Manufacturing method of optical light guide microstructure

Abstract

The invention relates to the technical field of manufacturing methods of optical light guide microstructures, in particular to a micro texture manufacturing method of a light guide diaphragm, an optical structure comprises a shading bottom layer, a light guide layer and a surface layer, and the manufacturing method comprises the following steps that S1, texture holes are punched in the surface layer; s2, the surface layer and the light guide layer are attached to form an assembly; s3, the assembly is turned over, and the surface layer is located on the lower portion; s4, the assembly is flattened and laid on a supporting table top; s5, an area light source is arranged on the supporting table top, and light rays pass through the holes in the surface layer; s6, a CCD camera is adopted above the assembly for photographing, and the relative positions of the holes in the surface layer and the reference coordinates are obtained; s7, corresponding textures are processed on the light guide layer, and the textures on the light guide layer and the texture holes in the surface layer are processed according to the same size; s8, checking the integrity of the micro textures; and S9, adhering a bottom layer to one side, deviating from the surface layer, of the light guide layer. After the light guide layer and the surface layer are bonded together, the texture of the light guide layer is manufactured, and the light utilization rate can be well increased.

Description

Technical Field

[0001] The present invention relates to the technical field of manufacturing methods for microstructures of optical light guide diaphragms, and particularly to a manufacturing method for microstructures of optical light guide diaphragms for interior and exterior automotive decorations. Background Art

[0002] The decorative parts in this solution refer to the parts that emit light through the textures of the light guide layer and the surface layer.

[0003] Such as Figure 1 , currently, there are two common structural forms for common light-emitting parts: one is to use a light guide layer, make textures on the light guide layer, and cover the light guide layer with a surface layer material corresponding to the textures. The light can pass through the textures on the light guide layer and the surface layer to form a light-emitting image effect; the other is to use multiple independent optical fibers for light guiding and cover a light-transmitting surface layer to form a decorative light-emitting pattern effect.

[0004] For the majority using the first structure, the traditional production process is to first press the reflective textures on the light guide layer and the surface layer, and then bond the surface layer, the light guide layer, and the light-shielding bottom layer together in sequence; since both the light guide layer and the surface layer are flexible materials, due to the thermal expansion and contraction caused by the environmental temperature and the influence of the force applied during the bonding process, it is easy to cause deviations in the textures on the light guide layer and the surface layer; the traditional solution is to make the texture area on the light guide layer larger. Usually, the diameter of the texture on the light guide layer is 8 mm larger than the diameter of the texture on the surface layer; after the texture on the light guide layer is increased, the utilization rate of light will be reduced.

[0005] There is an urgent need to provide a better solution to solve the above technical problems. Summary of the Invention

[0006] Based on the above description, the present invention provides a method for making micro-textures to solve the situation where the diameter of the texture on the traditional light guide layer is much larger than the diameter of the light-transmitting holes on the surface layer, resulting in too low light utilization rate.

[0007] The technical solution of the present invention to solve the above technical problems is as follows: A method for making light-emitting micro-textures, the part includes a light-shielding bottom layer, a light guide layer, and a surface layer, and includes the following steps: S1. According to the texture to be processed, punch holes on the surface layer, and the hole diameter is 1 - 1.5 mm; S2. Bond the surface layer to the light guide layer to form an assembly; at this time, the light guide layer has not been textured yet; S3. Flip the assembly so that the surface layer is located below; S4. Naturally flatten the assembly and lay it on the support tabletop; S5. Set a surface light source on the support tabletop, and the surface of the light source device shall not protrude above the support tabletop, and make the light pass through the holes on the surface layer; S6. Fix the assembly on the support tabletop, and use a CCD camera to take pictures above the assembly to obtain the relative positions of the holes on the surface layer and the reference coordinates. S7. Process corresponding textures on the light guide layer, and the textures on the light guide layer are processed in the same size as the texture holes on the surface layer. S8. Check the integrity of the micro-textures. S9. Bond a light-shielding bottom layer on the side of the light guide layer facing away from the surface layer.

