A diffusion sheet, its processing mold and processing method

Abstract

This invention discloses a diffuser sheet, its processing mold, and processing method. The diffuser sheet is integrally formed, with multiple pits distributed on both end faces. The material of the diffuser sheet is resin or glass. The processing mold includes a sleeve, a first mold, and a second mold. Both the first and second molds have protrusions that can extend into the sleeve. The protrusions are cylindrical, and their diameter is equal to the inner diameter of the sleeve. A metal coating with multiple protrusions is provided on the end face of the protrusion that extends into the sleeve. The processing method involves placing the raw material in the sleeve and clamping it with the first and second molds to form the diffuser sheet. The diffuser sheet of this invention has high uniformity; this invention improves the uniformity of the diffuser sheet and can reduce contamination during the processing of the diffuser sheet.

Description

Technical Field

[0001] This invention relates to the field of optical materials technology, and in particular to a diffuser sheet, its processing mold, and processing method. Background Technology

[0002] The diffuser is an important component of the backlight module, and its main function is to provide a uniform surface light source for the display. Typically, the diffuser substrate is made of resin materials with high transmittance, such as PMMA, PC, or PET, and a diffusion film is coated on the surface of the diffuser.

[0003] Generally, traditional diffusion films involve adding an appropriate amount of chemical particles as scattering particles to the coating and dispersing them on the surface of the diffusion film substrate. When light passes through the diffusion film, it continuously passes through materials with different refractive indices, resulting in many refraction, reflection, and scattering phenomena, thus creating an optical scattering effect.

[0004] The disadvantages of scattering particle coating diffusers are particularly prominent, specifically:

[0005] (1) The diffusion film coating contains organic solvents, which are easy to volatilize and cause uneven coating. In addition, the exhaust gas containing organic solvents pollutes the air.

[0006] (2) The coating production process involves a drying process, which consumes a lot of energy and has a long production cycle. The drying process is easily affected by temperature and humidity.

[0007] (3) The scattering particles have weak bonding with solvents and resins and are easy to detach;

[0008] (4) The uniformity of particle distribution is difficult to control, and the size of the diffuser aperture cannot be controlled. Summary of the Invention

[0009] The purpose of this invention is to provide a diffusion sheet, its processing mold, and processing method to solve the problems existing in the prior art, improve the uniformity of the diffusion sheet, and reduce contamination during the processing of the diffusion sheet.

[0010] To achieve the above objectives, the present invention provides the following solution:

[0011] The present invention provides a diffuser sheet, which is integrally formed and has multiple pits distributed on both end faces. The material of the diffuser sheet is resin or glass.

[0012] Preferably, the recess is hemispherical.

[0013] The present invention also provides a processing mold for the above-mentioned diffusion sheet, including a sleeve, a first mold and a second mold. Both the first mold and the second mold are provided with a protrusion that can extend into the sleeve. The protrusion is cylindrical and the diameter of the protrusion is equal to the inner diameter of the sleeve. A metal coating is provided on the end face of the end of the protrusion that extends into the sleeve, and a plurality of protrusions are provided on the metal coating.

[0014] Preferably, the protrusion is hemispherical.

[0015] The present invention also provides a method for processing the above-mentioned diffusion sheet, comprising the following steps:

[0016] (1) Prepare the above-mentioned processing mold:

[0017] 1) Prepare the sleeve, the first mold, and the second mold;

[0018] 2) Prepare a metal coating on the end face of the protrusion of the first mold and the protrusion of the second mold that extends into the sleeve;

[0019] 3) Perform ultra-precision machining on the inner wall surface of the sleeve, the surface of the protrusion of the first mold, and the surface of the protrusion of the second mold to form a bright mirror surface;

[0020] 4) The first mold and the second mold are subjected to heat treatment to cause the metal coating to recrystallize. After the grains grow, multiple protrusions are formed on the microscopic surface of the metal coating.

[0021] (2) The molten raw material is placed in the sleeve, wherein the raw material is resin or glass;

[0022] (3) Insert the protrusions of the first mold and the second mold into the sleeve respectively, so that the protrusions of the first mold and the second mold clamp the raw material in the sleeve, and maintain the pressure of the first mold and the second mold on the raw material at a set pressure.

[0023] (4) After maintaining the clamping for a set time, the raw material forms a diffuser sheet with multiple pits on the end face. The first mold and the second mold are removed from the sleeve, and then the formed diffuser sheet is taken out from the sleeve.

[0024] Preferably, the sleeve, the first mold, and the second mold are all made of stainless steel, and the surface roughness of the sleeve, the first mold, and the second mold is 8 μm.

[0025] Preferably, the thickness of the metal coating is 10 μm.

[0026] Preferably, the heat treatment process involves holding the sample at 900°C for 2 hours, with an argon atmosphere for protection.

[0027] The present invention achieves the following technical effects compared to the prior art:

[0028] The diffuser sheet of the present invention has high uniformity; the processing mold of the diffuser sheet of the present invention has a simple structure and is easy to use.

[0029] The diffusion sheet processing method of the present invention is formed by injection molding or die casting in one step, which has a short processing time and high efficiency.

[0030] Furthermore, the processing method of the diffusion sheet of the present invention does not use organic material coatings during the preparation process, which effectively avoids solid pollution and waste pollution containing organic materials, is beneficial to environmental protection, and is not affected by environmental humidity and temperature.

[0031] Furthermore, the processing method of the diffuser sheet of the present invention forms a dense microstructure on the surface of the diffuser sheet, with a metal bond bonding force, which is strong and the structural size and uniformity are easy to control. Attached Figure Description

[0032] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0033] Figure 1 This is a schematic diagram of the processing mold for the diffuser sheet of the present invention;

[0034] Figure 2 for Figure 1 A magnified view of a section at point A in the middle;

[0035] Among them, 1. First mold; 2. Second mold; 3. Sleeve; 4. Diffuser plate; 5. Protrusion. Detailed Implementation

[0036] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] The purpose of this invention is to provide a diffusion sheet, its processing mold, and processing method to solve the problems existing in the prior art, improve the uniformity of the diffusion sheet, and reduce contamination during the processing of the diffusion sheet.

