Diffraction Grating Mold Manufacturing via Mask Film Segmentation
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Solution Overview
Problem
The existing methods for manufacturing diffraction grating light guide plates face challenges such as damage to mold bases during the mask etching process due to thermal deformation or insufficient attachment force between the mask film and the mold base, and the need for frequent changes in mask films to form different diffraction grating patterns.
Innovation Solution
A method involving the use of a Faraday cage with a mesh part for plasma etching, where a first mask film with specific adhesive properties is attached to a molding base, allowing for the formation of pattern portions in independent regions with controlled etching rates and orientations, reducing the risk of thermal damage and improving pattern precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mask etching process is used to form diffraction grating patterns on mold base, then diffraction grating patterns can be formed, but the mold base is damaged due to thermal deformation or insufficient attachment force between mask film and mold base
Solution Approach 1:
The patent changes the physical and chemical parameters of the mask film by selecting materials with specific glass transition temperatures (70-100°C for the base, 230-350°C for the adhesive layer) and adhesive forces (30-50 gf/in). These parameter changes enable the mask film to withstand plasma etching conditions without thermal deformation while maintaining reliable attachment to the mold base, thus resolving the contradiction between pattern formation precision and mold base integrity
Solution Approach 2:
The patent uses a composite mask film structure consisting of a base layer and an adhesive layer made of different materials with complementary properties. The base layer (e.g., polyethylene terephthalate or polypropylene) provides thermal stability, while the adhesive layer (e.g., acrylic or silicone rubber) provides strong attachment force. This composite structure resolves the contradiction by combining materials that individually address different requirements
2Adaptability or versatility
If different mask films are used to form different diffraction grating patterns, then various patterns can be manufactured, but the manufacturing process becomes complex and time-consuming due to frequent mask film changes
Solution Approach 1:
The patent segments the mask film into a reusable base layer and a consumable adhesive layer. The base layer maintains its structural integrity and can be reused for multiple patterning operations, while only the adhesive layer needs to be replaced when changing patterns. This segmentation resolves the contradiction by enabling pattern variety through simple adhesive layer changes rather than complete mask film replacements, thus maintaining manufacturing efficiency
Solution Approach 2:
The patent performs preliminary action by pre-forming the base layer with high thermal stability and attachment properties before the actual patterning process. This pre-prepared base layer can then be used repeatedly with different adhesive layers for various patterns, eliminating the need to reprepare the entire mask film for each pattern change and thereby improving productivity while maintaining versatility
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method efficiently manufactures molds with various pattern portions on the surface, reducing the risk of thermal deformation and adhesive residue, while allowing for precise control over etching rates and orientations, thereby enhancing the manufacturing efficiency and quality of diffraction grating light guide plates.
Implementation Method 1
forming, by using plasma etching, a first pattern portion in a first region of one surface of the molding base
Data Source
AI summary
The present invention relates to a method of manufacturing a mold for a diffraction grating light guide plate by using two mask films, the mold having first to fourth pattern portions provided on one surface thereof, and to a method of manufacturing a diffraction grating light guide plate.