0030] The manufacturing method of the laminate according to this embodiment may include a resist formation step of forming a patterned resist layer before step A1. In the resist formation step, a patterned resist layer may be obtained by patterning at least a portion of the resist layer before patterning. For example, a patterned resist layer may be obtained by patterning at least a portion of a photosensitive composition layer formed by a photosensitive composition. The photosensitive composition is photosensitive to active light (ultraviolet light, etc.) and may have positive-type photosensitivity or negative-type photosensitivity. The photosensitive composition may have photocurability, meaning it hardens upon light irradiation. The constituent materials of the photosensitive composition are not particularly limited. The thickness of the photosensitive composition layer may be 5 to 200 μm, 5 to 25 μm, or 5 to 15 μm.

[0031] In the resist formation process, a patterned resist layer may be obtained by exposing the photosensitive composition layer and then removing (developing) the unexposed portion (if the photosensitive composition layer has negative-type photosensitivity) or the exposed portion (if the photosensitive composition layer has positive-type photosensitivity) of the photosensitive composition layer. For exposure, at least a portion of the photosensitive composition layer may be exposed using a mask, or at least a portion of the photosensitive composition layer may be exposed by a direct writing method.

[0032] Figure 2 is a schematic cross-sectional view illustrating an example of a method for manufacturing a laminate, and is a schematic cross-sectional view showing the laminate used to obtain the laminate 10 in Figure 1. The laminate 10a in Figure 2 comprises a transparent resin layer 11, a conductive member 13a before patterning, a base film 15, a photosensitive composition layer 17, and a protective film 19. The laminate 10a has a structure obtained by laminating the base film 15, the transparent resin layer 11, the conductive member 13a, the photosensitive composition layer 17, and the protective film 19 in this order. The transparent resin layer 11 and the base film 15 are the same as the transparent resin layer 11 and base film 15 in Figure 1, and the conductive member 13a is the same as the conductive member 13 in Figure 1 except that it is not patterned. The photosensitive composition layer 17 is formed of a photosensitive composition. The protective film 19 protects the photosensitive composition layer 17.

[0033] The laminate 10 in Figure 1 can be obtained, for example, using the laminate 10a in Figure 2 by the following procedure. First, after peeling off the protective film 19, or while the protective film 19 is present, the photosensitive composition layer 17 is exposed to light to form unexposed and exposed areas on the photosensitive composition layer 17. If exposure is performed while the protective film 19 is present, the protective film 19 is peeled off after exposure. Next, the unexposed or exposed areas of the photosensitive composition layer 17 are removed (developed) to obtain a patterned resist layer. Then, the conductive member 13a is etched using the patterned resist layer as a mask to pattern the conductive member 13a, thereby obtaining a laminate 10 comprising a conductive member 13 having a patterned portion.

[0034] The transparent antenna according to this embodiment can be obtained by the method for manufacturing the transparent antenna according to this embodiment. The transparent antenna according to this embodiment may include a support member, a substrate disposed on the support member, and a patterned conductive member disposed on the substrate.

[0035] The shape of the support member is not particularly limited and may be film-like, substrate-like, or irregularly shaped. Examples of constituent materials for the support member include resin materials and inorganic materials. Examples of resin materials include polyester (polyethylene terephthalate (PET), polybutylene terephthalate, polyethylene naphthalate, etc.), polyolefins (polyethylene, polypropylene, cycloolefin polymer, etc.), polycarbonate, polyamide, polyimide, polyamide-imide, polyetherimide, polyether sulfide, polyethersulfone, polyetherketone, polyphenylene ether, and polyphenylene sulfide. Examples of inorganic materials include glass. The support member is not limited to being transparent and may be transparent or opaque. The support member may be formed from a material having a total light transmittance of 90% or more. From the viewpoint of low dielectric properties, the support member may contain polyolefins.

[0036] The substrate in the transparent antenna according to this embodiment may include a cured product of the polymerizable composition of the transparent resin layer in the laminate according to this embodiment. The substrate may be a transparent substrate. The patterned conductive member in the transparent antenna according to this embodiment may be a conductive member in the laminate according to this embodiment.

