Laminate

Abstract

The purpose of the present disclosure is to improve the design of a laminate. A laminate (1) of the present disclosure comprises a base material sheet (10), a metal plate (15), and an antireflection layer (22). The base material sheet (10) includes a front surface (11), and a rear surface (12) opposite to the front surface (11). The metal plate (15) is fixed to the front surface (11) or the rear surface (12). The antireflection layer (22) is disposed facing the front surface (11). In a plan view of the front surface (11), the antireflection layer (22) covers the metal plate (15).

Description

Laminated body

[0001] The present disclosure relates to a laminated body.

[0002] Japanese Patent Application Laid-Open No. 2024-40624 (Patent Document 1) discloses a resin molded product including a film and a resin molded body. The film includes a film base material, a copper wiring, and an electrode terminal. The film base material has a main surface. The copper wiring and the electrode terminal are formed on the main surface of the film base material. The electrode terminal is electrically connected to the copper wiring. The resin molded body is formed on the main surface of the film base material, the copper wiring, and the electrode terminal.

[0003] Japanese Patent Application Laid-Open No. 2024-40624

[0004] In the resin molded product disclosed in Patent Document 1, ambient light incident from the main surface side of the film base material is reflected by the electrode terminal. Therefore, the design property of the resin molded product for a person viewing the resin molded product from the main surface side of the film base material is deteriorated. The present disclosure has been made in view of the above problem, and an object thereof is to provide a laminated body with improved design property.

[0005] The laminated body of the present disclosure includes a base sheet, a metal plate, and an antireflection layer. The base sheet includes a front surface and a back surface opposite to the front surface. The metal plate is fixed to the front surface or the back surface of the base sheet. The antireflection layer is disposed to face the front surface. In a plan view of the front surface, the antireflection layer covers the metal plate.

[0006] According to the laminated body of the present disclosure, the design property of the laminated body for a person viewing the laminated body from the front surface side of the base sheet is improved.

[0007] This is a schematic plan view of the laminate of Embodiment 1. This is a schematic cross-sectional view of the laminate of Embodiment 1 along the cross-sectional line II-II shown in Figure 1. This is a schematic cross-sectional view of the laminate of the first modified example of Embodiment 1. This is a schematic cross-sectional view of the laminate of the second modified example of Embodiment 1. This is a flowchart showing the manufacturing method of the laminate of Embodiment 1. This is a schematic cross-sectional view of the laminate of the third modified example of Embodiment 1. This is a schematic cross-sectional view of the laminate of Embodiment 2. This is a schematic partially enlarged plan view of the laminate of Embodiment 2. This is a flowchart showing the manufacturing method of the laminate of Embodiment 2. This is a schematic cross-sectional view of the laminate of Embodiment 3. This is a schematic cross-sectional view of the laminate of Embodiment 4. This is a schematic cross-sectional view of the laminate of the first modified example of Embodiment 4. This is a flowchart showing the manufacturing method of the laminate of the first modified example of Embodiment 4. This is a schematic cross-sectional view of the laminate of Embodiment 5.

[0008] Embodiments of the present disclosure will be described below. The same components will be given the same reference numerals, and their descriptions will not be repeated.

[0009] (Embodiment 1) The laminate 1 of Embodiment 1 will be described with reference to Figures 1 to 6. The laminate 1 is a film-like device 2 included in a cover panel such as the exterior panel of a car. The laminate 1 comprises a base sheet 10, a metal plate 15, and an anti-reflective layer 22. The laminate 1 may further comprise an adhesive layer 20. The laminate 1 may further comprise a conductive wire 28 and a conductive bonding member 29.

[0010] Referring to Figures 1 and 2, the base sheet 10 supports the metal plate 15. The base sheet 10 may be a transparent sheet. The base sheet 10 is formed of, for example, a thermoplastic resin. The base sheet 10 is formed of, for example, a polycarbonate resin, an ethylene resin, a propylene resin, a polyolefin resin, a polyester resin, a polyamide resin, polyvinyl chloride, or acrylonitrile-butadiene-styrene (ABS) resin. Dispersants, antioxidants, compatibilizers, ultraviolet stabilizers, antiblocking agents, or antistatic agents may be added to the base sheet 10.

[0011] The base sheet 10 includes a front surface 11 and a back surface 12 opposite to the front surface 11. The thickness of the base sheet 10 is the distance between the front surface 11 and the back surface 12. From the viewpoint of good moldability of the base sheet 10, the thickness of the base sheet 10 is preferably 100 μm or more and 1000 μm or less, and more preferably 375 μm or more and 500 μm or less. If the thickness of the base sheet 10 is 100 μm or more, the embedding process of the conductive wire 28 using ultrasound can be easily performed. If the thickness of the base sheet 10 is 375 μm or more, the base sheet 10 is less likely to twist during processing, and the handling of the base sheet 10 is improved. If the thickness of the base sheet 10 is 500 μm or less, the molding process of the base sheet 10 becomes easier. If the thickness of the base sheet 10 is 1000 μm or less, the laminate 1 will be less prone to cracking, and the molding of the resin molded product 3 (see Figures 7, 10, 12, and 14) described later will be easier.

[0012] The base sheet 10 may have through holes 13. The through holes 13 extend from the front surface 11 to the back surface 12 and penetrate the base sheet 10 in the thickness direction of the base sheet 10.

[0013] Referring to Figures 1 and 2, the metal plate 15 is, for example, an electrode pad 15a. The electrode pad 15a is electrically connected to an external electrical circuit (not shown) of the laminate 1. The electrode pad 15a is formed of a metal or alloy, such as phosphor bronze, aluminum, iron, or copper. The electrode pad 15a may be coated with a plating layer made of one or more conductive materials such as silver, tin, or nickel to facilitate the electrical connection between the electrode pad 15a and the conductive wire 28.