[0008] Through the above technical solutions, the texture holes on the surface layer and the textures on the light guide layer can be made the same size; moreover, during processing, the surface layer and the light guide layer are laid flat on the tabletop as an assembly naturally, so that the influence of external forces on the deformation of the material is small, and the adhesive layer between the surface layer and the light guide layer can be subjected to the same force, further avoiding the relative displacement of the textures on the surface layer and the light guide layer. In this solution, the diameters of the texture holes on the surface layer and the textures on the light guide layer are both 1 - 1.5 mm. According to the traditional process, the diameter of the texture on the light guide layer should be 9 - 9.5 mm, and the area ratio of light consumption is 81:1 to 90.25:2.25, greatly increasing the utilization rate of light.

[0009] Based on the above technical solutions, the present invention can be further improved as follows.

[0010] Further, low refractive index coatings are applied on both the upper and lower sides of the light guide layer.

[0011] Through the above technical solutions, the low refractive index coatings can preferably avoid the light loss caused by light refraction.

[0012] Further, a plurality of surface light sources are provided, and the plurality of surface light sources can be switched on and off independently.

[0013] Further, cover the edge of the assembly with a sealing film, and evacuate the gas between the sealing film and the assembly and the support tabletop.

[0014] Further, the method for checking the integrity of the micro-textures includes the following steps: S801. Turn the processed assembly over so that the surface layer is on the top, turn off the surface light source, and apply a light source to the light guide layer. S802. Automatically move the CCD camera above a certain hole position and obtain the relative position K1 of the hole and the reference coordinates. S803. Automatically move the CCD camera above another adjacent hole position and obtain the relative position K2 of the hole and the reference coordinates. S804. Send the complete hole map of the micro-textures to the control system that controls the movement of the CCD camera, and mark the above two points in sequence. S805. Calculate the vector direction S1 from K1 to K2, compare the value with the theoretical vector direction S0, and calculate the coordinates of all hole positions with hole K1 as the reference. S806. The CCD camera traverses all coordinate points to take pictures, checks whether there are bright spots, and records the bright spot status of the coordinate points. At the coordinate points with bright spots, the CCD camera can align the microstructures at the bottom of the upper light-emitting holes in combination with the position information of the micro-textures.

[0015] Furthermore, the surface layer is made of suede.

[0016] Furthermore, the light-shielding bottom layer is a black-bottom silver-surface cloth, and the black-bottom side is arranged close to the light guide layer.

[0017] In the above technical solution, the black-bottom silver-surface cloth is used to reflect light, and in cooperation with the light reflection of the surface layer, the light is kept moving in the light guide layer.

[0018] Compared with the prior art, the technical solution of the present application has the following beneficial technical effects: 1. After bonding the light guide layer to the surface layer, the texture on the light guide layer is processed. The texture diameter of the light guide layer can be made the same as the texture aperture of the surface layer, which can greatly improve the utilization rate of light.

[0019] 2. By using the CCD camera and combining the position information of the holes, the upper light-emitting holes and the bottom microstructures can be aligned. Description of the Drawings

[0020] Figure 1 It is a schematic diagram of the layer structure of the existing light-emitting part; Figure 2 It is a schematic flowchart of a method for manufacturing a light-emitting part according to an embodiment of the present invention; Figure 3 It is a schematic flowchart of a method for inspecting the position of the micro-texture in a method for manufacturing a light-emitting part according to an embodiment of the present invention; Figure 4 It is a schematic diagram of the layer structure of a light-emitting part according to an embodiment of the present invention; Figure 5 It is a schematic diagram of the structure of a light guide column according to an embodiment of the present invention; Figure 6 It is a schematic diagram of the texture processing on the light guide layer according to an embodiment of the present invention; Figure 7 It is a schematic diagram of the texture processing on the light guide layer according to an embodiment of the present invention.

