Light shielding member, assembly sheet, and method for manufacturing light shielding member

Abstract

This light shielding member 1 includes: a metal core layer 2; a resin layer 3 that covers the whole of both first surfaces S11, S12 of the core layer 2 in the thickness direction of the core layer 2; and a low reflection layer 4 that covers the whole of both second surfaces S21, 22 of the resin layer 3 in the thickness direction of the resin layer 3. The specular reflectance at 5 degrees of the low reflection layer 4 is lower than the specular reflectance at 5 degrees of the resin layer 3.

Description

Light-shielding member, assembly sheet, and method for manufacturing light-shielding member

[0001] The present invention relates to a light-shielding member, an assembly sheet, and a method for manufacturing the light-shielding member.

[0002] 2. Description of the Related Art Conventionally, a light-shielding member having an optical multilayer film on the surface of a substrate has been known (see, for example, Patent Document 1 below).

[0003] The substrate is made of resin. The optical multilayer film is composed of a light-absorbing layer and a dielectric layer. The light-absorbing layer and the dielectric layer are made of metal or metal oxide.

[0004] International Publication No. 2021 / 193652

[0005] In the light-shielding member described in the above-mentioned Patent Document 1, an optical multilayer film made of a metal or metal oxide is formed on the surface of a base material made of resin.

[0006] Therefore, it is difficult to achieve both rigidity and durability in the light blocking member.

[0007] The present invention provides a light-shielding member, an assembly sheet, and a method for manufacturing a light-shielding member that can achieve both rigidity and durability.

[0008] The present invention [1] is a light-shielding member comprising a metal core layer, a resin layer covering the entire first surfaces of both sides of the core layer in the thickness direction of the core layer, and a low-reflection layer covering the entire second surfaces of both sides of the resin layer in the thickness direction of the resin layer, wherein the 5° specular reflectance of the low-reflection layer is lower than the 5° specular reflectance of the resin layer.

[0009] With this configuration, the metal core layer can improve rigidity, and the resin layer can improve durability, meaning that this configuration can achieve both rigidity and durability.

[0010] In addition, the resin layer is covered with a low-reflection layer, which can suppress light reflection.

[0011] The present invention [2] includes the light-shielding member according to the above [1], wherein the 5° regular reflectance of the low-reflection layer is 1.0% or less.

[0012] According to this configuration, the low-reflection layer can reliably suppress light reflection.

[0013] The present invention [3] includes the light-shielding member described in the above [1], in which the resin layer covers a first side surface of the core layer in a direction perpendicular to the thickness direction, and the low-reflection layer covers a second side surface of the resin layer in the direction perpendicular to the thickness direction.

[0014] With this configuration, the resin layer can protect the side surfaces of the core layer, and the low-reflection layer can protect the side surfaces of the resin layer while suppressing light reflection on the side surfaces of the light-shielding member.

[0015] The present invention [4] includes the light-shielding member described in the above [3], in which the resin layer covers the entire first side surface of the core layer, and the low-reflection layer covers the entire second side surface of the resin layer.

[0016] With this configuration, the resin layer can reliably protect the side surfaces of the core layer, and the low-reflection layer can reliably protect the side surfaces of the resin layer while reliably suppressing light reflection on the side surfaces of the light-shielding member.

[0017] The present invention [5] includes the light-shielding member described in [3] above, in which the core layer has a first main body portion having the first surface and the first side surface, and a first protrusion portion protruding from the first side surface of the first main body portion in the perpendicular direction, and the first protrusion portion is exposed from the resin layer and the low-reflection layer.

[0018] With this configuration, the strength of the side surface of the light blocking member can be improved.

[0019] The present invention [6] includes the light-shielding member described in the above [3], in which the resin layer has a second main body portion having the second surface and the second side surface, and a second protrusion portion protruding in the perpendicular direction from the second side surface of the second main body portion, and the second protrusion portion is exposed from the low-reflection layer.

[0020] With this configuration, it is possible to suppress reflection of light on the side surface of the light blocking member.

[0021] The present invention [7] includes the light-shielding member according to any one of the above [1] to [6], in which the resin layer contains polyimide.

[0022] Such a configuration provides excellent dimensional accuracy.

[0023] The present invention [8] includes the light-shielding member according to claim 1, wherein the low-reflection layer contains a resin and a dye.

[0024] With this configuration, it is possible to reliably suppress light reflection.

[0025] The present invention [9] includes the light-shielding member according to the above [8], wherein the low-reflection layer further contains a filler.

[0026] With this configuration, light reflection can be more reliably suppressed.

[0027] The present invention

[10] includes the light-shielding member according to the above [8], further comprising a metal layer disposed between the resin layer and the low-reflection layer.

[0028] With this configuration, the adhesion between the resin layer and the low-reflection layer can be improved.

[0029] The present invention

[11] comprises the light-shielding member described in [5] above, a frame arranged at a distance from the light-shielding member, and a joint connecting the light-shielding member and the frame, wherein the joint is made of the same metal as the core layer and includes an assembly sheet that is continuous with the first protrusion.

[0030] According to this configuration, the light-shielding member can be handled while being supported by the frame via the joint, which improves the ease of handling of the light-shielding member. In addition, since the joint is made of the same metal as the core layer, it has excellent strength.

[0031] The present invention

[12] comprises the light-shielding member described in [6] above, a frame arranged at a distance from the light-shielding member, and a joint connecting the light-shielding member and the frame, wherein the joint includes an assembly sheet made of the same resin as the resin layer and continuous with the second protrusion.