[0014] The metal plate 15 includes a first main surface 16, a second main surface 17 opposite to the first main surface 16, and a side surface 18 connected to the first main surface 16 and the second main surface 17. In this embodiment, the first main surface 16 faces the front surface 11 of the base sheet 10. The metal plate 15 is fixed to the base sheet 10 using an adhesive layer 20. In this embodiment, the adhesive layer 20 adheres the metal plate 15 to the front surface 11 of the base sheet 10. The adhesive layer 20 is, for example, a photocurable adhesive layer 21 such as an ultraviolet (UV) curable adhesive layer, a thermosetting adhesive layer, or a pressure-sensitive adhesive layer. The metal plate 15 and the adhesive layer 20 may be a metal foil adhesive tape.

[0015] The thickness of the metal plate 15 is the distance between the first main surface 16 and the second main surface 17. The thickness of the metal plate 15 is, for example, 0.05 mm or more and 1.00 mm or less, preferably 0.10 mm or more and 0.30 mm or less. If the thickness of the metal plate 15 is 0.05 mm or more, the rigidity of the metal plate 15 necessary for connecting the metal plate 15 to the conductive wire 28 can be ensured, and the connection between the metal plate 15 and the conductive wire 28 becomes easier. If the thickness of the metal plate 15 is 0.10 mm or more, sufficient rigidity of the metal plate 15 necessary for connecting the metal plate 15 to the conductive wire 28 can be ensured, and the durability of the metal plate 15 is improved. If the thickness of the metal plate 15 is 1.00 mm or less, the shape of the metal plate 15 may not lift up from the surface of the resin molded product 3 (see Figures 7, 10, 12, and 14) described later, and the metal plate 15 may not peel off from the base sheet 10 during processing and use of the laminate 1. If the thickness of the metal plate 15 is 0.30 mm or less, the laminate 1 can be made thinner.

[0016] Referring to Figure 2, the anti-reflective layer 22 is positioned opposite the front surface 11 of the base sheet 10. In a plan view of the front surface 11 of the base sheet 10, the anti-reflective layer 22 covers the metal plate 15. The metal plate 15 is positioned on the side of the base sheet 10 relative to the anti-reflective layer 22. The anti-reflective layer 22 prevents light (e.g., ambient light) incident on the metal plate 15 from the side of the front surface 11 of the base sheet 10 from being reflected by the metal plate 15. The anti-reflective layer 22 covers the second main surface 17 of the metal plate 15. The anti-reflective layer 22 may cover the entire second main surface 17. If a part of the second main surface 17 is covered by another component (such as a cover or car bumper) and is not illuminated by light (e.g., ambient light), that part of the second main surface 17 may be exposed from the anti-reflective layer 22, and the remainder of the second main surface 17 may be covered by the anti-reflective layer 22. The anti-reflective layer 22 may be placed on the second main surface 17 of the metal plate 15. The anti-reflective layer 22 may further cover the side surface 18 of the metal plate 15. The anti-reflective layer 22 may further be placed on the side surface 18 of the metal plate 15.

[0017] In a plan view of the second main surface 17, the outer periphery of the anti-reflective layer 22 may surround the outer periphery of the second main surface 17. Therefore, even if the center of the anti-reflective layer 22 is offset from the center of the second main surface 17 when forming the anti-reflective layer 22 on the second main surface 17, the second main surface 17 can be more reliably covered by the anti-reflective layer 22. In addition, the anti-reflective layer 22 can prevent light traveling from an oblique direction relative to the second main surface 17 toward the side surface 18 of the metal plate 15 from being reflected by the side surface 18 of the metal plate 15.

[0018] Referring to Figure 2, the anti-reflective layer 22 may be a black film 23. The black film 23 may be a single-layer film such as a black polycarbonate (PC) film or a black polyethylene terephthalate (PET) film, or it may be a laminated film including a transparent film such as a transparent PC film or a transparent PET film and a black design layer on the transparent film. The black film 23 is formed on the second main surface 17 and the side surface 18 of the metal plate 15. The black film 23 is fixed to the metal plate 15 (specifically, the second main surface 17 and the side surface 18) and the front surface 11 of the base sheet 10 by a heat-based bonding method such as thermocompression bonding or ultrasonic welding, or by a mechanical fixing method such as crimping or clamping.

[0019] Referring to Figure 3, the anti-reflective layer 22 may be a black plating layer 24. The black plating layer 24 is, for example, a chromium plating layer. The black plating layer 24 is formed on the second main surface 17 of the metal plate 15. The side surface 18 of the metal plate 15 may be exposed from the black plating layer 24 or may be covered by the black plating layer 24.

[0020] Referring to Figure 4, the anti-reflective layer 22 may be a black tape 25. The black tape 25 includes a black layer 26 and an adhesive layer 27. The black layer 26 is, for example, a black resin layer. The black layer 26 is attached to the metal plate 15 (specifically, the second main surface 17) and the front surface 11 of the base sheet 10 via the adhesive layer 27. The side surface 18 of the metal plate 15 may be exposed from the black layer 26 or covered by the black layer 26. The side surface of the adhesive layer 20, the front surface 11 of the base sheet 10 and a portion of the conductive wire 28 may be covered by the black layer 26.

[0021] Referring to Figures 1 and 2, the conductive wire 28 is fixed to the base sheet 10. In this embodiment, the conductive wire 28 is fixed to the front surface 11 of the base sheet 10. A portion of the conductive wire 28 may be embedded in the base sheet 10. For example, the conductive wire 28 may be fixed to the base sheet 10 by ultrasonic welding. The conductive wire 28 may also be bonded to the base sheet 10 using an adhesive (not shown). In a plan view of the front surface 11, the conductive wire 28 may cross the metal plate 15 and the through hole 13. In a plan view of the front surface 11, the end of the conductive wire 28 may overlap the metal plate 15 or be inside the through hole 13.