[0021] Reference numerals: 1. Light-shielding bottom layer; 2. Light guide layer; 3. Surface layer; 4. CCD camera; 5. Light guide column; 6. Surface light source; 7. Support table; 8. Sealing edge film. Detailed Embodiments

[0022] To facilitate the understanding of this application, the following will provide a more comprehensive description of this application with reference to the relevant drawings. Embodiments of this application are shown in the drawings. However, this application can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, these embodiments are provided to make the disclosure of this application more thorough and comprehensive.

[0023] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the technical field to which this application belongs. The terms used in the specification of this application herein are only for the purpose of describing specific embodiments and are not intended to limit this application.

[0024] Embodiment: Reference Figures 1-7 , a method for manufacturing micro-textures of a light-emitting part, the light-emitting part includes a light-shielding bottom layer 1, a light guide layer 2 and a surface layer 3, and includes the following steps: S1. According to the texture to be processed, punch holes on the surface layer 3, and the hole diameter is 1 - 1.5 mm; Preferably 1 mm, the texture is composed of a plurality of holes, and the hole punching operation on the surface layer 3 can be processed by laser, stamping or engraving; S2. Attach the surface layer 3 to the light guide layer 2 to form an assembly; at this time, the light guide layer 2 has not been textured yet; low refractive index coatings are applied to both the upper and lower surfaces of the light guide layer 2; regarding the attachment of the light guide layer 2 and the surface layer 3, preferably, PUR glue is used for bonding; S3. Flip the assembly so that the surface layer 3 is located below; S4. Naturally flatten the assembly and lay it on the support table 7; cover the edge of the assembly with a sealing film 8, and evacuate the gas between the sealing film 8 and the assembly and the support table 7, and use air pressure to fix the assembly to the support table 7. Since the air pressure is evenly applied to the assembly instead of pulling, stretching or squeezing the assembly, deformation caused by external forces is avoided; S5. Set a surface light source 6 on the support table 7, and the surface of the light source device shall not be higher than the support table 7, and make the light pass through the holes on the surface layer 3; S6. Fix the assembly on the support table 7, and take a photo above the assembly with a CCD camera 4 to obtain the relative position between the hole positions on the surface layer 3 and the reference coordinates; S7. Process corresponding textures on the light guide layer 2, and the textures on the light guide layer 2 are processed according to the same size as the texture holes on the surface layer 3; S8. Check the integrity of the micro-textures; S9. Bond a light-shielding bottom layer 1 on the side of the light guide layer 2 facing away from the surface layer 3.

[0025] Preferably, the surface layer 3 is made of suede, ultra-fine fiber fabric, cloth or silicone leather.

[0026] Preferably, the light-shielding bottom layer 1 is a black-bottom silver-surface cloth, and the black-bottom side is arranged close to the light guide layer 2.

[0027] Furthermore, the method for inspecting the integrity of the micro-texture includes the following steps: S801: Turn the assembled unit after processing so that the surface layer 3 is on the top, turn off the surface light source 6, and apply a light source to the light guide layer 2. S802: Automatically move the CCD camera 4 above a certain hole position and obtain the relative position K1 of this hole and the reference coordinate. S803: Automatically move the CCD camera 4 above another adjacent hole position and obtain the relative position K2 of this hole and the reference coordinate. S804: Send the complete hole map of the micro-texture to the control system that controls the movement of the CCD camera 4, and mark the above two points in sequence. S805: Calculate the vector direction S1 from the actual K1 to K2, compare the value with the theoretical vector direction S0, and calculate the coordinates of all hole positions with hole K1 as the reference. S806: The CCD camera 4 traverses all coordinate points to take pictures, obtain whether there are bright spots, and record the bright spot status of the coordinate points; if there is a bright spot at the coordinate point, the texture holes of the light guide layer 2 and the texture holes of the surface layer 3 are qualified; if there is no bright spot, it is unqualified.