[0032] According to this configuration, the light blocking member can be handled while being supported by the frame via the joint, thereby improving the handleability of the light blocking member. In addition, since the joint is made of the same resin as the resin layer, it has excellent processability.

[0033] The present invention

[13] is a method for manufacturing a light-shielding member according to any one of the above [1] to

[10] , and includes a method for manufacturing a light-shielding member, comprising: a first step of preparing the core layer; a second step of covering the entire first surfaces of both sides of the core layer in the thickness direction of the core layer with the resin layer; and a third step of covering the entire second surfaces of both sides of the resin layer in the thickness direction of the resin layer with a low-reflection layer.

[0034] According to this configuration, a light-shielding member having excellent rigidity and durability can be manufactured.

[0035] The present invention

[14] includes the method for manufacturing a light-shielding member according to the above

[12] , wherein in the third step, the entire second surfaces of both of the resin layers are covered with the low-reflection layer by physical vapor deposition.

[0036] According to this configuration, the resin layer can be reliably covered with the low-reflection layer.

[0037] The present invention

[15] includes the method for manufacturing a light-shielding member described in the above

[13] , in which in the third step, the entire second surfaces of both of the resin layers are coated with the low-reflection layer by an electrodeposition coating method.

[0038] According to this configuration, the resin layer can be reliably covered with the low-reflection layer.

[0039] The present invention

[16] is a method for manufacturing a light-shielding member according to any one of the above [1] to

[10] , comprising a fourth step of preparing the resin layer, a fifth step of arranging the core layer on one surface in the thickness direction of the resin layer, a sixth step of arranging the resin layer on one surface in the thickness direction of the core layer and covering the entire first surfaces of both of the core layer in the thickness direction with the resin layer, and a seventh step of covering the entire second surfaces of both of the resin layer in the thickness direction of the resin layer with the low-reflection layer.

[0040] According to this configuration, a light-shielding member having excellent rigidity and durability can be manufactured.

[0041] The present invention

[17] includes the method for manufacturing a light-shielding member according to the above

[16] , wherein in the fifth step, the core layer is disposed on one surface of the resin layer in the thickness direction by plating.

[0042] With this configuration, the core layer can be reliably disposed on the resin layer.

[0043] According to the light-shielding member of the present invention, it is possible to achieve both rigidity and durability.

[0044] According to the assembly sheet of the present invention, the handleability of the light-shielding member can be improved.

[0045] According to the method for manufacturing a light-shielding member of the present invention, a light-shielding member having excellent rigidity and durability can be manufactured.

[0046] FIG. 1 is a perspective view of a light-shielding member according to one embodiment of the present invention. FIG. 2 is an A-A cross-sectional view of the light-shielding member shown in FIG. 1. FIGS. 3A to 3E illustrate one embodiment of a method for manufacturing a light-shielding member of the present invention. FIG. 3A illustrates a first step in which a substrate made of a material for the core layer is prepared. FIG. 3B illustrates a first step in which a substrate is etched to prepare a core layer. FIG. 3C illustrates a second step in which both first surfaces of the core layer are entirely coated with a resin layer in the thickness direction of the core layer. FIG. 3D illustrates a third step in which both second surfaces of the resin layer are entirely coated with a low-reflection layer in the thickness direction of the resin layer. FIG. 3E illustrates a third step in which a resin composition is selected as the material for the low-reflection layer. FIGS. 4A to 4E illustrate a first modified example of a method for manufacturing a light-shielding member. FIG. 4A illustrates a first step in which a substrate made of a material for the core layer is prepared. FIG. 4B illustrates a first step in which a resin layer is disposed on the other surface of the substrate in the thickness direction. FIG. 4C shows a first step in which a substrate is etched to prepare a core layer. FIG. 4D shows a second step in which both entire first surfaces of the core layer, as well as both entire first side surfaces of the core layer, are covered with a resin layer. FIG. 4E shows a third step in which both entire second surfaces of the resin layer, as well as both entire second side surfaces of the resin layer, are covered with a low-reflection layer. FIGS. 5A to 5E show a second modified example of a method for manufacturing a light-shielding member. FIG. 5A shows a fourth step in which a resin layer 3 is prepared. FIG. 5B shows a fifth step in which a seed layer is formed on one surface of the resin layer in the thickness direction. FIG. 5C shows a fifth step in which a core layer is disposed on the seed layer. FIG. 5D shows a sixth step in which a resin layer is disposed on one surface of the core layer in the thickness direction, thereby covering both entire first surfaces of the core layer 2 in the thickness direction with the resin layer. FIG. 5E shows a seventh step in which both entire second surfaces of the resin layer are covered with a low-reflection layer in the thickness direction of the resin layer. Fig. 6 is a perspective view of a first modified example of the light blocking member. Fig. 7A is a plan view of the light blocking member shown in Fig. 6. Fig. 7B is a B-B cross-sectional view of the light blocking member shown in Fig. 6A. Fig. 8 is a plan view of an assembly sheet in the first modified example of the light blocking member. Fig. 9 is a perspective view of a second modified example of the light blocking member. Fig. 10A is a plan view of the light blocking member shown in Fig. 9A. Fig. 10B is a CC cross-sectional view of the light blocking member shown in Fig. 10A.FIG. 11 is a plan view of an assembly sheet in a second modified example of the light blocking member.

[0047] 1. Light-Shielding Member One embodiment of the light-shielding member of the present invention will be described with reference to FIGS.