[0022] The conductive wire 28 is electrically connected to the metal plate 15 (electrode pad 15a). The conductive wire 28 may be joined to the electrode pad 15a using a conductive bonding member 29. The conductive bonding member 29 is, for example, solder or an anisotropic conductive film. The conductive wire 28 may be joined to the electrode pad 15a by thermocompression bonding, welding, or ultrasonic welding. In this embodiment, the conductive wire 28 is joined to the first main surface 16 of the metal plate 15.

[0023] The laminate 1, comprising conductive wires 28 and electrode pads 15a, is an electrical device. For example, at least a portion of the conductive wires 28 is a heat-retaining resistor such as nickel-chromium (NiCr) alloy or platinum (Pt), and the laminate 1 may be a heater such as a film heater. The heater is used for snow melting, for example, by being incorporated into a car emblem or bumper. For example, in a plan view of the front surface 11 of the base sheet 10, at least a portion of the conductive wires 28 may have a meandering shape (see Figure 1), a zigzag shape, or a spiral shape. When the laminate 1 is a heater, the metal plate 15 is the electrode terminal of the heater.

[0024] The conductive wire 28 includes a metal wire (not shown). The metal wire is formed of, for example, copper or a copper-containing alloy (for example, an alloy containing copper and silver). The conductive wire 28 may also include an insulating coating layer (not shown) that covers the metal wire. The insulating coating layer is formed of, for example, a polyurethane-based material or a polyamide-imide-based material. The color of the coating layer may be such that the conductive wire 28 is difficult to see for someone viewing the laminate 1 (for example, black, or the same color as the design layer 35 described later (see Figures 11, 12, and 14)).

[0025] The diameter of the conductive wire 28 is, for example, 30 μm or more and 300 μm or less, preferably 50 μm or more and 180 μm or less. If the diameter of the conductive wire 28 is 30 μm or more, the heat generation characteristics of the conductive wire 28 are improved. If the diameter of the conductive wire 28 is 50 μm or more, it is possible to prevent the conductive wire 28 from breaking when it is embedded in the base sheet 10. If the diameter of the conductive wire 28 is 300 μm or less, it becomes easier to embed the conductive wire 28 in the base sheet 10 and easier to bend the conductive wire 28 into a meandering shape or the like. If the diameter of the conductive wire 28 is 180 μm or less, the conductive wire 28 becomes less noticeable.

[0026] Referring to Figure 5, an example of a method for manufacturing the laminate 1 of this embodiment will be described. Through holes 13 are formed in the base sheet 10 (step S1). The through holes 13 are formed, for example, by punching, laser processing, or cutting with a knife.

[0027] The conductive wire 28 is fixed to the base sheet 10 (step S2). For example, the conductive wire 28 is fixed to the front surface 11 of the base sheet 10 by ultrasonic welding.

[0028] Step S3 involves fixing the metal plate 15 to the base sheet 10 using the adhesive layer 20. For example, a UV-curing adhesive is supplied between the metal plate 15 and the front surface 11 of the base sheet 10. UV light is irradiated from the back surface 12 of the base sheet 10 to cure the UV-curing adhesive. In this way, the metal plate 15 is fixed to the base sheet 10 using the adhesive layer 20. Step S2 may be performed after step S3.

[0029] The metal plate 15 is joined to the conductive wire 28 (step S4). In one example, a conductive joining member 29, such as solder, is supplied between the metal plate 15 and the conductive wire 28 through the through hole 13. In another example, the conductive wire 28 may be joined to the metal plate 15 by thermocompression bonding, welding, or ultrasonic welding.

[0030] An anti-reflective layer 22 is formed (step S5). As shown in Figure 2, the anti-reflective layer 22 may be formed by heat-pressing a black film 23 onto the metal plate 15 and the front surface 11 of the base sheet 10. As shown in Figure 3, the anti-reflective layer 22 may be formed by plating the second main surface 17 of the metal plate 15 with a black plating layer 24. The black plating layer 24 may also be formed on the side surface 18 of the metal plate 15. As shown in Figure 4, the anti-reflective layer 22 may be formed by attaching a black tape 25 to the metal plate 15 and the front surface 11 of the base sheet 10. In this way, the laminate 1 of this embodiment is obtained.

[0031] Referring to Figure 6, the metal plate 15 may be fixed to the back surface 12 of the base sheet 10. The first main surface 16 of the metal plate 15 faces the back surface 12 of the base sheet 10. The conductive wire 28 may be fixed to the back surface 12 of the base sheet 10. The anti-reflective layer 22 may be formed on the front surface 11 of the base sheet 10. In Figure 6, the through hole 13 does not need to be formed.

[0032] The laminate 1 may further comprise a first functional layer (not shown), such as a hard coat layer, an adhesion-improving layer, or an ultraviolet shielding layer. The first functional layer is formed, for example, on the front surface 11 of the base sheet 10. The laminate 1 may further comprise a second functional layer (not shown), such as a hard coat layer or a rust-preventive layer. The second functional layer is formed on the second main surface 17 of the metal plate 15. The rust-preventive layer can prevent corrosion or discoloration of the metal plate 15 due to oxidation or sulfidation of the metal plate 15.

[0033] The effects of the laminate 1 of this embodiment will now be explained. The laminate 1 of this embodiment comprises a base sheet 10, a metal plate 15, and an anti-reflective layer 22. The base sheet 10 includes a front surface 11 and a back surface 12 opposite to the front surface 11. The metal plate 15 is fixed to either the front surface 11 or the back surface 12. The anti-reflective layer 22 is positioned opposite the front surface 11. In a plan view of the front surface 11, the anti-reflective layer 22 covers the metal plate 15.

[0034] Light that enters the metal plate 15 from the front surface 11 of the base sheet 10 and is reflected by the metal plate 15 is unwanted light. If this light is visible to someone viewing the laminate 1 from the front surface 11 of the base sheet 10, the aesthetic appeal of the laminate 1 is reduced. However, the anti-reflective layer 22 prevents light (for example, ambient light) that enters the metal plate 15 from the front surface 11 of the base sheet 10 from being reflected by the metal plate 15. This improves the aesthetic appeal of the laminate 1 to someone viewing it from the front surface 11 of the base sheet 10.

