Film-Type Light Guide Plate UV Curing Mass Production
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Solution Overview
Problem
Conventional light guide plates face challenges in mass production due to high manufacturing costs, labor-intensive mold creation, and limitations in achieving lightweight and thin designs, making it difficult to meet the demands for miniaturization and slimness in display devices.
Innovation Solution
A film-type light guide plate is manufactured using a base film coated with ultraviolet curable resin, featuring a prism pattern and a dot pattern, which are formed through extrusion molding and curing processes, allowing for continuous production and achieving a total thickness of 120 to 500 μm, enabling slimness and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If injection molding method is used to manufacture light guide plate, then manufacturing precision can be achieved, but manufacturing cost increases and mass production becomes difficult
Solution Approach 1:
The patent replaces the mechanical injection molding process with a chemical process using ultraviolet curable resin. The resin is coated on a base film and cured using UV irradiation, eliminating the need for complex injection molding machinery and molds. This substitution enables continuous production while maintaining manufacturing precision, as the resin can be precisely controlled during coating and curing processes.
Solution Approach 2:
The patent changes the manufacturing parameters from high-pressure injection molding to low-pressure UV curing. By using ultraviolet curable resin that cures upon UV exposure, the process operates under different physical-chemical parameters, allowing for continuous production on flexible base films without the constraints of rigid injection molding equipment.
2Strength
If conventional light guide plate is manufactured, then structural strength is maintained, but weight reduction and thinness become difficult
Solution Approach 1:
The patent employs a flexible base film as the substrate for the light guide plate. This base film allows the plate to be made extremely thin while maintaining sufficient mechanical strength through the properties of the film material and the cured resin layer. The flexible nature of the base film enables weight reduction and achieves the slimness required for modern display devices.
Solution Approach 2:
The patent creates a composite structure by combining the base film with ultraviolet curable resin. This composite material system leverages the strength and flexibility of the base film while the cured resin provides additional structural integrity and optical properties. The combination achieves both weight reduction and maintained strength, resolving the contradiction between these two requirements.
3Manufacturing precision
If mold creation process is used, then light guide plate shape can be precisely formed, but production time and labor cost increase
Solution Approach 1:
The patent extracts the pattern formation step from the traditional injection molding process. Instead of forming the entire light guide plate shape through complex molds, the invention applies patterned resin directly onto a pre-formed base film using coating techniques. This separation of functions eliminates the need for expensive and time-consuming mold creation while maintaining shape precision through controlled resin application and UV curing.
Solution Approach 2:
The patent performs preliminary preparation by selecting an appropriate base film with desired thickness and mechanical properties before applying the resin pattern. This preliminary action eliminates the need for subsequent machining or mold-based shaping, reducing production time and labor costs while maintaining manufacturing precision through the inherent properties of the pre-selected base film.
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 enables efficient mass production of lightweight and thin light guide plates, reducing production costs and time, while allowing for the use of flexible and slim light guide plates that can accommodate thin light sources like LEDs, enhancing the lifecycle and brightness of display devices.
Implementation Method 1
curing the prism pattern using an ultraviolet lamp
Data Source
AI summary
Disclosed are a film-type light guide plate capable of readily securing mass-production and realizing low weight and slimness, a method for manufacturing the same and a backlight unit using the same. The method includes loading a base film on a movable first conveyor belt, coating a liquid ultraviolet curable resin on the first surface of the base film, rotating a surface-treated roll on the coated ultraviolet curable resin to form a prism pattern provided with a first protrusion pattern, and curing the prism pattern using an ultraviolet lamp.