[0048] As shown in Fig. 1, the light-blocking member 1 has a flat plate shape. The light-blocking member 1 has a surface S1 on one side and a surface S2 on the other side in the thickness direction. The light-blocking member 1 has a side surface S3 in an orthogonal direction perpendicular to the thickness direction. The light-blocking member 1 extends in the orthogonal direction. The light-blocking member 1 blocks at least visible light.

[0049] The visible light transmittance (JIS 7375) of the light-shielding member 1 in the thickness direction is, for example, 1.0% or less, preferably 0.01% or less, and more preferably 0%.

[0050] The 5° specular reflectance of visible light on each surface (surfaces S1, S2 and side surface S3) of the light-shielding member 1 is, for example, 1.0% or less, preferably 0.5% or less, and for example, 0% or more.

[0051] The regular reflectance is measured as the average value of the reflectance of visible light having a wavelength of 500 nm to 600 nm.

[0052] The flexural modulus (JIS 7171) of the light-shielding member 1 is, for example, 10 GPa or more, or preferably 50 GPa or more, and for example, 250 GPa or less.

[0053] The thickness T of the light-shielding member 1 is, for example, 10 μm or more, preferably 20 μm or more, more preferably 30 μm or more, and for example, 150 μm or less, preferably 100 μm or less, more preferably 90 μm or less. The thickness T of the light-shielding member 1 may be, for example, 10 μm to 150 μm, 20 μm to 100 μm, or 30 μm to 90 μm.

[0054] As shown in FIG. 2, the light-shielding member 1 includes a core layer 2 , a resin layer 3 , and a low-reflection layer 4 .

[0055] <Core Layer> The core layer 2 is disposed approximately in the center of the light blocking member 1 in the thickness direction. The core layer 2 extends in the orthogonal direction. The core layer 2 has a flat plate shape. The core layer 2 has a first surface S11 on one side and a first surface S12 on the other side in the thickness direction. The core layer 2 has a first side surface S13 in the orthogonal direction.

[0056] The thickness T1 of the core layer 2 is, for example, 5 μm or more, preferably 10 μm or more, and for example, 70 μm or less, preferably 30 μm or less. When the thickness T1 of the core layer 2 is equal to or more than the above lower limit, the rigidity of the light-shielding member 1 can be ensured. The thickness T1 of the core layer 2 may be 5 μm to 70 μm, or 10 μm to 30 μm.

[0057] When the thickness T of the light-shielding member 1 is taken as 100%, the thickness T1 of the core layer 2 is, for example, 10% or more, preferably 15% or more, and for example, 50% or less, preferably 40% or less. When the ratio of the thickness T1 of the core layer 2 to the thickness T of the light-shielding member 1 is equal to or greater than the above lower limit, the rigidity of the light-shielding member 1 can be ensured. The ratio of the thickness T1 of the core layer 2 to the thickness T of the light-shielding member 1 may be 10% to 50%, or 15% to 40%.

[0058] The 5° specular reflectance of visible light from each surface (first surfaces S11, S12 and first side surface S13) of the core layer 2 is, for example, 10% to 80%.

[0059] The core layer 2 is made of a metal. Examples of materials for the core layer 2 include copper, copper alloys, stainless steel, aluminum, titanium, nickel, tantalum, and magnesium. Preferred materials for the core layer 2 include copper and stainless steel.

[0060] <Resin Layer> The resin layer 3 covers the core layer 2. Specifically, the resin layer 3 covers the entire first surfaces S11, S12 of the core layer 2 in the thickness direction. That is, the resin layer 3 covers the entire first surfaces S11, S12 of both of the core layer 2 in the thickness direction of the core layer 2. Furthermore, the resin layer 3 covers the first side surface S13 of the core layer 2 in the perpendicular direction. The resin layer 3 covers the entire first side surface S13 of the core layer 2 (all four side surfaces S13 of the core layer 2).

[0061] The 5° specular reflectance of the resin layer 3 for visible light is, for example, 5% to 20%.

[0062] The thickness T2 of the resin layer 3 is, for example, 3 μm or more, preferably 5 μm or more, and for example, 500 μm or less, preferably 20 μm or less. When the thickness T2 of the resin layer 3 is equal to or greater than the above lower limit, the durability of the light-shielding member 1 can be improved. The thickness T2 of the resin layer 3 may be 3 μm to 50 μm, or 5 μm to 20 μm.

[0063] The thickness T2 of the resin layer 3 is thinner than the thickness T1 of the core layer 2. When the thickness T1 of the core layer 2 is taken as 100%, the thickness T2 of the resin layer 3 is in the range of, for example, 40% to 90%, or preferably 50% to 70%.

[0064] When the thickness T of the light-shielding member 1 is taken as 100%, the thickness T2 of the resin layer 3 is, for example, 5% or more, preferably 10% or more, and for example, 40% or less, preferably 30% or less. When the thickness T2 of the resin layer 3 relative to the thickness T of the light-shielding member 1 is equal to or greater than the above-mentioned lower limit, the durability of the light-shielding member 1 can be ensured. The thickness T2 of the resin layer 3 relative to the thickness T of the light-shielding member 1 may be 5% to 40% or 10% to 30%.

[0065] Examples of materials for the resin layer 3 include resins. Examples of resins include acrylic resins, epoxy resins, polyimides (e.g., photosensitive polyimides), and silicone-based resins. A preferred example of the resin is polyimide. That is, the resin layer 3 preferably contains polyimide. If the resin layer 3 contains polyimide, it will have excellent dimensional accuracy.