[0035] In the laminate 1 of this embodiment, the metal plate 15 is fixed to the front surface 11. The metal plate 15 includes a first main surface 16 facing the front surface 11 and a second main surface 17 opposite to the first main surface 16. The anti-reflective layer 22 is arranged on the second main surface 17.

[0036] The anti-reflective layer 22 prevents light incident on the metal plate 15 from the front surface 11 of the base sheet 10 from being reflected by the second main surface 17 of the metal plate 15. This improves the aesthetic appearance of the laminate 1 to those who view it from the front surface 11 of the base sheet 10.

[0037] In the laminate 1 of this embodiment, the metal plate 15 includes a side surface 18 connected to the first main surface 16 and the second main surface 17. The anti-reflective layer 22 covers the side surface 18.

[0038] The anti-reflective layer 22 prevents light incident on the metal plate 15 from being reflected off the side surface 18 of the metal plate 15. This improves the aesthetic appeal of the laminate 1 to those viewing it from the front surface 11 of the base sheet 10.

[0039] The laminate 1 according to the present embodiment further includes a conductive wire 28. The metal plate 15 is an electrode pad 15a. The conductive wire 28 is fixed to the base sheet 10 and is electrically connected to the electrode pad 15a.

[0040] The antireflection layer 22 prevents light that is incident onto the electrode pad 15a from the front surface 11 side of the base sheet 10 from being reflected at the electrode pad 15a. The laminate 1 including the conductive wire 28 and the electrode pad 15a is an electrical device. The design of the electrical device is improved.

[0041] In the laminate 1 according to the present embodiment, at least a part of the conductive wire 28 is a heating resistor.

[0042] The laminate 1 including the heating resistor is a heater. The design of the heater is improved. (Embodiment 2) Referring to FIG. 7 and FIG. 8, the laminate 1 according to Embodiment 2 will be described. The laminate 1 according to the present embodiment has a configuration similar to that of the laminate 1 according to Embodiment 1 (see FIG. 1 and FIG. 2), but differs from the laminate 1 according to Embodiment 1 mainly in the following points.

[0043] Referring to FIG. 7, the laminate 1 according to the present embodiment further includes a first molded body 30 and a second molded body 32, and is a resin molded product 3. The laminate 1 according to the present embodiment is a cover panel, such as an exterior panel of a car.

[0044] The first molded body 30 is formed of transparent resin or transparent glass. The second molded body 32 is formed of transparent resin, transparent glass, opaque resin, or opaque glass. The first molded body 30 and the second molded body 32 are formed into a three-dimensional shape such as a flat plate shape or a curved plate shape.

[0045] The first molded body 30 covers the front surface 11 of the base sheet 10, the metal plate 15, and the anti-reflective layer 22. The first molded body 30 is formed on the front surface 11 of the base sheet 10, the metal plate 15, and the anti-reflective layer 22. The first molded body 30 can prevent the metal plate 15 and the anti-reflective layer 22 from peeling off from the base sheet 10. The first molded body 30 may further cover the conductive wire 28. The first molded body 30 may further be formed on the conductive wire 28. The first molded body 30 can prevent the conductive wire 28 from peeling off from the base sheet 10. The first molded body 30 improves the durability, waterproofing, and dustproofing capabilities of the laminate 1.

[0046] The second molded body 32 covers the back surface 12 of the base sheet 10. The second molded body 32 is formed on the back surface 12 of the base sheet 10. The second molded body 32 improves the durability, waterproofing, and dustproofing capabilities of the laminate 1. The through holes 13 may be filled with the second molded body 32.

[0047] Referring to Figure 8, in a plan view of the front surface 11 of the base sheet 10, the anti-reflective layer 22 includes an outer peripheral region 22a. In a plan view of the front surface 11 of the base sheet 10, the outer peripheral region 22a is the region of the anti-reflective layer 22 outside the metal plate 15. The outer peripheral region 22a includes a first outer peripheral region portion 22b fixed to the base sheet 10 and a second outer peripheral region portion 22c not fixed to the base sheet 10. The first outer peripheral region portion 22b includes, for example, an outer peripheral region portion 22d located upstream of the resin flow (for example, the second direction DR2) when forming the first molded body 30, within the outer peripheral region 22a of the anti-reflective layer 22. Therefore, even if air bubbles get trapped between the anti-reflective layer 22 and the metal plate 15 when forming the first molded body 30, the bubbles are discharged through the gap between the second outer peripheral region portion 22c and the base sheet 10. This prevents air bubbles from being trapped in the anti-reflective layer 22 and the metal plate 15.

[0048] Referring to Fig. 9, an example of a method for producing the laminate 1 (resin molded product 3) of the present embodiment will be described. In addition to the steps of the method for producing the laminate 1 (film-like device 2) of Embodiment 1 shown in Fig. 5, the method for producing the laminate 1 of the present embodiment further includes forming a first molded body 30 (step S6) and forming a second molded body 32 (step S7).

[0049] In step S6, the first molded body 30 is formed on the front surface 11 of the base sheet 10, the metal plate 15, and the antireflection layer 22. The first molded body 30 may be formed by insert molding, in-mold molding, or the like. Alternatively, the pre-shaped first molded body 30 may be adhered to the front surface 11 of the base sheet 10, the metal plate 15, and the antireflection layer 22.

[0050] As shown in Fig. 8, when the second outer peripheral region portion 22c of the antireflection layer 22 is not fixed to the base sheet 10, even if air bubbles enter between the antireflection layer 22 and the metal plate 15 during formation of the first molded body 30, the air bubbles are discharged through the gap between the second outer peripheral region portion 22c and the base sheet 10. This prevents air bubbles from being trapped between the antireflection layer 22 and the metal plate 15.

