Wire Grid Structure Manufacturing Yield via Preliminary Patterning
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Solution Overview
Problem
The manufacturing process of wire grid structures faces low yields due to the small height of cast pieces, which can be crushed and damaged during patterning, leading to low yields in both the cast piece and wire grid structure production.
Innovation Solution
A manufacturing method involving extruding a molten mixed material to form a cast piece with a large thickness, patterning it to create a precursor with a preset wire grid structure pattern, and then stretching it to form a wire grid structure, where the cast piece's larger dimension in the height direction simplifies the patterning process and reduces damage, while incorporating reflective particle additives on the surface or inside the wire grid structure to enhance reflectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the cast piece height is reduced to achieve the required wire grid structure, then the wire grid structure dimensions are correct, but the cast piece is easily crushed and damaged during patterning
Solution Approach 1:
The patent applies preliminary action by performing the patterning operation on a thick cast piece before stretching it to the final thin dimensions. This sequence ensures that the patterning is done when the material is mechanically strong and resistant to damage, rather than attempting to pattern the already-thin final structure. The thick cast piece serves as a robust substrate for the patterning process.
Solution Approach 2:
The manufacturing process is segmented into distinct stages: first creating a thick cast piece, then patterning it, and finally stretching it to the target thin dimensions. This segmentation allows each operation to be optimized independently - the patterning operation works on a thick, damage-resistant substrate, while the stretching operation achieves the final thin dimensions without compromising the patterned structure.
2Manufacturing precision
If the cast piece height is reduced to match the wire grid structure height, then the final product dimensions are accurate, but the patterning yield decreases due to crushing and damage
Solution Approach 1:
The patent performs patterning on a thick cast piece before stretching, which is the preliminary action stage. This approach maintains high patterning yield because the thick material is resistant to crushing and damage during the patterning process. The final thin dimensions are achieved in the subsequent stretching stage, decoupling the patterning yield from the final product thickness.
Solution Approach 2:
The patent uses dimensionality change by transitioning from a thick three-dimensional cast piece to a thin stretched structure. The patterning is performed in the thick-dimension state where the material is mechanically robust, and then the structure is stretched in the height dimension to achieve the final thin dimensions. This dimensional transformation allows high-yield patterning while achieving the required thin final product.
3Illumination intensity
If reflective particle additives are added to enhance reflectivity, then the projection screen brightness improves, but the material composition complexity increases
Solution Approach 1:
The patent applies composite materials by incorporating reflective particle additives into the polymer matrix of the wire grid structure. This creates a composite material that combines the structural properties of the polymer with the optical properties of the reflective particles, achieving enhanced brightness and reflectivity while maintaining the structural integrity of the wire grid.
Solution Approach 2:
The reflective particle additives are applied locally to specific surfaces of the wire grid structure - particularly the front surface and potentially the rear surface - rather than uniformly throughout the entire material volume. This localized application enhances reflectivity where it is most needed for projection screen performance while minimizing the overall material composition complexity.
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 improves the yield of wire grid structures by reducing damage during patterning, lowers manufacturing costs, and increases the reflectivity and brightness of the projection screen by using reflective particle additives, resulting in a more efficient and cost-effective production process.
Implementation Method 1
the projection surface is configured to reflect projection light
Implementation Method 2
reflective particle additives, and the reflective particle additives are provided on a surface of the grid structure body and/or are provided in an interior of the wire grid structure body
Data Source
AI summary
A wire grid structure and a manufacturing method therefor, and a projection screen are provided. The manufacturing method includes: extruding a molten mixed material body in a melt extruder to a casting roll to form a casting piece; patterning the casting piece by means of an impression roll to form a precursor having a preset wire grid structure pattern, where the precursor is wound on the impression roll and has a first dimension in a height direction; stretching the precursor by a first group of stretching rolls and a second group of stretching rolls in two opposite directions along a direction perpendicular to the height direction to form the wire grid structure, a preset distance being configured between the first group of stretching rolls and the second group of stretching rolls. The wire grid structure has a second dimension in the height direction that is greater than the second dimension.