[0066] <Low-Reflection Layer> The low-reflection layer 4 covers the resin layer 3. Specifically, the low-reflection layer 4 covers the entire second surfaces S21, S22 of the resin layer 3 in the thickness direction. That is, the low-reflection layer 4 covers the entire second surfaces S21, S22 of the resin layer 3 in the thickness direction of the resin layer 3. The low-reflection layer 4 also covers the second side surface S23 of the resin layer 3 in the orthogonal direction. The low-reflection layer 4 covers the entire second side surface S23 of the resin layer 3 (all four side surfaces S23 of the resin layer 3).

[0067] The 5° specular reflectance of visible light of the low-reflection layer 4 is lower than the 5° specular reflectance of visible light of the resin layer 3. The 5° specular reflectance of visible light of the low-reflection layer 4 is, for example, 1.0% or less, preferably 0.5% or less, for example, 0% or more.

[0068] The thickness T3 of the low-reflection layer 4 is, for example, 0.01 μm or more, preferably 0.05 μm or more, and for example, 30 μm or less, preferably 20 μm or less. When the thickness T3 of the low-reflection layer 4 is equal to or greater than the above lower limit, the light-blocking property of the light-blocking member 1 can be improved. The thickness T3 of the low-reflection layer 4 may be 0.01 μm to 30 μm, or 0.05 μm to 20 μm.

[0069] More specifically, when the low reflective layer 4 is disposed by physical vapor deposition in the third step described later, the thickness T3 of the low reflective layer 4 is, for example, 0.01 μm to 1 μm, or preferably 0.05 μm to 0.5 μm.

[0070] Furthermore, when the low reflective layer 4 is disposed by plating in the third step described below, the thickness T3 of the low reflective layer 4 is in the range of, for example, 0.5 μm to 30 μm, or preferably 1 μm to 20 μm.

[0071] Furthermore, when the low-reflection layer 4 is disposed by electrodeposition coating in the third step described below, the thickness T3 of the low-reflection layer 4 is, for example, 0.5 μm to 30 μm, or preferably 1 μm to 20 μm.

[0072] When the thickness T1 of the core layer 2 is taken as 100%, the thickness T3 of the low reflection layer 4 is in the range of, for example, 0.1% to 150%, or preferably 0.3% to 140%.

[0073] When the thickness T of the light-shielding member 1 is taken as 100%, the thickness T3 of the low-reflection layer 4 is, for example, 0.05% or more, preferably 0.1% or more, and for example, 40% or less, preferably 30% or less. When the thickness T3 of the low-reflection layer 4 relative to the thickness T of the light-shielding member 1 is equal to or greater than the above-mentioned lower limit, the light-shielding performance of the light-shielding member 1 can be ensured. Furthermore, when the thickness T3 of the low-reflection layer 4 relative to the thickness T of the light-shielding member 1 is equal to or less than the above-mentioned upper limit, weight reduction can be achieved. The thickness T3 of the low-reflection layer 4 relative to the thickness T of the light-shielding member 1 may be 0.05% to 40%, or 0.1% to 30%.

[0074] The surface roughness of the low reflective layer 4 is, for example, 1.0 nm or more, preferably 2.0 nm or more, for example, 1000 nm or less.

[0075] Examples of materials for the low-reflection layer 4 include titanium, nickel, chromium, and oxides thereof. When the low-reflection layer 4 is disposed by physical vapor deposition in the third step described below, titanium and its oxides are preferably selected as the material for the low-reflection layer 4. When the low-reflection layer 4 is disposed by plating in the third step described below, nickel and its oxides are preferably selected as the material for the low-reflection layer 4. When the low-reflection layer 4 is disposed by electrodeposition coating in the third step described below, a resin composition is preferably selected as the material for the low-reflection layer 4.

[0076] The resin composition contains a resin, a dye, and a filler. That is, when the material of the low-reflection layer 4 is a resin composition, the low-reflection layer 4 contains a resin, a dye, and a filler.

[0077] Examples of the resin include acrylic resin, epoxy resin, polyimide, and polyamide, and preferably acrylic resin.

[0078] The resin content in the resin composition is, for example, 20% by mass to 80% by mass, or preferably 30% by mass to 70% by mass.

[0079] Examples of the pigment include black pigments and gray pigments. Preferably, the pigment is black pigment. Preferably, the black pigment is black pigment and black dye. Preferably, the black pigment is carbon black or a titanium-based pigment. Preferably, the black dye is a mixture of dyes such as phthalocyanine blue, phthalocyanine green, monoazo yellow, disazo yellow, benzimidazolone yellow, quinacridone red, monoazo red, boriazo red, and perylene red. More preferably, the pigment is black. Still more preferably, the pigment is carbon black.

[0080] The content of the dye in the resin composition is, for example, 0.1 to 20% by mass, or preferably 0.5 to 10% by mass.

[0081] The content of the dye relative to 100 parts by mass of the resin is, for example, 1 to 50 parts by mass, or preferably 5 to 30 parts by mass.

[0082] Examples of the filler include acrylic microgel and silica, and preferably, acrylic microgel.

[0083] The average particle size of the filler is measured by a laser diffraction scattering method and is, for example, 1.0 μm or more, preferably 5.0 μm or more, and for example, 20.0 μm or less.

[0084] The content of the filler in the resin composition is, for example, 1 to 50% by mass, or preferably 5 to 30% by mass.

[0085] The content ratio of the filler relative to 100 parts by mass of the resin is, for example, 5 to 50 parts by mass, or preferably 10 to 40 parts by mass.

[0086] 2. Method for Manufacturing Light-Shielding Member One embodiment of a method for manufacturing the light-shielding member 1 will be described with reference to FIGS. 3A to 3D.