[0051] In step S7, the second molded body 32 is formed on the back surface 12 of the base sheet 10. The second molded body 32 may be formed by insert molding, in-mold molding, or the like. Alternatively, the pre-shaped second molded body 32 may be adhered to the back surface 12 of the base sheet 10. In this way, the laminate 1 of the present embodiment is obtained. Note that step S6 may be performed after step S7.

[0052] The second molded body 32 may be omitted. The first molded body 30 may be omitted. That is, the laminate 1 of the present embodiment only needs to include at least one of the first molded body 30 and the second molded body 32.

[0053] In addition to the effects of the laminate 1 of Embodiment 1, the laminate 1 of the present embodiment exhibits the following effects.

[0054] The laminate 1 of this embodiment further comprises a first molded body 30. The first molded body 30 covers the front surface 11 of the base sheet 10, the metal plate 15, and the anti-reflective layer 22.

[0055] The first molded body 30 can prevent the metal plate 15 and the anti-reflective layer 22 from peeling off from the base sheet 10. Therefore, the first molded body 30 improves the durability, waterproofing, and dustproofing capabilities of the laminate 1.

[0056] In the laminate 1 of this embodiment, in a plan view of the front surface 11 of the base sheet 10, the anti-reflective layer 22 includes an outer peripheral region 22a. The outer peripheral region 22a includes a first outer peripheral region portion 22b fixed to the base sheet 10 and a second outer peripheral region portion 22c not fixed to the base sheet 10. The first outer peripheral region portion 22b includes an outer peripheral region portion 22d located upstream of the resin flow when forming the first molded body 30, within the outer peripheral region 22a.

[0057] Therefore, when forming the first molded body 30, even if air bubbles get trapped between the anti-reflective layer 22 and the metal plate 15, the air bubbles are discharged through the gap between the second outer peripheral region 22c and the base sheet 10. This prevents air bubbles from being trapped in the anti-reflective layer 22 and the metal plate 15. It prevents a person viewing the laminate 1 from the front surface 11 of the base sheet 10 from seeing the air bubbles and the bulges in the anti-reflective layer 22 and the first molded body 30 caused by the air bubbles. This improves the aesthetic appeal of the laminate 1 to a person viewing it from the front surface 11 of the base sheet 10. Furthermore, it prevents cracks from occurring in the first molded body 30 due to air bubbles. It also prevents the metal plate 15 from rusting and deteriorating due to air bubbles.

[0058] (Embodiment 3) The laminate 1 of Embodiment 3 will be described with reference to Figure 10. The laminate 1 of this embodiment has the same configuration as the laminate 1 of Embodiment 2, but differs from the laminate 1 of Embodiment 2 (see Figure 7) mainly in the following points.

[0059] The first molded body 30 includes a surface 31 distal to the base sheet 10. The anti-reflective layer 22 is disposed on the surface 31. The anti-reflective layer 22 may be a black film 23, which may be heat-pressed or bonded to the surface 31. The anti-reflective layer 22 may be a black tape 25 (see Figure 4), which may be bonded to the surface 31. The anti-reflective layer 22 is formed on the surface 31 after the first molded body 30 is formed. In a plan view of the second main surface 17 of the metal plate 15, the outer periphery of the anti-reflective layer 22 surrounds the outer periphery of the second main surface 17 of the metal plate 15.

[0060] The laminate 1 of this embodiment provides the following effects in addition to the effects of the laminate 1 of embodiment 2.

[0061] The laminate 1 of this embodiment further comprises a first molded body 30. The first molded body 30 covers the front surface 11 of the base sheet 10 and the metal plate 15. The anti-reflective layer 22 is disposed on the surface 31 of the first molded body 30 distal to the base sheet 10.

[0062] The first molded body 30 can prevent the metal plate 15 from peeling off from the base sheet 10. Therefore, the first molded body 30 improves the durability, waterproofing, and dustproofing capabilities of the laminate 1. In addition, the heat and pressure applied during the process of forming the first molded body 30 can prevent the anti-reflective layer 22 from peeling, tearing, or wrinkling.

[0063] (Embodiment 4) The laminate 1 of Embodiment 4 will be described with reference to Figure 11. The laminate 1 of this embodiment has the same configuration as the laminate 1 of Embodiment 1 (see Figure 2), but differs from the laminate 1 of Embodiment 1 mainly in the following points.

[0064] The laminate 1 is a decorative sheet 4 and includes a design layer 35. The design layer 35 is coated with a pattern such as a wood grain or a design such as coloring. The design layer 35 is placed on the back surface 12 of the base sheet 10. The design layer 35 may also be placed on the front surface 11 of the base sheet 10. A person viewing the laminate 1 from the side of the front surface 11 of the base sheet 10 will see the design of the design layer 35. The design layer 35 prevents a person viewing the laminate 1 from the side of the front surface 11 of the base sheet 10 from seeing objects on the back surface 12 side of the base sheet 10 (for example, a light source). The light transmittance of the design layer 35 is lower than the light transmittance of the base sheet 10.

[0065] An opening 36 is provided in the design layer 35. In a plan view of the first main surface 16 of the metal plate 15, the opening 36 overlaps the light-curing adhesive layer 21. In a plan view of the first main surface 16, the outer periphery of the opening 36 in the design layer 35 surrounds the outer periphery of the through hole 13 in the base sheet 10. When the adhesive layer 20 is a light-curing adhesive layer 21, the light-curing adhesive is cured by irradiation with light (e.g., UV light) passing through the opening 36. In this way, the adhesive layer 20 is formed. In a plan view of the first main surface 16, the outer periphery of the adhesive layer 20 may surround the outer periphery of the opening 36, or the outer periphery of the opening 36 may surround the outer periphery of the adhesive layer 20. In a plan view of the first main surface 16, the outer periphery of the metal plate 15 preferably surrounds the outer periphery of the opening 36. Therefore, misalignment of the metal plate 15 during the manufacturing of the laminate 1 or light leakage caused by diffraction or scattering of light within the adhesive layer 20 can be prevented.

