Light Guide Plate Composite Structure for Large Panel Thinning
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Solution Overview
Problem
Existing methods for manufacturing light guide plates, such as injection molding, thermal compression molding, and printing, face limitations including size constraints, high manufacturing costs, low transfer ratios, and inability to produce geometric structures beyond polygons and points, especially as panel sizes increase and thinning requirements become more stringent.
Innovation Solution
A light guide plate with a two-side composite structure is manufactured using a combination of screen-printing and light-solidification and imprinting processes, featuring a substrate with screen-printed layers and micro-structured light-solidified layers, allowing for flexible material selection and micro-structure design, including circle, V-shape, pyramid, and prism structures, to enhance light distribution and panel thinning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding method is used, then manufacturing efficiency is improved, but size is limited to about 32 inch and thickness is limited to 2 mm
Solution Approach 1:
The light guide plate manufacturing is divided into two independent stages: first forming a base layer through injection molding, then adding a patterned layer through screen printing. This segmentation allows the base layer to be produced efficiently by injection molding while the patterned layer can be customized for larger sizes and thinner profiles, resolving the contradiction between manufacturing efficiency and size/thickness limitations.
Solution Approach 2:
The patent merges injection molding and screen printing processes into a composite manufacturing method. The injection molded base layer provides structural integrity and light guidance, while the screen printed patterned layer adds light diffusion and redistribution capabilities. This combination enables production of large-size, thin light guide plates with high manufacturing efficiency.
2Shape
If thermal compression molding method is used, then geometric structures can be formed, but transfer ratio is only 70% and manufacturing cost is higher
Solution Approach 1:
The patent replaces thermal compression molding with screen printing technology to form geometric patterns. Screen printing uses a mesh stencil and squeegee to deposit material precisely, achieving higher transfer ratios and better pattern fidelity compared to thermal compression molding. This substitution maintains the ability to form complex geometric structures while improving manufacturing precision and reducing costs.
3Adaptability or versatility
If printing method is used, then production flexibility is improved, but printing point size shifts and point spreading ratio is 20-40%
Solution Approach 1:
The patent introduces a mesh screen as an intermediary tool in the screen printing process. The screen acts as a precise template that defines the exact pattern geometry, preventing point size shifts and reducing spreading. The screen's mesh structure allows precise control of material deposition, maintaining both production flexibility and manufacturing precision.
Solution Approach 2:
The patent optimizes screen printing parameters including mesh count, squeegee pressure, and material viscosity to minimize point spreading ratio and prevent printing point size shifts. By carefully controlling these parameters, the process achieves high precision pattern transfer while maintaining the flexibility to produce various light guide plate designs.
4Ease of manufacture
If single-sided structure is used, then manufacturing simplicity is maintained, but light distribution uniformity is insufficient
Solution Approach 1:
The patent transitions from single-sided to double-sided light guide plate structure, adding a second functional layer on the opposite side. This dimensional change enables light to be guided and distributed from both surfaces, significantly improving light distribution uniformity across the panel while maintaining manufacturing simplicity through the modular screen printing process.
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 approach enables thinning, high transfer ratio, automatic production, and flexibility in production point size, enhancing the competitiveness of light guide plates by allowing for customized light emission geometry and efficient panel illumination.
Implementation Method 1
The first screen-printed layer is formed on the first surface of the substrate by a screen-printing process
Implementation Method 2
a UV lamp can be used to irradiate and solidify the light-solidified resin to form the light-solidified layer and the plurality of micro-structures
Data Source
AI summary
A light guide plate and a manufacturing method thereof are disclosed. The light guide plate includes a substrate, a screen-printed layer, and a light-solidified layer. The substrate has a first surface and a second surface, and the first surface and the second surface are opposite. The screen-printed layer is formed on the first surface of the substrate by a screen-printing process. The light-solidified layer is formed on the second surface of the substrate by a light-solidification and imprinting process. The screen-printed layer has a plurality of screen point patterns. The light-solidified layer has a plurality of micro-structures.