[0038] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0039] like Figures 1-2 As shown, this embodiment provides a diffuser sheet 4, which is integrally formed. Multiple recesses are distributed on both end faces of the diffuser sheet 4. The material of the diffuser sheet 4 is resin or glass. The recesses are hemispherical.

[0040] Compared with existing scattering particle coated diffusers, the diffuser sheet 4 in this embodiment does not have a diffusion film coating. Instead, it is formed by injection molding or die casting. The diffuser sheet 4 in this embodiment has high uniformity, the preparation process is pollution-free, and there is no problem of scattered ion shedding.

[0041] This embodiment also provides a processing mold for the above-mentioned diffuser sheet 4, including a sleeve 3, a first mold 1, and a second mold 2. Both the first mold 1 and the second mold 2 are provided with protrusions 5 that can extend into the sleeve 3. The protrusions 5 are cylindrical, and their diameter is equal to the inner diameter of the sleeve 3. A metal coating is provided on the end face of the protrusion 5 that extends into the sleeve 3, and multiple protrusions are provided on the metal coating. Preferably, the protrusions are hemispherical.

[0042] This embodiment also provides a method for processing the above-mentioned diffusion sheet 4, including the following steps:

[0043] (1) Prepare the above-mentioned processing mold:

[0044] 1) Prepare sleeve 3, first mold 1, and second mold 2;

[0045] The sleeve 3, the first mold 1, and the second mold 2 are all made of stainless steel, and the surface roughness of the sleeve 3, the first mold 1, and the second mold 2 is 8μm.

[0046] 2) Prepare a metal coating on the end face of the protrusion 5 of the first mold 1 and the protrusion 5 of the second mold 2 that extends into the sleeve 3.

[0047] The thickness of the metal coating is 10 μm.

[0048] 3) The inner wall surface of the sleeve 3, the surface of the protrusion 5 of the first mold 1, and the surface of the protrusion 5 of the second mold 2 are subjected to ultra-precision machining to form a bright mirror surface.

[0049] 4) The first mold 1 and the second mold 2 are subjected to heat treatment, specifically: held at 900℃ for 2 hours under argon atmosphere protection. This causes recrystallization of the metal coating, and after grain growth, multiple protrusions are formed on the microscopic surface of the metal coating, and all the protrusions are densely distributed on the surface of the metal coating.

[0050] (2) Place the molten raw material in the sleeve 3. The raw material is resin or glass.

[0051] (3) Insert the protrusion 5 of the first mold 1 and the protrusion 5 of the second mold 2 into the sleeve 3 respectively, so that the protrusion 5 of the first mold 1 and the protrusion 5 of the second mold 2 clamp the material in the sleeve 3, and keep the pressure of the first mold 1 and the second mold 2 on the material at the set pressure.

[0052] (4) After maintaining the clamping time, the raw material forms a diffuser sheet 4 with multiple pits on the end face, and all the pits are densely distributed on the end face of the diffuser sheet. The first mold 1 and the second mold 2 are removed from the sleeve 3, and then the formed diffuser sheet 4 is taken out from the sleeve 3.

[0053] In this embodiment, the diffuser plate 4 has dense pits on both end faces. When light passes through the diffuser plate 4, the light is reflected, refracted and scattered under the action of the dense microstructure on the surface, and the light source is atomized, thus forming the light diffusion effect.

[0054] In the description of this invention, it should be noted that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0055] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A method for processing a diffuser sheet, characterized in that, Includes the following steps: (1) Preparation of processing molds: 1) Prepare the sleeve, the first mold, and the second mold; 2) One of the protrusions of the first mold and the second mold extends into the sleeve. A metal coating is prepared on the end face of the end; 3) The inner wall surface of the sleeve, the surface of the protrusion of the first mold, and the second mold. The surface of the protruding part is machined with ultra-precision to form a bright mirror surface; 4) Perform heat treatment on the first mold and the second mold to make the metal coating... After recrystallization and grain growth, multiple protrusions are formed on the microscopic surface of the metal coating; (2) The molten raw material is placed in the sleeve, wherein the raw material is resin or glass; (3) Insert the protrusions of the first mold and the second mold into the sleeve respectively, so that the protrusions of the first mold and the second mold clamp the raw material in the sleeve, and maintain the pressure of the first mold and the second mold on the raw material at a set pressure. (4) After maintaining the clamping for a set time, the raw material forms a diffuser sheet with multiple pits on the end face. The first mold and the second mold are removed from the sleeve, and then the formed diffuser sheet is taken out from the sleeve.

2. The method for processing the diffuser sheet according to claim 1, characterized in that: The sleeve, the first mold, and the second mold are all made of stainless steel, and the surface roughness of the sleeve, the first mold, and the second mold is 8 μm.

3. The method for processing the diffuser sheet according to claim 1, characterized in that: The thickness of the metal coating is 10 μm.

4. The method for processing the diffuser sheet according to claim 1, characterized in that: The heat treatment process involves holding the temperature at 900°C for 2 hours, with argon atmosphere protection.

5. A diffusion sheet processed using the method of claim 1, characterized in that: The diffuser sheet is integrally formed, and multiple pits are distributed on both end faces of the diffuser sheet. Neither end face of the diffuser sheet is coated. The material of the diffuser sheet is resin or glass.

6. The diffusion sheet processed according to the method of claim 5, characterized in that: The pit is hemispherical.

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