Manufacturing and processing technology of light guide plate with double patterns

Abstract

The invention discloses a manufacturing and processing technology of a light guide plate with double patterns. The manufacturing and processing technology comprises the following steps: (1) preparing a light guide plate material; cutting according to each specification of each inch, and manufacturing a small plate according to the specification through mirror surface processing; (2) engraving the module by using a laser engraving machine to form a circular pattern template with circular salient points on the surface; (3) manufacturing a pattern engraving template; (4) a concave hole template in a positive carving shape is manufactured; (5) the circular pattern template and the embossed concave hole template are installed on the outer wall face of a winding drum corresponding to the coining device; and (6) conveying the light guide plate body along a conveying channel of the imprinting device, and forming a plurality of circular concave spots and concave holes on the bottom surface of the light guide plate body. The light guide plate can be continuously machined at a time, a plurality of round concave points and a plurality of semicircular concave holes are formed in the bottom face of the light guide plate, machining efficiency is high, the effect is good, and the device is suitable for mass production.

Description

Technical field:

[0001] The present invention relates to the technical field of optical accessories, and more specifically to a manufacturing process of a light guide plate with double patterns and an imprinting device thereof. Background technology:

[0002] At present, commercial light guide plates have a single pattern, and it is difficult to further improve the brightness under backlight. The light generated by the LED light source located in the backlight is basically fully reflected, passing through the light guide plate, and the pattern of the light guide plate generates light scattering, which is emitted outside the light guide plate.

[0003] The illumination structure of the existing lamp is that the bottom is a reflective sheet, above which are a light guide plate, a diffuser, and above that a prism sheet, which ultimately form the backlight brightness through their respective functions.

[0004] In order to meet the need for high backlight brightness by limiting power consumption, some parts need to minimize the brightness of the module, so there is a situation where the brightness is maximized in the backlight components. There are many parts required in the backlight, among which it is necessary to ensure brightness through the pattern density and shape design of the light guide plate that emits light from the light source evenly.

[0005] At present, the pattern of the light guide plate generally manufactured is a technology with only a single pattern, and the reflection amount of the LED light source is limited, so it is difficult to further improve the brightness. Therefore, it can be changed to a double pattern instead of a single pattern, thereby increasing the brightness transmitted from the backlight by maximizing the LED radiation angle.

[0006] According to research, forming deeper concave holes on the bottom surface of the light guide plate can increase the refraction angle of the light source while maintaining the overall uniformity of the screen. Through the software simulation results of the Light tool, it is confirmed that the uniformity of the screen with a semicircular shape is 80%, the number of Rays is 10KK standard, and the brightness efficiency is about 10.6%. The light guide plate with circular concave points and semicircular concave holes was tested. The upper surface of the light guide plate is a lens-shaped pattern (the surface of the unprocessed light guide plate is a lens-shaped pattern). After many tests, the experimental result of a 10% increase in brightness efficiency compared with a single pattern was obtained.

[0007] However, it is necessary to form two patterns of concave holes on the bottom surface of the light guide plate. The concave holes of the existing light guide plates are all formed by laser processing and engraving. However, laser engraving has high cost and low processing efficiency. In addition, two patterns need to be processed by laser engraving twice, which greatly increases the difficulty, low efficiency, and difficulty in mass production. Summary of the invention:

[0008] The purpose of the present invention is to overcome the shortcomings of the prior art and provide a manufacturing process for a double-pattern light guide plate, which can continuously process the light guide plate at one time so that a plurality of circular concave points and a plurality of semicircular concave holes are formed on its bottom surface. The processing efficiency is high, the effect is good, and it is suitable for mass production.

[0009] The solution of the present invention to solve the technical problem is:

[0010] A manufacturing process for a light guide plate with a double pattern, comprising the following steps:

[0011] (1) Prepare the light guide plate material. Cut it according to the specifications of each inch, and make small plates according to the specifications through mirror processing;

[0012] (2) Using a laser engraving machine to engrave a circular pattern template with circular convex points on the surface of the module;

[0013] (3) Making a template for engraving patterns;

[0014] (4) making a recessed hole template in a positive shape;

[0015] (5) Installing the circular pattern template and the positive-engraved concave hole template on the outer wall surface of the corresponding roll of the imprinting device;

[0016] (6) The light guide plate body is transported along the transport channel of the stamping device, and a plurality of circular concave spots and concave holes are formed on the bottom surface thereof.

