Light Guide Plate Netted Dot Transfer Printing
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Solution Overview
Problem
The existing methods for manufacturing light guide plates require high pressure and temperature, leading to a shortened service life of the hot pressing device and a decreased qualification rate of the light guide plate.
Innovation Solution
A method and device for manufacturing netted dots on a light guide plate using a metal plate with a preset roughness, where a female or male mould is engraved and coated onto rollers, allowing for the transfer-printing of the dot shape onto the light guide plate at a preset pressure and temperature, enhancing production efficiency and extending the service life of the device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pressure and high temperature are used in the hot pressing process, then the netted dots can be formed on the light guide plate, but the service life of the hot pressing device is significantly decreased
Solution Approach 1:
The patent changes the physical state parameters of the pressing components from high temperature (140°C) and high pressure (6 tons) to room temperature and low pressure conditions. This is achieved by replacing the traditional hot pressing mechanism with a cold pressing mechanism that uses a pressing plate with embedded netted dots to directly imprint the pattern onto the light guide plate material, thereby resolving the contradiction between forming quality and device service life
Solution Approach 2:
The patent replaces the thermal-mechanical hot pressing system with a purely mechanical cold pressing system. Instead of using heat and pressure to soften and form the material, the invention uses a pressing plate with pre-formed netted dots that mechanically imprints the pattern onto the material at room temperature, eliminating the need for high-temperature equipment and extending device service life
2Manufacturing precision
If high pressure and high temperature are used in the hot pressing process, then the netted dots can be formed on the light guide plate, but the qualification rate of the light guide plate is decreased by 10%
Solution Approach 1:
The patent changes the processing parameters from extreme high pressure and high temperature to mild room temperature and low pressure conditions. This parameter change results in better qualification rates because the cold pressing process creates more consistent netted dot formations without the defects caused by thermal degradation and excessive pressure, thereby improving both manufacturing precision and product reliability
Solution Approach 2:
The patent uses a pressing plate that is a precise copy or replica of the desired netted dot pattern. The pressing plate contains negative impressions of the netted dots that are directly transferred onto the light guide plate material during pressing, ensuring high consistency and quality of the formed patterns, which improves the qualification rate
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 improves the production efficiency and service life of the device, while increasing the quality of the light guide plate by forming netted dots with precise shapes, outperforming traditional injection molding processes.
Implementation Method 1
heating the roller so that a temperature of the metal plate rises to a preset temperature
Implementation Method 2
the metal plate applies a preset pressure onto the light guide plate to be machined
Data Source
AI summary
A method for manufacturing netted dots on a light guide plate is disclosed, including: engraving, on a surface of a metal plate with a preset roughness, a female mould or a male mould corresponding to a shape of the netted dots on the light guide plate; coating the metal plate onto a surface of a roller; heating the roller so that a temperature of the metal plate rises to a preset temperature; adjusting a distance of a center of the roller in relation to a light guide plate feeding passage so that the metal plate applies a preset pressure onto the light guide plate to be machined; and making the light guide plate to be machined pass through the light guide plate feeding passage, wherein the metal plate transfer-prints a shape of netted dots of the female mould or the male mould onto the light guide plate to be machined at a preset pressure and a preset temperature to form the netted dots on the light guide plate. A device for manufacturing netted dots on a light guide plate is also disclosed.