[0087] The manufacturing method of the light-shielding member 1 includes a first step of preparing a core layer 2, a second step of covering both first surfaces S11, S12 of the core layer 2 in the thickness direction of the core layer 2 with a resin layer 3, and a third step of covering both second surfaces S21, S22 of the resin layer 3 in the thickness direction of the resin layer 3 with a low-reflection layer 4. In one embodiment, in the second step, both first surfaces S11, S12 of the core layer 2 and both first side surfaces S13 of the core layer 2 (all four side surfaces S13 of the core layer 2) are covered with the resin layer 3. In the third step, both second surfaces S21, S22 of the resin layer 3 and both second side surfaces S23 of the resin layer 3 (all four side surfaces S23 of the resin layer 3) are covered with the low-reflection layer 4.

[0088] <First Step> In the first step, the core layer 2 is prepared as shown in Fig. 3A. To prepare the core layer 2, first, a base material M made of the material for the core layer 2 described above is prepared. Next, as shown in Fig. 3B, the base material M is etched to prepare the core layer 2. More specifically, the portion where the core layer 2 is to be formed is covered with an etching resist, and the base material M exposed from the etching resist is removed by etching. In this way, the core layer 2 is prepared.

[0089] <Second step> In the second step, as shown in FIG. 3C , the entire first surfaces S11, S12 of the core layer 2, as well as the entire first side surfaces S13 of the core layer 2 (all four side surfaces S13 of the core layer 2) are covered with the resin layer 3.

[0090] Specifically, the resin solution (varnish) is applied to both first surfaces S11, S12 of the core layer 2 and both first side surfaces S13 of the core layer 2 (all four side surfaces S13 of the core layer 2), and then dried. As a result, both first surfaces S11, S12 of the core layer 2 and both first side surfaces S13 of the core layer 2 (all four side surfaces S13 of the core layer 2) are covered with the resin layer 3.

[0091] <Third Step> In the third step, as shown in FIG. 3D , both second surfaces S21, S22 of the resin layer 3 as well as both second side surfaces S23 of the resin layer 3 (all four side surfaces S23 of the resin layer 3) are entirely covered with the low-reflection layer 4.

[0092] Examples of methods for coating the resin layer 3 with the low-reflection layer 4 include physical vapor deposition, plating (for example, electrolytic plating), and electrodeposition coating.

[0093] As a method for covering the resin layer 3 with the low reflection layer 4, a physical vapor deposition method is preferably used from the viewpoint of reliably covering the resin layer 3 with the low reflection layer 4.

[0094] Examples of the physical vapor deposition method include vacuum deposition, sputtering, and ion plating. Of the physical vapor deposition methods, sputtering is preferred.

[0095] In this manner, the light blocking member 1 is manufactured. According to this method for manufacturing the light blocking member 1, the light blocking member 1 can be manufactured with excellent rigidity and durability.

[0096] On the other hand, when a resin composition is selected as the material for the low-reflection layer 4, the method for coating the resin layer 3 with the low-reflection layer 4 in the third step is preferably an electrodeposition coating method.

[0097] 3E , to coat the resin layer 3 with the low-reflection layer 4 by electrodeposition coating, first, both second surfaces S21, S22 of the resin layer 3 as well as both second side surfaces S23 of the resin layer 3 (all four side surfaces S23 of the resin layer 3) are entirely coated with a metal layer 5, and the low-reflection layer 4 is then coated via the metal layer 5. In this case, the light-shielding member 1 includes the metal layer 5 disposed between the resin layer 3 and the low-reflection layer 4.

[0098] Examples of materials for the metal layer 5 include chromium, nickel, titanium, copper, nickel chromium, tungsten, cobalt, and alloys thereof.

[0099] The materials for the metal layer 5 can be used alone or in combination of two or more.

[0100] Examples of methods for coating the metal layer 5 include the physical vapor deposition method and electroless plating method described above.

[0101] The thickness T4 of the metal layer 5 is, for example, 1 nm to 1000 nm, or preferably 10 nm to 500 nm. When the thickness T4 of the metal layer 5 is equal to or more than the above lower limit, the adhesion between the resin layer 3 and the low-reflection layer 4 can be improved.

[0102] In this way, the light-shielding member 1 is manufactured. As shown in Fig. 3E, the light-shielding member 1 includes a core layer 2, a resin layer 3, a metal layer 5, and a low-reflection layer 4. In detail, the light-shielding member 1 includes the core layer 2, the resin layer 3 that covers the core layer 2, the metal layer 5 that covers the resin layer 3, and the low-reflection layer 4 that covers the metal layer 5.

[0103] The metal layer 5 may also be a single layer or a multilayer.

[0104] 3. Effects The light-shielding member 1 includes a core layer 2 and a resin layer 3. Therefore, the core layer 2 can improve rigidity, and the resin layer 3 can improve durability. This makes it possible to achieve both rigidity and durability.

[0105] Furthermore, in the light-shielding member 1, the resin layer 3 is covered with the low-reflection layer 4. Therefore, it is possible to suppress the reflection of light.

[0106] In the light-blocking member 1, the 5° regular reflectance of the low-reflectivity layer is 1.0% or less. Therefore, the low-reflectivity layer 4 can reliably suppress light reflection.