[0017] The manufacturing process of the engraved pattern template is to use a semicircular module to engrave on the surface of the template to make an intaglio-shaped semicircular concave hole template.

[0018] The process of making the positive-carved concave hole template is to use a casting process to make a positive-carved concave hole template with semicircular protrusions on the semicircular concave hole template.

[0019] In the step (6), the roll temperature in the embossing device is controlled at 90 degrees Celsius to 110 degrees Celsius.

[0020] The surface of the recessed hole template is electroplated with a nickel material layer.

[0021] The top surface of the semicircular protrusion of the concave hole template is a semispherical surface.

[0022] The stamping device includes a frame, a first roller is installed on the upper left side of the frame, a second roller is installed on the upper right side of the frame, a third roller is installed on the lower left side of the frame, and a fourth roller is installed on the lower right side of the frame. The first roller is close to the second roller, the fourth roller is close to the third roller, the first roller is directly above the third roller, the second roller is directly above the fourth roller, a first channel is formed between the first roller and the third roller, a second channel is formed between the second roller and the fourth roller, and the first channel is aligned left and right with the second channel and is connected.

[0023] The top surface of the circular pattern template is formed with a hemispherical protrusion, the height of which is 5 μm to 9 μm.

[0024] A plurality of mounting grooves are formed on the outer side walls of the first roller, the second roller, the third roller and the fourth roller. The circular pattern template is installed in the corresponding mounting groove of the fourth roller, and the hemispherical protrusion of the circular pattern template extends out of the outer side wall of the fourth roller. The concave hole template is installed in the corresponding mounting groove of the third roller, and its semicircular protrusion extends out of the outer side wall of the third roller.

[0025] The outer wall surface of the module installed at the installation groove of the first roller and the second roller is a smooth surface, which is located on the same cylindrical side wall as the outer side wall of the first roller.

[0026] The outstanding effects of the present invention are:

[0027] The light guide plate can be processed continuously at one time, so that a plurality of circular concave points and a plurality of semicircular concave holes are formed on the bottom surface thereof. The processing efficiency is high, the effect is good, and the light guide plate is suitable for mass production. Description of the drawings:

[0028] Figure 1 is a partial schematic diagram of a light guide plate made by the present invention;

[0029] Figure 2 It is a schematic diagram of reflection of the light guide plate made by the present invention after being irradiated with light;

[0030] Figure 3 It is a partial structural schematic diagram of an imprinting device used for manufacturing a light guide plate;

[0031] Figure 4 It is a simplified schematic diagram of the operation of four rollers and light guide plate;

[0032] Figure 5 It is a partial cross-sectional view of the concave hole template;

[0033] Figure 6 It is a partial cross-sectional view of a circular pattern template. Specific implementation method:

[0034] For example, see Figures 1 to 6As shown, a manufacturing process of a light guide plate with a double pattern includes the following steps:

[0035] (1) Prepare the light guide plate material. Cut it according to the specifications of each inch, and make small plates according to the specifications through mirror processing; this process can adopt the existing process.

[0036] (2) Using a laser engraving machine to engrave a circular pattern template with circular convex points on the surface of the module; this process can adopt existing technology.

[0037] (3) Making a template for engraving patterns;

[0038] (4) making a recessed hole template in a positive shape;

[0039] (5) Installing the circular pattern template and the positive-engraved concave hole template on the outer wall surface of the corresponding roll of the imprinting device;

[0040] (6) The light guide plate body is transported along the transport channel of the stamping device, and a plurality of circular concave spots and concave holes are formed on the bottom surface thereof.

[0041] Furthermore, the manufacturing process of the engraved pattern template is to use a semicircular module to engrave on the surface of the template to make an intaglio-shaped semicircular concave hole template.

[0042] Furthermore, the process of making the positive-engraved concave hole template is to use a casting process to make a positive-engraved concave hole template with semicircular protrusions on the semicircular concave hole template, such as fixing a frame portion on the edge of the semicircular concave hole template, pouring casting materials such as molten metal into the frame portion and the semicircular concave holes of the concave hole template corresponding to the frame portion, and then covering the top surface of the frame portion with a cover plate. After cooling and demolding, the positive-engraved concave hole template is made.

[0043] Furthermore, in step (6), the temperature of the roll in the embossing device is controlled at 90 degrees Celsius to 110 degrees Celsius. In this embodiment, 100 degrees Celsius is used.

[0044] Furthermore, the surface of the recessed hole template is electroplated with a nickel material layer.