[0066] The laminate 1 includes a light-shielding layer 38. The light-shielding layer 38 blocks light (for example, light emitted from an illumination light source) that passes through the opening 36 from the back surface 12 of the base sheet 10 to the front surface 11 of the base sheet 10. The light-shielding layer 38 may be a single-layer film such as a black PC film or a black PET film, a laminated film including a transparent film such as a transparent PC film or a transparent PET film and a black design layer on the transparent film, or a black tape. The light-shielding layer 38 is positioned on the side of the base sheet 10 opposite to the metal plate 15. In a plan view of the first main surface 16 of the metal plate 15, the light-shielding layer 38 covers the opening 36. For example, the light-shielding layer 38 is positioned on the back surface 12 of the base sheet 10 and closes the opening 36. The light-shielding layer 38 may be part of the design layer 35. The light-shielding layer 38 only needs to be formed where light leakage prevention is required.

[0067] The laminate 1 may further comprise a first functional layer (not shown), such as a hard coat layer, an adhesion-improving layer, or an ultraviolet shielding layer. The hard coat layer is formed, for example, on at least one of the following: the front surface 11 of the base sheet 10 or the first surface of the design layer 35 opposite to the second surface of the design layer 35 facing the base sheet 10. The adhesion-improving layer is formed, for example, on at least one of the following: the front surface 11 of the base sheet 10, the back surface 12 of the base sheet 10, or the first surface of the design layer 35. The ultraviolet shielding layer is formed, for example, on the front surface 11 of the base sheet 10. The laminate 1 may further comprise a second functional layer (not shown), such as a hard coat layer or a rust-preventive layer. The second functional layer is formed on the second main surface 17 of the metal plate 15.

[0068] In addition to the effects of the laminate 1 of Embodiment 1, the laminate 1 of this embodiment provides the following effects.

[0069] The laminate 1 of this embodiment further comprises a design layer 35. The design layer 35 is disposed on the back surface 12 of the base sheet 10. The light transmittance of the design layer 35 is lower than that of the base sheet 10.

[0070] When viewing the laminate 1 from the front surface 11 of the base sheet 10, the design of the design layer 35 is visible. The design layer 35 prevents the viewer of objects on the back surface 12 of the base sheet 10 (for example, lighting sources) when viewing the laminate 1 from the front surface 11 of the base sheet 10. Therefore, the aesthetic appeal of the laminate 1 to the viewer of the front surface 11 of the base sheet 10 is improved.

[0071] The laminate 1 of this embodiment further comprises an adhesive layer 20, such as a photocurable adhesive layer 21, and a light-shielding layer 38. The photocurable adhesive layer 21 adheres the metal plate 15 to the front surface 11 of the base sheet 10. An opening 36 is provided in the design layer 35. In a plan view of the first main surface 16 of the metal plate 15, the opening 36 overlaps the photocurable adhesive layer 21. The light-shielding layer 38 is positioned on the opposite side of the base sheet 10 from the metal plate 15, and covers the opening 36 in a plan view of the first main surface 16 of the metal plate 15.

[0072] The light-curing adhesive hardens when irradiated with light (e.g., UV light) passing through the aperture 36, forming a light-curing adhesive layer 21. The metal plate 15 can be bonded to the base sheet 10 using the light-curing adhesive layer 21. This makes it easier to fix the metal plate 15 to the base sheet 10.

[0073] Light that passes through the opening 36 from the back surface 12 of the base sheet 10 to the front surface 11 of the base sheet 10 (for example, light emitted from an illumination light source) is unwanted light. If this light is visible to someone viewing the laminate 1 from the front surface 11 of the base sheet 10, the aesthetic appeal of the laminate 1 will be reduced. However, the light-shielding layer 38 blocks the light that passes through the opening 36 from the back surface 12 of the base sheet 10 to the front surface 11 of the base sheet 10. Therefore, the aesthetic appeal of the laminate 1 to someone viewing the laminate 1 from the front surface 11 of the base sheet 10 is improved.

[0074] In the laminate 1 of this embodiment, the light-shielding layer 38 is arranged on the back surface 12 of the base sheet 10 and closes the opening 36.

[0075] The light-shielding layer 38 blocks light (for example, light emitted from an illumination light source) that passes through the opening 36 from the back surface 12 of the base sheet 10 to the front surface 11 of the base sheet 10. As a result, the aesthetic appearance of the laminate 1 is improved for those who view the laminate 1 from the side of the front surface 11 of the base sheet 10.

[0076] (First Modification of Embodiment 4) Referring to Figure 12, the laminate 1 of the first modification of Embodiment 4 will be described. The laminate 1 may further comprise a first molded body 30 and a second molded body 32. The laminate 1 may also be a decorative molded product 5 which is a resin molded product 3 including a decorative sheet 4 (see Figure 11). The first molded body 30 and the second molded body 32 in this embodiment are the same as the first molded body 30 and the second molded body 32 in Embodiment 2. In this embodiment, the second molded body 32 covers the back surface 12 of the base sheet 10 and the design layer 35. The second molded body 32 further covers the light-shielding layer 38.

[0077] Referring to Figure 13, an example of a manufacturing method for the resin molded product 3 (laminated body 1, decorated molded product 5) shown in Figure 12 will be described. The manufacturing method for the resin molded product 3 shown in Figure 12 further includes, in addition to the steps of the manufacturing method for the resin molded product 3 (laminated body 1) of Embodiment 2 shown in Figure 9, forming a design layer 35 (step S8), forming an opening 36 in the design layer 35 (step S9), and forming a light-shielding layer 38 (step S10).

[0078] In step S8, for example, the design layer 35 may be adhered to the back surface 12 of the base sheet 10. Step S8 may be performed before forming the through holes 13 in the base sheet 10 (step S1). If step S8 is performed before step S1, in step S8, the through holes 13 are formed in the design layer 35 in addition to the base sheet 10.

[0079] In step S9, the opening 36 may be formed by laser processing the design layer 35, or it may be formed by not printing the design layer 35. Step S9 may be performed after step S2 and before step S3.