[0107] In the light-shielding member 1, the resin layer 3 covers the first side surface S13 of the core layer 2 in the orthogonal direction perpendicular to the thickness direction, and the low-reflection layer 4 covers the second side surface S23 of the resin layer 3 in the orthogonal direction. Therefore, the resin layer 3 can protect the side surface of the core layer 2. Furthermore, the low-reflection layer 4 can protect the side surface of the resin layer 3 while suppressing light reflection on the side surface of the light-shielding member 1.

[0108] In the light-blocking member 1, the resin layer 3 covers the entire first side surface S13 of the core layer 2, and the low-reflection layer 4 covers the entire second side surface S23 of the resin layer 3. This allows the resin layer 3 to reliably protect the side surface of the core layer 2. Furthermore, the low-reflection layer 4 can reliably protect the side surface of the resin layer 3 while reliably suppressing light reflection on the side surface of the light-blocking member 1.

[0109] In the light-shielding member 1, if the resin layer 3 contains polyimide, the dimensional accuracy can be improved.

[0110] 4. Modifications In the modification examples, the same components and steps as those in the first embodiment are denoted by the same reference numerals, and detailed descriptions thereof will be omitted. Furthermore, the modification examples can achieve the same effects as those in the first embodiment unless otherwise specified. Furthermore, the first embodiment and the modification examples can be combined as appropriate.

[0111] <First Modification of Method for Manufacturing Light-Shielding Member> A first modification of the method for manufacturing the light-shielding member 1 will be described with reference to FIGS. 4A to 4E.

[0112] In the above description, in the first step, the base material M made of the material of the core layer 2 is etched to prepare the core layer 2, but it is also possible to prepare the core layer 2 by coating a portion of the base material M made of the material of the core layer 2 with the resin layer 3 and then etching the base material M.

[0113] More specifically, in the first step, as shown in FIG. 4A, a substrate M made of the material of the core layer 2 is prepared.

[0114] 4B , a resin layer 3 is disposed on the other surface in the thickness direction of the substrate M. Specifically, a solution (varnish) of the resin is applied to the other surface in the thickness direction of the substrate M and dried. As a result, the resin layer 3 is disposed on the other surface in the thickness direction of the substrate M.

[0115] Next, as shown in FIG. 4C, the substrate M is etched to prepare the core layer 2 (the core layer 2 having the entire first surface S12 covered with the resin layer 3).

[0116] 4D , in the second step, both of the first surfaces S11 of the core layer 2 and both of the first side surfaces S13 of the core layer 2 (all of the four side surfaces S13 of the core layer 2) are entirely covered with the resin layer 3. The method for covering the core layer 2 with the resin layer 3 is the same as the second step in the above embodiment.

[0117] In the third step, as shown in FIG. 4E , the entire second surfaces S21, S22 of the resin layer 3, as well as the entire second side surfaces S23 of the resin layer 3 (all four side surfaces S23 of the resin layer 3) are covered with the low-reflection layer 4.

[0118] According to this method for manufacturing the light-shielding member 1, it is possible to manufacture a light-shielding member 1 that is excellent in rigidity and durability.

[0119] <Second Modification of Method for Manufacturing Light Shielding Member> A second modification of the method for manufacturing light shielding member 1 will be described with reference to FIGS. 5A to 5E.

[0120] The manufacturing method of the light-shielding member 1 includes a fourth step of preparing a resin layer 3, a fifth step of arranging a core layer 2 on one thickness-wise surface of the resin layer 3, a sixth step of arranging the resin layer 3 on one thickness-wise surface of the core layer 2 and covering the entire first surfaces S11, S12 of both of the core layer 2 in the thickness direction with the resin layer 3, and a seventh step of covering the entire second surfaces S21, S22 of both of the resin layer 3 in the thickness direction with a low-reflection layer 4.

[0121] [Step 4] In step 4, a resin layer 3 is prepared as shown in Fig. 5A. Specifically, a solution (varnish) of the resin is applied to one surface of the substrate M1 in the thickness direction and then dried. The substrate M1 is made of a metal that can be removed by etching. Stainless steel, for example, is an example of a material for the substrate M1. This results in the resin layer 3 being disposed on one surface of the substrate M1 in the thickness direction.

[0122] 5B , in the fifth step, the core layer 2 is disposed on one surface in the thickness direction of the resin layer 3. Specifically, first, a seed layer M2 is formed by sputtering on one surface in the thickness direction of the resin layer 3. Examples of materials for the seed layer M2 include chromium, copper, nickel, titanium, and alloys thereof.

[0123] 5C, a plating resist R having an opening where the core layer 2 is to be formed is formed on the seed layer M2, and the core layer 2 is disposed by electrolytic plating on the seed layer M2 exposed from the plating resist R. The plating method allows the core layer 2 to be disposed reliably.

[0124] [Sixth Step] In the sixth step, as shown in Fig. 5D, a resin layer 3 is disposed on one thickness-wise surface of the core layer 2, and both first surfaces S11, S12 of the core layer 2 are entirely covered with the resin layer 3. Furthermore, in the sixth step, both first side surfaces S13 of the core layer 2 (all four side surfaces S13 of the core layer 2) are entirely covered with the resin layer 3. The method for covering the core layer 2 with the resin layer 3 is the same as in the second step in the above embodiment. Thereafter, the substrate M1 is removed by etching. Note that in Fig. 5D, the core layer 2 and the seed layer M2 are integrated to form the core layer 2.

[0125] [Seventh Step] In the seventh step, both second surfaces S21, S22 of the resin layer 3 are entirely coated with the low-reflection layer 4 in the thickness direction of the resin layer 3. Furthermore, in the seventh step, both second side surfaces S23 of the resin layer 3 (all four side surfaces S23 of the resin layer 3) are entirely coated with the low-reflection layer 4. The method for coating the resin layer 3 with the low-reflection layer 4 is the same as in the third step in the above embodiment. In this manner, the light-shielding member 1 is manufactured.