[0028] Preferably, multiple surface light sources 6 can be set as needed, and multiple surface light sources 6 can be individually turned on and off. Preferably, the circumferential surfaces of multiple light guide columns 5 are closely arranged in contact, and multiple dot light sources at the end faces form a surface light source 6. Preferably, the diameter of the light guide column 5 is 2.5 - 3 mm, and the circumferential surface of the light guide column 5 is covered with a light-shielding material.

[0029] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A method for manufacturing an optical light-guiding microstructure, wherein the product comprises a light-shielding bottom layer, a light-guiding layer and a surface layer, characterized in that: The steps include: S1. According to the texture to be processed, punch holes on the surface layer with a hole diameter of 1-1.5mm; S2, laminating the surface layer to the light guide layer to form an assembly; at this time, the light guide layer is not textured; S3, turn the assembly over so that the surface layer is at the bottom; S4. Flatten the assembly naturally and lay it on the supporting table; S5. Set up a surface light source on the support table. The surface of the light source equipment shall not be higher than the support table, and the light shall pass through the holes on the surface layer; S6. Fix the assembly on the support table, take a picture with a CCD camera above the assembly, and obtain the relative position of the hole on the surface layer and the reference coordinate; S7, processing a corresponding texture on the light guide layer, and the texture holes on the light guide layer and the texture holes on the surface layer are processed in the same size; S8. Check the integrity of the microtexture; S9, bonding a light-shielding bottom layer to the side of the light-guiding layer facing away from the surface layer.

2. The method for manufacturing an optical light-guiding microstructure according to claim 1, characterized in that: The light-guiding layer is coated with low-refractive-index coatings on both the upper and lower sides.

3. The method for manufacturing an optical light-guiding microstructure according to claim 1, characterized in that: A plurality of the surface light sources are provided, and the plurality of the surface light sources can be switched on and off individually.

4. The method for manufacturing an optical light-guiding microstructure according to claim 3, characterized in that: The texture is composed of a plurality of pores; The circumferential surfaces of multiple light guides are closely arranged, and multiple point light sources on the end surfaces form a surface light source; The diameter of the light guide column is 2.5-3 mm, and the circumferential surface of the light guide column is covered with light-shielding material.

5. The method for manufacturing an optical light-guiding microstructure according to claim 1, characterized in that: The edge of the assembly is covered with an edge-sealing film, and the air between the edge-sealing film and the assembly and the supporting table is evacuated.

6. The method for manufacturing an optical light-guiding microstructure according to claim 1, characterized in that: The method for checking the integrity of microtexture comprises the following steps: S801, turning over the processed assembly so that the surface layer is on the top, turning off the surface light source, and applying light to the light guide layer; S802, manually move the CCD camera to a certain hole position, and obtain the relative position K1 of the hole and the reference coordinate; S803, manually move the CCD camera to above another adjacent hole position, and obtain the relative position K2 of the hole and the reference coordinate; S804, sending the complete hole position map of the micro texture to the control system that controls the movement of the CCD camera, and marking the above two points in sequence; S805, calculating the actual vector direction S1 from K1 to K2, and comparing the value with the theoretical vector direction S0, and taking hole K1 as a reference, calculating the coordinates of all hole positions; S806, the CCD camera traverses all coordinate points to take pictures, obtains whether there is a bright spot, and records the bright spot status of the coordinate point; if there is a bright spot at the coordinate point, the texture hole of the light guide layer and the texture hole of the surface layer are qualified; if there is no bright spot, it is unqualified.

7. The method for manufacturing an optical light-guiding microstructure according to claim 1, characterized in that: The surface layer is made of suede.

8. The method for manufacturing an optical light-guiding microstructure according to claim 1, characterized in that: The light-shielding bottom layer is a black-bottom silver-surface cloth, and one side of the black-bottom is arranged close to the light-guiding layer.

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