CN1316297C - Light guide plate and manufacturing method thereof - Google Patents

Abstract

The invention relates to a method for manufacturing a light guide plate, which comprises the following steps: firstly, providing a film with a transfer printing material layer, then providing a light guide plate forming machine with a mould cavity, then arranging the film in the light guide plate forming machine, and making at least part of the transfer printing material layer be positioned in the mould cavity, and finally forming a light guide plate body in the mould cavity. The transfer printing material layer is transferred on the light guide plate body, so that the transfer printing material layer and the light guide plate are integrally formed. The manufacturing method of the light guide plate simplifies the manufacturing process, reduces the cost, improves the reproducibility of the manufactured light guide plate, reduces the thickness of the light guide plate, and reduces the possibility of light leakage of the light guide plate.

Description

Light guide plate and manufacturing method thereof

technical field

The present invention relates to a light guide and a manufacturing method thereof, in particular to a light guide using transfer printing technology and a manufacturing method thereof.

Background technique

The rapid progress of the multimedia society is mostly due to the rapid progress of semiconductor components or man-machine display devices. As far as displays are concerned, cathode ray tubes (Cathode Ray Tube, CRT) have been monopolizing the display market in recent years due to their excellent display quality and economy. However, for the environment where most of the personal operations are terminals/display devices, if we cut in from the viewpoint of environmental protection, or predict the trend of saving energy, there are still many problems in the use of space and energy consumption of cathode ray tubes. However, there is no effective solution to the requirements of lightness, thinness, shortness, smallness and low power consumption. Therefore, liquid crystal displays (Liquid Crystal Display, LCD) with superior characteristics such as high image quality, increased space utilization efficiency, low power consumption, and no radiation have gradually become the mainstream of the market.

In the liquid crystal display, since the liquid crystal panel (Liquid crystal panel) does not have the function of emitting light, a backlight module (Back light module) must be arranged under the liquid crystal panel to provide a light source to achieve the display function. Among the light sources of the backlight module, in addition to the cold cathode fluorescent lamp (Cold Cathode Fluorescent Lamp, CCFL), there is also a light emitting diode (Light Emitting Diode, LED), which is also one of the main light sources of the backlight module at present.

Please refer to FIG. 1 , which is an assembly diagram of a conventional backlight module. The conventional backlight module 100 is mainly composed of a light guide plate 110 , a light source 120 , at least one reflective sheet 130 and a multilayer optical film 140 . After being incident on the light incident surface S1 of the light guide plate 110 , the light provided by the light source 120 is reflected by the bottom surface S2 and exits from the light exit surface S3 . Therefore, with the function of the light guide plate 110, the light provided by the light source 120 can be converted into the surface light source required by the liquid crystal panel.

In addition, in order to increase the uniformity of the surface light source provided by the backlight module 100, generally when making the light guide plate 110, etching (etching), electroforming (electromolding) and other technologies are used to make molds with various concave-convex patterns on the bottom surface. , so that the light guide plate 110 injection-molded using this mold has a corresponding concave-convex pattern 112 on its bottom surface S2. In this way, after the light provided by the light source 120 is scattered by the concave-convex pattern 112 , a uniform surface light source can be generated. However, the manufacturing method of this conventional light guide plate is not only complicated in process, but also affected by too many process parameters (such as mold flow traction caused by concave-convex pattern, etching uniformity, cooling rate, etc.), so the manufactured The produced light guide plate 110 has poor reproducibility, which leads to failure to improve the yield of products.

Another conventional manufacturing method of the light guide plate is to print the light diffusion pattern on the bottom surface S2 by printing after the light guide plate 110 is completed. However, this printing method is generally limited to the manufacture of large-sized light guide plates, and cannot be completed simultaneously with the light guide plate 110 .

In addition, in order to increase the brightness of the surface light source provided by the backlight module 100 , generally a reflective sheet 130 is attached on the bottom surface S2 of the light guide plate 110 . However, attaching the reflection sheet 130 not only increases the manufacturing time and cost, but also increases the overall thickness of the backlight module 100 . Moreover, even after the light guide plate 110 is pasted with the reflective sheet 130 on the surface other than the light incident surface S1 and the light exit surface S3 , the light guide plate 110 may still have light leakage at the joints of the reflective sheets 130 . Therefore, for liquid crystal displays that are developing towards ultra-high brightness and ultra-thin size, there are still many shortcomings to be overcome in the conventional manufacturing method of the light guide plate.

