Thin Light Guide Panel Surface Structures for Mold Removal
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Solution Overview
Problem
Existing liquid crystal display devices face challenges in reducing thickness, particularly with light guide panels, as conventional projection molding methods struggle to produce panels thinner than 1 mm due to incomplete resin filling and mold removal issues.
Innovation Solution
A liquid crystal display device design featuring a thin light guide panel with surface structures formed by thermoplastic material flow, including raised and reflection surfaces, which allows for a thickness of 1 mm or less, and employs a molding process where the thermoplastic material flows around mold ribs to create free surfaces and voids, enabling easier panel removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If projection molding method is used to manufacture light guide panel, then manufacturing process is simple, but panel thickness cannot be reduced below 1 mm due to incomplete resin filling and mold removal difficulties
Solution Approach 1:
The mold is divided into multiple segments including a first mold, second mold, and third mold that can move relative to each other. The third mold acts as a removable core that segments the molding process, allowing it to be extracted after injection without requiring the entire mold assembly to be opened, thus enabling thin panel production while simplifying manufacturing.
Solution Approach 2:
The mold structure is made dynamic with the third mold capable of moving along the injection direction and being selectively removed. This dynamic configuration allows the mold to adapt between maintaining structural integrity during injection and enabling easy removal after curing, resolving the contradiction between thin panel production and manufacturing ease.
2Length of moving object
If light guide panel thickness is reduced to achieve compact display device, then device size is reduced, but light distribution uniformity and control become difficult
Solution Approach 1:
Different regions of the light guide panel are given different properties through the surface structures (protrusions and recesses) formed during molding. These local structural variations optimize light scattering and distribution in specific areas, ensuring uniform light output even in thin panels where traditional uniform structures would fail.
Solution Approach 2:
The surface structures including protrusions and recesses are pre-formed during the molding process itself rather than requiring post-processing. This preliminary action ensures precise control over light distribution characteristics is built into the panel structure from manufacturing, maintaining optical precision in thin designs.
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 solution enables the production of a thin light guide panel with a thickness of 1 mm or less, improving the compactness of liquid crystal display devices while maintaining effective light distribution and minimizing light leakage.
Implementation Method 1
a plurality of surface structures including: a first raised surface extending outward from the at least one of the front surface and the back surface, the first raised surface being formed as a free surface due to a flow of the thermoplastic material
Implementation Method 2
the light guide panel has an appropriate structure for scattering incident light from the side surface to the front surface thereof uniformly
Data Source
AI summary
Provided is a liquid crystal display device including: an optical switching member; a light guide panel; and a light source, the light guide panel including, on at least one of a front surface and a back surface thereof, a plurality of surface structures including: a first raised surface extending outward being formed as a free surface; a first light reflection surface entering inside from the first raised surface; a second light reflection surface extending outside from the first light reflection surface; and a second raised surface which continues from the second light reflection surface and is formed as a free surface, whereby a liquid crystal display device may be obtained, which includes a thin light guide panel with a thickness of, for example, 1 mm or less.