[0045] Furthermore, the top surface of the semicircular protrusion of the concave hole template is a semispherical surface.

[0046] Further, the stamping device includes a frame 100, a first roller 110 is installed on the upper left side of the frame 100, a second roller 120 is installed on the upper right side of the frame 100, a third roller 130 is installed on the lower left side of the frame 100, and a fourth roller 140 is installed on the lower right side of the frame 100. The first roller 110 is close to the second roller 120, and the fourth roller 140 is close to the third roller 130. The first roller 110 is directly above the third roller 130, and the second roller 120 is directly above the fourth roller 140. A first channel is formed between the first roller 110 and the third roller 130, and a second channel is formed between the second roller 120 and the fourth roller 140. The first channel is aligned left and right with the second channel and is connected. The first roller 110, the second roller 120, the third roller 130 and the fourth roller 140 can be driven to rotate individually by corresponding motors, or the ends of the rotating shafts of the first roller 110, the second roller 120, the third roller 130 and the fourth roller 140 can be fixed with transmission gears, a first reduction motor is fixed on the upper part of the frame, and a second reduction motor is fixed on the lower part, and driving gears are fixed on the first reduction motor and the second reduction motor, and the driving gears of the first reduction motor are meshed with the transmission gears of the first roller 110 and the second roller 120, and the driving gears of the second reduction motor are meshed with the transmission gears of the third roller 130 and the fourth roller 140, so as to adopt dual motor drive.

[0047] Furthermore, the top surface of the circular pattern template forms a hemispherical protrusion with a height of 5μm to 9μm. In this embodiment, 7μm is used, which is based on the fact that the height of the circular protrusion formed in the hot pressing is about 7μm, and the height of the formed light guide plate mesh is 2μm. It can be inferred that the pattern forming rate is about 25%. Therefore, the circular protrusion with a height of about 7μm can form a circular concave point with a height of 2μm, and the circular concave point of 2μm meets the design requirements.

[0048] Furthermore, a plurality of mounting grooves 150 are formed on the outer walls of the first roller 110, the second roller 120, the third roller 130 and the fourth roller 140, the circular pattern template is installed in the corresponding mounting groove 150 of the fourth roller 140, and the hemispherical protrusion of the circular pattern template extends out of the outer wall of the fourth roller 140, and the concave hole template is installed in the corresponding mounting groove 150 of the third roller 130, and its semicircular protrusion extends out of the outer wall of the third roller 130.

[0049] Furthermore, the outer wall surface of the module installed in the installation groove 150 of the first roller 110 and the second roller 120 is a smooth surface, which is on the same cylindrical side wall as the outer side wall of the first roller 110 or the second roller 120 . Figure 3 and Figure 4 No corresponding module, circular pattern template or concave hole template is installed in the installation groove 150.

[0050] Among them, screw holes are formed on the inner wall surfaces of the installation grooves 150 of the first roller 110, the second roller 120, the third roller 130 and the fourth roller 140, so that the concave hole template, the circular pattern template and the module can be inserted into the corresponding installation grooves 150 and then fixed by bolts, which is convenient for installation and disassembly.

[0051] When in use, the light guide plate enters from the first channel, and first passes through the first roller 110 and the third roller 130. The module of the first roller 110 embosses the top surface of the light guide plate, and the concave hole template of the third roller 130 embosses the bottom surface of the light guide plate with semicircular concave holes 12. Then, the light guide plate enters the second channel, and the module of the second roller 120 embosses the top surface of the light guide plate, and the circular pattern template of the fourth roller 140 embosses the bottom surface of the light guide plate with circular concave points 11. Then, the light guide plate is input. The embossing temperature is 100°C.

[0052] It adopts continuous hot pressing process to make it possible to continuously process the light guide plate and form it in one step. It has high processing efficiency and good effect and is suitable for mass production.

[0053] The bottom surface of the light guide plate body 10 manufactured in this embodiment is formed with a plurality of circular concave spots 11 extending upward and a plurality of concave holes 12. The top surface of the concave holes 12 is larger than the top surface of the circular concave spots 11.