[0126] According to this method for manufacturing the light-shielding member 1, it is possible to manufacture a light-shielding member 1 that is excellent in rigidity and durability.

[0127] <First Modification of Light Shielding Member> As shown in FIGS. 6, 7A, and 7B, the core layer 2 may have a first main body portion 21 and a first protrusion portion 22.

[0128] The first main body portion 21 extends in the orthogonal direction. The first main body portion 21 has a flat plate shape. The first main body portion 21 has a first surface S11 on one side and a first surface S12 on the other side in the thickness direction. The first main body portion 21 has a first side surface S13 in the orthogonal direction.

[0129] The first protrusion 22 protrudes in the perpendicular direction from the first side surface S13 of the first main body portion 21. In the protruding direction of the first protrusion 22, an end face S31 of the first protrusion 22 is exposed from the resin layer 3 and the low-reflection layer 4. The end face S31 of the first protrusion 22 may be flush with the surface of the low-reflection layer 4. The end face S31 of the first protrusion 22 does not have to be flush with the surface of the low-reflection layer 4. The first protrusion 22 may be a remaining portion of a first joint J1, which will be described later.

[0130] With this configuration, the strength of the side surface of the light blocking member 1 can be improved.

[0131] When the area of ​​the side surface S3 of the light-shielding member 1 is taken as 100%, the area of ​​the end surface S31 of the first protrusion 22 is, for example, 75% or less, preferably 50% or less, for example, 1% or more. If the ratio of the area of ​​the end surface S31 of the first protrusion 22 to the area of ​​the side surface S3 of the light-shielding member 1 is equal to or less than the above upper limit, excessive increase in light reflection at the side surface S3 can be suppressed.

[0132] 8 , in the manufacture of the light-shielding member 1 described above, an assembly sheet 100 having a plurality of light-shielding members 1 may be manufactured. The assembly sheet 100 includes a plurality of light-shielding members 1, a frame F, and a plurality of first joints J1.

[0133] The frame F is disposed at a distance from the light blocking members 1. The frame F has, for example, a frame shape. The frame F is made of the same metal as the core layer 2. The frame F is disposed around the plurality of light blocking members 1.

[0134] The first joint J1 is disposed between the light blocking member 1 and the frame F. The first joint J1 connects the light blocking member 1 and the frame F. The joint J1 is made of the same metal as the core layer 2. The first joint J1 is continuous with the first protrusion 22, as shown in FIG. 7A .

[0135] Furthermore, in this modified example, a plurality of light blocking members 1 can be handled while being supported by the frame F via the first joints J1, thereby improving the ease of handling of the light blocking members 1. Furthermore, the first joints J1 are made of the same metal as the core layer 2, and therefore have excellent strength.

[0136] Furthermore, the assembly sheet 100 is manufactured, for example, in the first step ( FIG. 3B ) of one embodiment, by etching the substrate M into the shape of the assembly sheet 100 to prepare the core layer 2, and then in the same manner as in one embodiment.

[0137] <Second Modification of Light Shielding Member> As shown in FIGS. 9, 10A, and 10B, the resin layer 3 may have a second main body portion 23 and a second protrusion portion 24.

[0138] The second main body portion 23 extends in the orthogonal direction. The second main body portion 23 has a flat plate shape. The second main body portion 23 has a second surface S21 on one side and a second surface S22 on the other side in the thickness direction. The second main body portion 23 has a second side surface S23 in the orthogonal direction.

[0139] The second protrusion 24 protrudes in a direction perpendicular to the second side surface S23 of the second main body portion 23. In the protruding direction of the first protrusion 24, an end face S32 of the second protrusion 24 is exposed from the low-reflection layer 4. The end face S32 of the second protrusion 24 may be flush with the surface of the low-reflection layer 4. The end face S32 of the second protrusion 24 does not have to be flush with the surface of the low-reflection layer 4. The second protrusion 24 may be a remaining part of a second joint J1, which will be described later.

[0140] With this configuration, reflection of light on the side surface of the light blocking member 1 can be suppressed.

[0141] When the area of ​​the side surface S3 of the light-shielding member 1 is taken as 100%, the area of ​​the end surface S32 of the second protrusion 24 is, for example, 75% or less, preferably 50% or less, for example, 1% or more. If the ratio of the area of ​​the end surface S32 of the second protrusion 24 to the area of ​​the side surface S3 of the light-shielding member 1 is equal to or less than the above upper limit, it is possible to prevent light reflection at the side surface S3 from increasing excessively.

[0142] 11 , in the manufacture of the light-shielding member 1 described above, an assembly sheet 100 having a plurality of light-shielding members 1 may be manufactured. The assembly sheet 100 includes a plurality of light-shielding members 1, a frame F, and a plurality of second joints J2.

[0143] The frame F is disposed at a distance from the light blocking members 1. The frame F has, for example, a frame shape. The frame F is made of the same resin as the resin layer 3. The frame F is disposed around the plurality of light blocking members 1.

[0144] The second joint J2 is disposed between the light blocking member 1 and the frame F. The second joint J2 connects the light blocking member 1 and the frame F. The second joint J2 is made of the same resin as the resin layer 3. The second joint J2 is continuous with the second protrusion 24, as shown in FIG. 10A .

