Precise Extrusion Apparatus for Light Guide Plate Warpage Reduction
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Solution Overview
Problem
The existing injection molding process for light guide plates results in residual stress due to flow stress, thermal stress, and uneven shrinkage, leading to deformation and dimensional inaccuracies in the finished product.
Innovation Solution
A precise extrusion and transfer apparatus is developed, comprising a feed hopper, dehumidifying and drying device, screw conveyor, screw extrusion device, and control switch, which includes precise roller bearings and a winding roller with a soft film, enabling one-step molding of ultra-thin light guide films with improved temperature control and material handling to reduce warpage and enhance production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding process is used to manufacture light guide plates, then production efficiency is improved, but residual stress causes deformation and dimensional inaccuracies
Solution Approach 1:
The patent changes the fundamental processing parameters by switching from injection molding to extrusion molding. This parameter change eliminates the flow stress and thermal stress issues inherent in injection molding, thereby preventing residual stress and deformation while maintaining high production efficiency through continuous extrusion processing.
Solution Approach 2:
The patent extracts and removes the problematic injection molding process step, replacing it with extrusion molding. By taking out the harmful process (injection molding that causes residual stress), the patent achieves both high productivity and dimensional accuracy without the adverse effects of the original process.
2Productivity
If injection molding process is used to manufacture light guide plates, then production efficiency is improved, but residual stress leads to warpage of the product
Solution Approach 1:
The patent changes the processing method from injection molding to extrusion molding, fundamentally altering the stress distribution parameters during manufacturing. This parameter change eliminates the causes of warpage (flow stress and thermal stress) while maintaining continuous production capability for high efficiency.
Solution Approach 2:
The patent converts the potential harm of residual stress into benefit by using extrusion molding, which creates more uniform stress distribution. The continuous extrusion process allows for better stress control and eliminates the sudden pressure changes in injection molding, turning a previously harmful process into a beneficial one that produces flat, warp-free light guide plates.
3Manufacturing precision
If traditional molding process is used, then production cycle is long, but product quality can be maintained
Solution Approach 1:
The patent implements continuous extrusion molding that operates without interruption, eliminating the repeated heating, injection, cooling, and ejection cycles of traditional injection molding. This continuous action maintains product quality through consistent processing parameters while dramatically reducing production cycle time.
Solution Approach 2:
The patent performs preliminary drying of the acrylic resin material before extrusion, preventing moisture-related defects and eliminating the need for post-processing drying steps. This preliminary action ensures product quality while reducing overall production time by consolidating process steps.
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
The apparatus allows for the production of ultra-thin, high-quality light guide films with improved brightness and light transmittance, reducing production costs and cycle time, and enhancing market competitiveness by overcoming warpage issues and improving production efficiency.
Implementation Method 1
dehumidifying and drying device
Implementation Method 2
dehumidifying and drying device
Implementation Method 3
screw extrusion device
Implementation Method 4
screw extrusion device
Implementation Method 5
screw extrusion device
Implementation Method 6
first precise roller bearings and second precise roller bearing
Data Source
AI summary
The present invention discloses a precise extrusion and transfer apparatus for light guide plate production, including: a feed hopper; a dehumidifying and drying device; a screw conveyor fixedly mounted on one side of the outer wall of the dehumidifying and drying device; a screw extrusion device; and a molding box fixedly mounted with first motors and a second motor on one side of the outer wall by means of bolts, where power output ends of two sets of first motors pass through the molding box and are fixedly mounted with first precise roller bearings by means of rotating shafts, and a power output end of the second motor passes through the molding box and is fixedly mounted with a second precise roller bearing by means of a rotating shaft. According to the present invention, one-step molding from a particle base material to a finished light guide film is implemented, the problem of warpage is overcome, the production efficiency is improved, and the production cycle can be shortened to 1 s; and the product is thinner and can be as thin as 80 μm, the production costs such as material consumption and labor are greatly reduced, key indicators of the product such as brightness and light transmittance of the light guide film are comprehensively improved, and the advantages in quality and costs are enabled in fierce market competition.