[0037] The transparent antenna according to this embodiment can be used in image display devices, components of automobiles (windshields, rear windows, sunroofs, windows, etc.), buildings, etc. The image display device, automobile, or building according to this embodiment is equipped with the transparent antenna according to this embodiment. The image display device may have an image display unit for displaying an image and a bezel (frame) unit located around the image display unit, and the transparent antenna may be arranged on the image display unit. The image display device may be used in various electronic devices such as personal computers, navigation systems, mobile phones, watches, and electronic dictionaries. The image display device according to this embodiment may include the transparent antenna according to this embodiment, a protective layer disposed on the transparent antenna, and a covering member disposed on the protective layer.

[0038] As described above, the method for manufacturing a transparent antenna according to this embodiment includes a lamination step of laminating a laminate A on a support member, wherein the transparent resin layer in the laminate A, which comprises a transparent resin layer and a patterned conductive member, is positioned on the support member side of the conductive member. The conductive member has a patterned portion during the lamination step. If the laminate according to this embodiment includes a first layer positioned on the opposite side of the conductive member from the transparent resin layer, the first layer may be peeled off before the lamination step. If the laminate according to this embodiment includes a second layer positioned on the opposite side of the transparent resin layer from the conductive member, the second layer may be peeled off before or after the lamination step.

[0039] Figure 3 is a schematic cross-sectional view showing an example of a transparent antenna manufacturing method, illustrating an example of a transparent antenna manufacturing method using the laminate 10 shown in Figure 1. In the lamination process, as shown in Figure 3(a), after peeling off the base film 15 of the laminate 10, as shown in Figure 3(b), the laminate A is laminated onto the support member 20 with the transparent resin layer 11 of the laminate A, which includes a transparent resin layer 11 and a patterned conductive member 13, positioned closer to the support member 20 than the conductive member 13. With this transparent antenna manufacturing method, by preparing the laminate 10 having the laminate A in advance and then laminating the laminate A onto the support member 20, it is not necessary to form each component on the support member 20 each time a transparent antenna is manufactured, and a transparent antenna can be obtained by a simple method.

[0040] The manufacturing method for the transparent antenna according to this embodiment may include a curing step in which at least a portion of the transparent resin layer is cured before the lamination step, after the lamination step, or before or after the lamination step. In the curing step, at least a portion of the transparent resin layer can be cured by heating, irradiation with active light (ultraviolet light, etc.), or the like. [Explanation of Symbols]

[0041] 10, 10a, A... Laminate, 11... Transparent resin layer, 13, 13a... Conductive member, 15... Base film, 17... Photosensitive composition layer, 19... Protective film, 20... Support member.

Claims

1. The laminate comprises a transparent resin layer and a conductive member disposed on the transparent resin layer, and the laminate is laminated on a support member such that the transparent resin layer is positioned closer to the support member than the conductive member. The transparent resin layer comprises at least one selected from the group consisting of polymerizable compositions and cured products thereof. The polymerizable composition contains an elastomer, a polymerizable compound, and a polymerization initiator. A method for manufacturing a transparent antenna, wherein the conductive member has a patterned portion.

2. The method for manufacturing a transparent antenna according to claim 1, wherein the conductive member contains copper.

3. The method for manufacturing a transparent antenna according to claim 1 or 2, wherein the thickness of the conductive member is 5 μm or less.

4. The method for manufacturing a transparent antenna according to claim 1 or 2, wherein, before the lamination step, a layer is peeled off that is positioned on the opposite side of the conductive member, sandwiching the transparent resin layer.

5. The method for manufacturing a transparent antenna according to claim 1 or 2, wherein the elastomer comprises at least one selected from the group consisting of styrene elastomers, olefin elastomers, urethane elastomers, polyester elastomers, polyamide elastomers, and silicone elastomers.

6. The device comprises a transparent resin layer, a conductive member disposed on the transparent resin layer, and a peelable layer disposed on the opposite side of the transparent resin layer from the conductive member, The transparent resin layer comprises at least one selected from the group consisting of polymerizable compositions and cured products thereof. The polymerizable composition contains an elastomer, a polymerizable compound, and a polymerization initiator. A laminate having a patterned portion of the conductive member.

7. The laminate according to claim 6, further comprising a layer disposed on the opposite side of the transparent resin layer, with the conductive member in between.

8. The laminate according to claim 6 or 7, wherein the conductive member contains copper.

9. The laminate according to claim 6 or 7, wherein the thickness of the conductive member is 5 μm or less.

10. The laminate according to claim 6 or 7, wherein the elastomer comprises at least one selected from the group consisting of styrene elastomers, olefin elastomers, urethane elastomers, polyester elastomers, polyamide elastomers, and silicone elastomers.

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