Light-Transmissive Sheet Cutting with UV Adhesion
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Solution Overview
Problem
Current methods for manufacturing light-transmissive members and light-emitting devices are complex and inefficient, particularly in creating layered structures with phosphor-free and phosphor-containing portions, which often result in deformation and scattering of cut pieces during the manufacturing process.
Innovation Solution
A method involving a supporting member with a light-transmissive sheet comprising a phosphor-free first layer and a phosphor-containing second layer, where the sheet is divided using a blade to form light-transmissive members with phosphor-free and phosphor-containing portions layered on each other, utilizing a UV-curable adhesive and a cutting device with a suction mechanism to minimize deformation and scattering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to divide optical sheets into light-transmissive members, then manufacturing can proceed, but deformation and scattering of cut pieces occur during the process
Solution Approach 1:
The patent applies preliminary action by providing a supporting member with a light-transmissive sheet before the cutting process begins. The supporting member is designed to hold the light-transmissive sheet in a stable state during division, preventing deformation and scattering of cut pieces. This preliminary setup ensures that the sheet maintains its structural integrity throughout the manufacturing process.
Solution Approach 2:
The supporting member acts as an intermediary between the cutting blade and the light-transmissive sheet. It provides a stable base that allows the blade to divide the sheet cleanly without causing deformation. The supporting member mediates the cutting process by absorbing mechanical stress and preventing direct transmission of cutting forces to the light-transmissive sheet, thereby maintaining positioning accuracy and structural integrity.
2Manufacturing precision
If complex manufacturing processes are used to create layered structures with phosphor-free and phosphor-containing portions, then the desired structure can be achieved, but the manufacturing process becomes inefficient
Solution Approach 1:
The patent merges multiple manufacturing steps into a single integrated process. By providing a light-transmissive sheet that already contains both phosphor-free and phosphor-containing portions in a layered structure before cutting, the invention eliminates the need for separate steps to create and assemble these layers. This combining of structure preparation and division operations improves manufacturing efficiency while maintaining precise layered structure formation.
Solution Approach 2:
The layered structure with phosphor-free and phosphor-containing portions is prepared in advance on the supporting member before the cutting process. This preliminary preparation allows the subsequent division to simply separate pre-formed layers rather than requiring complex assembly operations after cutting, thereby significantly improving manufacturing efficiency while ensuring precise layered structure formation.
3Ease of manufacture
If the light-transmissive sheet is divided without proper support, then the cutting process is simpler, but deformation and scattering of cut pieces occur
Solution Approach 1:
The supporting member serves as an intermediary that simplifies the cutting process while maintaining manufacturing precision. It provides a stable platform that allows for straightforward cutting operations without requiring complex handling procedures. The supporting member ensures that cut pieces remain in precise positions throughout the process, eliminating the need for complicated positioning and handling steps that would otherwise be necessary to prevent deformation and scattering.
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 simplifies the manufacturing process, reduces deformation and scattering of light-transmissive members, and enables efficient production of light-emitting devices with improved handling and assembly by ensuring strong adhesion of the phosphor-free portions and controlled removal of cutting chips.
Implementation Method 1
utilizing a UV-curable adhesive
Implementation Method 2
a cutting device with a suction mechanism
Data Source
AI summary
A method for manufacturing a light-transmissive member includes: providing a supporting member, and a light-transmissive sheet disposed on the supporting member, the light-transmissive sheet including: a first layer containing substantially no phosphor, and a second layer containing a phosphor; and forming a plurality of light-transmissive members from the light-transmissive sheet by dividing the light-transmissive sheet with a blade over the supporting member, such that each light-transmissive member includes: a first portion formed by separation of the first layer by a first crevice, the first portion containing substantially no phosphor, and a second portion formed by separation of the second layer by a second crevice, the second portion containing a phosphor, wherein one of the first portion and the second portion is layered on the other of the first portion and the second portion.