[0080] In step S3, if the adhesive layer 20 is a photocurable adhesive layer 21, the photocurable adhesive is cured by irradiation with light (for example, UV light) passing through the aperture 36. In this way, the metal plate 15 is fixed to the base sheet 10 using the adhesive layer 20.

[0081] In step S10, a light-shielding layer 38 is formed such that, in a plan view of the first main surface 16 of the metal plate 15, the light-shielding layer 38 covers the opening 36. The light-shielding layer 38 may be, for example, pressed or bonded to the base sheet 10 and the design layer 35. In this embodiment, the light-shielding layer 38 is formed on the back surface 12 of the base sheet 10 and closes the opening 36. Step S10 is performed after step S9 and in step S7. Step S10 may also be performed after step S5 and before step S6.

[0082] In step S7, the second molded body 32 is formed such that it covers the back surface 12 of the base sheet 10 and the design layer 35. In this embodiment, the second molded body 32 further covers the light-shielding layer 38. In this way, the resin molded product 3 (laminated body 1, decorated molded product 5) shown in Figure 12 is obtained.

[0083] The second molded body 32 may be omitted. The first molded body 30 may be omitted. In other words, the laminate 1 of the first modified example of this embodiment only needs to include at least one of the first molded body 30 or the second molded body 32.

[0084] The first molded body 30 can prevent the metal plate 15 and the anti-reflective layer 22 from peeling off from the base sheet 10. The second molded body 32 can prevent the design layer 35 and the light-shielding layer 38 from peeling off from the base sheet 10. Therefore, the first molded body 30 and the second molded body 32 improve the durability, waterproofing ability and dustproofing ability of the laminate 1.

[0085] (Second Modification of Embodiment 4) Referring to Figure 11, the laminate 1 of the second modification of Embodiment 4 will be described. The laminate 1 of this embodiment differs from the laminate 1 of Embodiment 4 mainly in the following respects.

[0086] If no measures are needed to prevent the reflection of light incident on the metal plate 15 from the front surface 11 of the base sheet 10, and only measures are needed to prevent light leakage from the back surface 12 of the base sheet 10 to the front surface 11 of the base sheet 10 through the opening 36, then the laminate 1 may be configured to have a light-shielding layer 38 instead of an anti-reflective layer 22. In other words, the laminate 1 of the second modification of Embodiment 4 has a configuration that does not have an anti-reflective layer 22 compared to the laminate 1 of Embodiment 4.

[0087] Light that passes through the opening 36 from the back surface 12 of the base sheet 10 to the front surface 11 of the base sheet 10 (for example, light emitted from an illumination light source) is unwanted light. If this light is visible to someone viewing the laminate 1 from the front surface 11 of the base sheet 10, the aesthetic appeal of the laminate 1 will be reduced. However, the light-shielding layer 38 blocks the light that passes through the opening 36 from the back surface 12 of the base sheet 10 to the front surface 11 of the base sheet 10. Therefore, the aesthetic appeal of the laminate 1 to someone viewing the laminate 1 from the front surface 11 of the base sheet 10 is improved.

[0088] Referring to Figure 12, the laminate 1 of the second modified embodiment of the fourth embodiment may comprise at least one of the first molded body 30 or the second molded body 32.

[0089] (Embodiment 5) The laminate 1 of Embodiment 5 will be described with reference to Figure 14. The laminate 1 of this embodiment has the same configuration as the laminate 1 of the first modified example of Embodiment 4 (see Figure 12), but differs from the laminate 1 of the first modified example of Embodiment 4 mainly in the following points.

[0090] The second molded body 32 includes a surface 33 distal to the base sheet 10. The light-shielding layer 38 is disposed on the surface 33. The light-shielding layer 38 may be heat-pressed or bonded to the surface 33. The light-shielding layer 38 is formed on the surface 33 after the second molded body 32 has been formed.

[0091] The laminate 1 of this embodiment provides the same effects as the laminate 1 of the first modified example of Embodiment 4 (see Figure 12), as shown in Figure 12.

[0092] The laminate 1 of this embodiment further comprises a second molded body 32. The second molded body 32 covers the back surface 12 of the base sheet 10. The light-shielding layer 38 is disposed on the surface of the second molded body 32 distal to the base sheet 10.

[0093] The second molded body 32 improves the durability, waterproofing, and dustproofing capabilities of the laminate 1. The light-shielding layer 38 blocks light (for example, light emitted from an illumination light source) that passes through the opening 36 from the back surface 12 of the base sheet 10 to the front surface 11 of the base sheet 10. As a result, the aesthetic appearance of the laminate 1 is improved for those who view the laminate 1 from the side of the front surface 11 of the base sheet 10.

[0094] (Modified Version of Embodiment 5) Referring to Figure 14, a modified version of the laminate 1 of Embodiment 5 will be described. The laminate 1 of this embodiment differs from the laminate 1 of Embodiment 5 mainly in the following respects.

[0095] If no measures are needed to prevent the reflection of light incident on the metal plate 15 from the front surface 11 of the base sheet 10, and only measures are needed to prevent light leakage from the back surface 12 of the base sheet 10 to the front surface 11 of the base sheet 10 through the opening 36, then the laminate 1 may be configured to have a light-shielding layer 38 instead of an anti-reflective layer 22. In other words, the modified laminate 1 of Embodiment 5 has a configuration that does not have an anti-reflective layer 22 compared to the laminate 1 of Embodiment 5.

[0096] The second molded body 32 improves the durability, waterproofing, and dustproofing capabilities of the laminate 1. Light that passes through the opening 36 from the back surface 12 of the base sheet 10 to the front surface 11 of the base sheet 10 (for example, light emitted from an illumination light source) is unwanted light. If this light is visible to someone viewing the laminate 1 from the front surface 11 of the base sheet 10, the aesthetic appeal of the laminate 1 is reduced. However, the light-shielding layer 38 blocks the light that passes through the opening 36 from the back surface 12 of the base sheet 10 to the front surface 11 of the base sheet 10 (for example, light emitted from an illumination light source). Therefore, the aesthetic appeal of the laminate 1 is improved for someone viewing the laminate 1 from the front surface 11 of the base sheet 10.