[0054] One side wall of the concave hole 12 is a vertically extending arc-shaped side wall, and the other wall surfaces are spherical wall surfaces, that is, its top surface is a spherical wall surface, and the bottom surface of the spherical wall surface extends downward to the bottom surface of the light guide plate body 10, which is a semicircular concave hole. The circular concave points 11 and the concave holes 12 are arranged in such a way that a plurality of circular concave points 11 are arranged in a row of concave points, and a plurality of concave holes 12 are arranged in a row of concave holes, and a row of concave holes is provided between each two adjacent rows of concave points. The circular concave points 11 and the concave holes 12 are arranged in an alternating manner, and in an adjacent row of concave points and a row of concave holes, the concave holes 12 are located in a row of concave holes on one side between the corresponding two circular concave points 11. The depth of the circular concave points 11 is about 2 μm.

[0055] like Figure 2 As shown, the added concave hole 12 in this embodiment is a semicircular concave hole, and the remaining wall surface is an arc-shaped wall surface, whose area is larger than the wall surface of the circular concave point 11, so that the range of the light source reflected and outputted is widened. In addition, the light refracted by the inner wall surface of the concave hole 12 will become a viewing angle, generating an additional light source, and the figure shows a new viewing angle extending to the right. According to the illumination needs, this concave hole 12 can improve the need for reflection to the upper right. And as Figure 2 As shown, during the extrusion molding process, a convex portion ( Figure 2In order to show the reflection line at the raised part, some shadows are not filled). Therefore, the top surface of the circular pattern template between two adjacent hemispherical protrusions of the corresponding circular pattern template is formed with an arc groove, such as Figure 6 shown.

Claims

1. A manufacturing process for a light guide plate with a double pattern, characterized in that: It includes the following steps: (1) Prepare the light guide plate material. Cut it according to the specifications of each inch, and make small plates according to the specifications through mirror processing; (2) Using a laser engraving machine to engrave a circular pattern template with circular convex points on the surface of the module; (3) Making a template for engraving patterns; (4) making a recessed hole template in a positive shape; (5) Installing the circular pattern template and the positive-engraved concave hole template on the outer wall surface of the corresponding roll of the imprinting device; (6) The light guide plate body is transported along the transport channel of the stamping device, and a plurality of circular concave spots and concave holes are formed on the bottom surface thereof.

2. The manufacturing process of a light guide plate with double patterns according to claim 1, characterized in that: The manufacturing process of the engraved pattern template is to use a semicircular module to engrave on the surface of the template to make an intaglio-shaped semicircular concave hole template.

3. The manufacturing process of a double-patterned light guide plate according to claim 1, characterized in that: The process of making the positive-carved concave hole template is to use a casting process to make a positive-carved concave hole template with semicircular protrusions on the semicircular concave hole template.

4. The manufacturing process of a double-patterned light guide plate according to claim 1, characterized in that: In the step (6), the roll temperature in the embossing device is controlled at 90 degrees Celsius to 110 degrees Celsius.

5. The manufacturing process of a light guide plate with double patterns according to claim 1, characterized in that: The surface of the recessed hole template is electroplated with a nickel material layer.

6. The high brightness light guide plate with two pattern shapes according to claim 1, characterized in that: The top surface of the semicircular protrusion of the concave hole template is a semispherical surface.

7. The high brightness light guide plate with two pattern shapes according to claim 1, characterized in that: The stamping device includes a frame, a first roller is installed on the upper left side of the frame, a second roller is installed on the upper right side of the frame, a third roller is installed on the lower left side of the frame, and a fourth roller is installed on the lower right side of the frame. The first roller is close to the second roller, the fourth roller is close to the third roller, the first roller is directly above the third roller, the second roller is directly above the fourth roller, a first channel is formed between the first roller and the third roller, a second channel is formed between the second roller and the fourth roller, and the first channel is aligned left and right with the second channel and is connected.

8. The high brightness light guide plate with two pattern shapes according to claim 1, characterized in that: The top surface of the circular pattern template is formed with a hemispherical protrusion, the height of which is 5 μm to 9 μm.

9. The high brightness light guide plate with two pattern shapes according to claim 7, characterized in that: A plurality of mounting grooves are formed on the outer side walls of the first roller, the second roller, the third roller and the fourth roller. The circular pattern template is installed in the corresponding mounting groove of the fourth roller, and the hemispherical protrusion of the circular pattern template extends out of the outer side wall of the fourth roller. The concave hole template is installed in the corresponding mounting groove of the third roller, and its semicircular protrusion extends out of the outer side wall of the third roller.

10. The high brightness light guide plate with two pattern shapes according to claim 7, characterized in that: The outer wall surface of the module installed at the installation groove of the first roller and the second roller is a smooth surface, which is located on the same cylindrical side wall as the outer side wall of the first roller.

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