UV-Cured Resin Prism Patterns for Large Light Guide Plates

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Solution Overview

Problem

Conventional methods for fabricating light guide plates, such as injection molding and thermal press molding, face challenges in producing larger sizes and enhancing optical efficiency due to limitations in forming minute prism patterns and high yield, as well as deformation issues with ultraviolet curing resins on metal rollers.

Innovation Solution

A method involving a flexible mold with engraved patterns to transfer and cure ultraviolet curing resin on a base member, using polymethylmethacrylate or polystyrene with pre-processing to enhance adhesive force, allowing for the formation of prism patterns with controlled angles for improved light distribution and efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If injection molding or thermal press molding method is used to fabricate light guide plate, then manufacturing process is established, but it is difficult to make the light guide plate larger and obtain high yield because it is necessary to spend a long period for heating and cooling

Engineering Contradiction:

Improveproduction speedVSAvoidheating and cooling period

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces thermal processing (heating and cooling) with ultraviolet light irradiation for curing the resin. This substitution of the curing mechanism eliminates the time-consuming thermal cycles while achieving complete solidification of the resin to form prism patterns on the light guide plate

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes the phase transition of ultraviolet-curing resin from liquid to solid state through photopolymerization. This phase change occurs rapidly upon UV irradiation, enabling quick curing without the prolonged heating and cooling periods required by conventional thermal methods

Inventive Principle:

Principle #36Phase transitions

2Manufacturing precision

If injection molding or thermal press molding method is used to fabricate light guide plate, then manufacturing process is established, but there is a limit to enhancing an optical efficiency because it is impossible to form minute prism patterns due to a low pattern molding rate

Engineering Contradiction:

Improveprism pattern formation precisionVSAvoidpattern molding rate

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent introduces ultraviolet-curing resin as an intermediary material that is applied to the light guide plate surface and then cured with UV light. This intermediary approach allows for the formation of precise minute prism patterns through photopolymerization, achieving high manufacturing precision without compromising productivity

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces mechanical pattern molding with ultraviolet light-induced photopolymerization. This substitution enables the formation of minute prism patterns with high precision through chemical curing rather than mechanical deformation, overcoming the limitations of low pattern molding rate in conventional methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If ultraviolet curing resin is used on metal roller, then pattern transfer is attempted, but deformation of minute prism patterns occurs

Engineering Contradiction:

Improveprism pattern accuracyVSAvoidpattern shape stability

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The patent replaces metal roller-based mechanical pattern transfer with direct ultraviolet light irradiation curing. This substitution eliminates the mechanical contact and deformation issues associated with metal rollers, allowing minute prism patterns to be formed with high accuracy and shape stability through photopolymerization of the resin directly on the light guide plate

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 the production of medium to large-sized light guide plates with enhanced light efficiency and even brightness, overcoming previous limitations in size and pattern formation while preventing deformation of minute prism patterns.

Implementation Method 1

irradiating the patterned curing resin under ultraviolet ray to form a prism light guide plate

Methodology Applied

Scientific EffectUltraviolet curing: Photopolymerisation

Data Source

PatentUS8663750B2Backlight unit and a method of fabricating the same

Publication Date: 2014.03.04 LG DISPLAY CO LTD

AI summary

A method of fabricating backlight unit is disclosed. The backlight unit method of fabricating backlight unit includes, preparing a base member having a predetermined thickness, applying ultraviolet curing resin on a surface of the base member, transferring prism patterns to the ultraviolet curing resin using a flexible mold having engraved patterns corresponding to the prism patterns, and curing the prism patterns before the prism patterns are separated from the engraved patterns of the flexible mold.