[0145] Furthermore, in this modified example, a plurality of light blocking members 1 can be handled while being supported by the frame F via the second joints J2, thereby improving the ease of handling of the light blocking members 1. Furthermore, the second joints J2 are made of the same resin as the resin layer 3, and therefore have excellent processability.

[0146] The assembly sheet 100 is manufactured, for example, by preparing a plurality of core layers 2 (core layers 2 whose entire first surface S12 is covered with a resin layer 3) in the first step of the first modified example ( FIG. 4C ), then connecting the plurality of core layers 2 via the resin layer 3 to form the shape of the assembly sheet 100 in the second step, and then arranging the low-reflection layer 4 in the third step.

[0147] <Other Modifications> In the embodiment described above, the light-shielding member 1 is composed of the core layer 2, the resin layer 3, and the low-reflection layer 4, but the configuration of the light-shielding member 1 is not limited to the embodiment described above. The light-shielding member 1 may include components other than the core layer 2, the resin layer 3, and the low-reflection layer 4. For example, the light-shielding member 1 may have an adhesion layer disposed between the core layer 2 and the resin layer 3 and / or between the resin layer 3 and the low-reflection layer 4.

[0148] The above invention is provided as an exemplary embodiment of the present invention, but this is merely an example and should not be interpreted as limiting. Modifications of the present invention that are obvious to those skilled in the art are intended to be included in the scope of the following claims.

[0149] The light-shielding member, assembly sheet, and method for manufacturing a light-shielding member of the present invention are suitably used, for example, in the manufacture of industrial products that require light-shielding.

[0150] REFERENCE SIGNS LIST 1 Light-shielding member 2 Core layer 3 Resin layer 4 Low-reflection layer 21 First main body portion 22 First protrusion 23 Second main body portion 24 Second protrusion 100 Assembly sheet S11 First surface of core layer S12 First surface of core layer S13 First side surface of core layer S21 Second surface of resin layer S22 Second surface of resin layer S23 Second side surface of resin layer F Frame J1 First joint J2 Second joint

Claims

1. A light-shielding member comprising: a metal core layer; a resin layer covering the entire first surfaces of both sides of the core layer in the thickness direction of the core layer; and a low-reflection layer covering the entire second surfaces of both sides of the resin layer in the thickness direction of the resin layer, wherein the 5° specular reflectance of the low-reflection layer is lower than the 5° specular reflectance of the resin layer.

2. The light-shielding member according to claim 1, wherein the 5° regular reflectance of said low-reflection layer is 1.0% or less.

3. The light-shielding member according to claim 1, wherein the resin layer covers a first side surface of the core layer in a direction perpendicular to the thickness direction, and the low-reflection layer covers a second side surface of the resin layer in the direction perpendicular to the thickness direction.

4. The light-shielding member according to claim 3, wherein the resin layer covers the entire first side surface of the core layer, and the low-reflection layer covers the entire second side surface of the resin layer.

5. A light-blocking member as described in claim 3, wherein the core layer has a first main body portion having the first surface and the first side surface, and a first protrusion portion protruding from the first side surface of the first main body portion in the perpendicular direction, and the first protrusion portion is exposed from the resin layer and the low-reflection layer.

6. A light-blocking member as described in claim 3, wherein the resin layer has a second main body portion having the second surface and the second side surface, and a second protrusion portion protruding from the second side surface of the second main body portion in the perpendicular direction, and the second protrusion portion is exposed from the low-reflection layer.

7. The light-shielding member according to claim 1, wherein the resin layer contains polyimide.

8. The light-shielding member according to claim 1, wherein the low-reflection layer contains a resin and a dye.

9. The light-shielding member according to claim 8, wherein the low-reflection layer further contains a filler.

10. The light-shielding member according to claim 8, further comprising a metal layer disposed between said resin layer and said low-reflection layer.

11. An assembly sheet comprising: a light-shielding member according to claim 5; a frame arranged at a distance from said light-shielding member; and a joint connecting said light-shielding member and said frame, said joint being made of the same metal as said core layer and being continuous with said first protruding portion.

12. An assembly sheet comprising: a light-shielding member according to claim 6; a frame arranged at a distance from said light-shielding member; and a joint connecting said light-shielding member and said frame, said joint being made of the same resin as said resin layer and being continuous with said second protruding portion.

13. A method for manufacturing a light-shielding member according to any one of claims 1 to 10, comprising: a first step of preparing the core layer; a second step of covering the entire first surfaces of both sides of the core layer in the thickness direction of the core layer with the resin layer; and a third step of covering the entire second surfaces of both sides of the resin layer in the thickness direction of the resin layer with the low-reflection layer.

14. The method for manufacturing a light-shielding member according to claim 12, wherein in the third step, the entire second surfaces of both of the resin layers are covered with the low-reflection layer by physical vapor deposition.

15. The method for manufacturing a light-shielding member according to claim 13, wherein in the third step, the entire second surfaces of both of the resin layers are covered with the low-reflection layer by an electrodeposition coating method.

16. A method for manufacturing a light-shielding member according to any one of claims 1 to 10, comprising: a fourth step of preparing the resin layer; a fifth step of arranging the core layer on one surface in the thickness direction of the resin layer; a sixth step of arranging the resin layer on one surface in the thickness direction of the core layer and covering both entire first surfaces of the core layer in the thickness direction with the resin layer; and a seventh step of covering both entire second surfaces of the resin layer in the thickness direction of the resin layer with the low-reflection layer.

17. A method for manufacturing a light-shielding member according to claim 16, wherein in the fifth step, the core layer is disposed on one surface of the resin layer in the thickness direction by plating.

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