[0097] The various aspects of this disclosure are described below as appendices. (Appendix 1) A laminate comprising: a base sheet including a front surface and a back surface opposite to the front surface; a metal plate fixed to the front surface or the back surface of the base sheet; and an anti-reflective layer disposed opposite to the front surface, wherein in a plan view of the front surface, the anti-reflective layer covers the metal plate. (Appendix 2) The laminate according to Appendix 1, wherein the metal plate is fixed to the front surface, the metal plate includes a first main surface opposite to the front surface and a second main surface opposite to the first main surface, and the anti-reflective layer is disposed on the second main surface. (Appendix 3) The laminate according to Appendix 2, wherein the metal plate includes a side surface connected to the first main surface and the second main surface, and the anti-reflective layer covers the side surface. (Note 4) The laminate according to Note 2 or Note 3, further comprising a first molded body that covers the front surface, the metal plate, and the anti-reflective layer. (Note 5) The laminate according to Note 4, wherein, in a plan view of the front surface, the anti-reflective layer includes an outer peripheral region, the outer peripheral region includes a first outer peripheral region portion fixed to the base sheet and a second outer peripheral region portion not fixed to the base sheet, and the first outer peripheral region portion includes an outer peripheral region portion of the outer peripheral region that is upstream of the resin flow when forming the first molded body. (Note 6) The laminate according to any one of Notes 2 to 5, further comprising a design layer disposed on the back surface, wherein the light transmittance of the design layer is lower than the light transmittance of the base sheet. (Note 7) The laminate according to Note 6, further comprising a light-curing adhesive layer for adhering the metal plate to the front surface of the base sheet, and a light-shielding layer, wherein an opening is provided in the design layer, the opening overlaps the light-curing adhesive layer in a plan view of the first main surface, the light-shielding layer is positioned on the opposite side of the base sheet from the metal plate, and covers the opening in a plan view of the first main surface. (Note 8) The laminate according to Note 7, wherein the light-shielding layer is positioned on the back surface and closes the opening.(Note 9) The laminate according to Note 7, further comprising a second molded body covering the back surface, wherein the light-shielding layer is disposed on the surface of the second molded body distal to the base sheet. (Note 10) The laminate according to Note 1, further comprising a first molded body covering the front surface and the metal plate, wherein the anti-reflective layer is disposed on the surface of the first molded body distal to the base sheet. (Note 11) The laminate according to any one of Notes 1 to 10, further comprising a conductive wire fixed to the base sheet, wherein the metal plate is an electrode pad, and the conductive wire is electrically connected to the electrode pad. (Note 12) The laminate according to Note 11, wherein at least a portion of the conductive wire is a heat-generating resistor.

[0098] Embodiments 1-5 and their variations disclosed herein should be considered illustrative and not restrictive. The scope of this disclosure is indicated by the claims rather than the foregoing description and is intended to include all modifications in the sense and scope equivalent to the claims.

[0099] 1 Laminate, 2 Film-like device, 3 Resin molded product, 4 Decorative sheet, 5 Decorative molded product, 10 Base sheet, 11 Front surface, 12 Back surface, 13 Through hole, 15 Metal plate, 15a Electrode pad, 16 First main surface, 17 Second main surface, 18 Side surface, 20 Adhesive layer, 21 Photocurable adhesive layer, 22 Anti-reflective layer, 22a Outer peripheral region, 22b First outer peripheral region portion, 22c Second outer peripheral region portion, 22d Outer peripheral region portion, 23 Black film, 24 Black plating layer, 25 Black tape, 26 Black layer, 27 Adhesive layer, 28 Conductive wire, 29 Conductive bonding member, 30 First molded body, 31 Surface, 32 Second molded body, 33 Surface, 35 Design layer, Opening, 38 Light-shielding layer.

Claims

1. A laminate comprising: a base sheet including a front surface and a back surface opposite to the front surface; a metal plate fixed to the front surface or the back surface of the base sheet; and an anti-reflective layer disposed opposite to the front surface, wherein, in a plan view of the front surface, the anti-reflective layer covers the metal plate.

2. The laminate according to claim 1, wherein the metal plate is fixed to the front surface, the metal plate includes a first main surface facing the front surface and a second main surface opposite to the first main surface, and the anti-reflective layer is disposed on the second main surface.

3. The laminate according to claim 2, wherein the metal plate includes a side surface connected to the first main surface and the second main surface, and the anti-reflective layer covers the side surface.

4. The laminate according to claim 2, further comprising a first molded body covering the front surface, the metal plate, and the anti-reflective layer, wherein in a plan view of the front surface, the anti-reflective layer includes an outer peripheral region, the outer peripheral region includes a first outer peripheral region portion fixed to the base sheet and a second outer peripheral region portion not fixed to the base sheet, and the first outer peripheral region portion includes an outer peripheral region portion of the outer peripheral region that is upstream of the resin flow when forming the first molded body.

5. The laminate according to claim 2, further comprising: a design layer disposed on the back surface; a light-curing adhesive layer for bonding the metal plate to the front surface of the base sheet; and a light-shielding layer, wherein an opening is provided in the design layer, the opening overlaps the light-curing adhesive layer in a plan view of the first main surface, the light-shielding layer is disposed on the opposite side of the base sheet from the metal plate, and covers the opening in a plan view of the first main surface.

6. The laminate according to claim 5, wherein the light-shielding layer is disposed on the back surface and closes the opening.

7. The laminate according to any one of claims 1 to 6, further comprising conductive wires fixed to the base sheet, wherein the metal plate is an electrode pad, the conductive wires are electrically connected to the electrode pads, and at least a portion of the conductive wires is a heat-generating resistor.

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