It can be seen that the above-mentioned existing light guide plate and its manufacturing method obviously still have inconveniences and defects in terms of structure, manufacturing method and use, and need to be further improved urgently. In order to solve the problems existing in the light guide plate and its manufacturing method, the relevant manufacturers have tried their best to find a solution, but no suitable design has been developed for a long time, and there is no suitable structure for general products to solve the above problems , this is obviously a problem that relevant industry players are eager to solve.

In view of the defects existing in the above-mentioned existing light guide plate and its manufacturing method, the inventor, based on years of rich practical experience and professional knowledge engaged in the design and manufacture of this type of product, and in conjunction with the application of academic theory, actively researched and innovated, in order to create a The light guide plate with novel structure and its manufacturing method can improve the general existing light guide plate and its manufacturing method, making it more practical. Through continuous research, design, and after repeated trial samples and improvements, the present invention with practical value is finally created.

Contents of the invention

The object of the present invention is to overcome the defects of the existing light guide plate manufacturing method and provide a new light guide plate manufacturing method. The technical problem to be solved is to simplify the manufacturing process and reduce the cost, while improving the manufactured The replicability of the light guide plate is more suitable for practical use.

Another object of the present invention is to provide a light guide plate. The technical problem to be solved is to reduce the thickness of the light guide plate and reduce the possibility of light leakage from the light guide plate, so that it is more suitable for practical use.

The purpose of the present invention and the solution to its technical problems are achieved by adopting the following technical solutions. According to a manufacturing method of a light guide plate proposed by the present invention, it includes the following steps: providing a film with a transfer material layer on the film; providing a light guide plate forming machine, the light guide plate forming machine has a mold cavity; configuring the The film is placed in the light guide plate molding machine, and at least part of the transfer material layer is located in the mold cavity; and a light guide plate body is formed in the mold cavity, and the transfer material layer is transferred on the light guide plate body , so that the transfer material layer and the light guide plate are integrally formed.

The purpose of the present invention and its technical problems can also be further realized by adopting the following technical measures.

In the aforementioned manufacturing method of the light guide plate, the transfer material layer is a light diffusion pattern layer.

The aforementioned manufacturing method of the light guide plate, wherein the formation of the transfer material layer includes the following steps: forming a light reflection layer on the film; and forming a light diffusion pattern layer on the light reflection layer.

The manufacturing method of the aforementioned light guide plate, wherein the light guide plate body has a light exit surface, a bottom surface, at least one light incident surface and a plurality of side surfaces, the light incident surface and the side surfaces are respectively adjacent to the bottom surface and the light Between the emitting surfaces, the light diffusion pattern layer is transferred on the bottom surface, and the light reflection layer is transferred on the bottom surface.

In the aforementioned manufacturing method of the light guide plate, the light reflection layer is further transferred on the side surfaces.

In the aforementioned manufacturing method of the light guide plate, the method of arranging the film in the light guide plate molding machine includes using a winding mechanism to roll the film so that at least part of the transfer material layer is located in the mold cavity.

In the aforementioned manufacturing method of the light guide plate, the transfer material layer has a plurality of pattern blocks, and one of the pattern blocks is located in the mold cavity after the film is rolled.

The purpose of the present invention and the solution to its technical problems are also achieved by the following technical solutions. A light guide plate proposed according to the present invention includes: a light guide plate body having a light exit surface, a bottom surface, at least one light incident surface and a plurality of side surfaces, and the light incident surface and the side surfaces are respectively adjacent to the between the bottom surface and the light-exiting surface; and a transfer material layer disposed on at least the bottom surface, and the transfer material layer is integrally formed with the light guide plate body. .

The purpose of the present invention and its technical problems can also be further realized by adopting the following technical measures.

The aforementioned light guide plate, wherein the transfer material layer is integrally formed with the light guide plate body.

In the aforementioned light guide plate, the transfer material layer is a light diffusion pattern layer.

In the aforementioned light guide plate, the transfer material layer includes: a light diffusion pattern layer disposed on the bottom surface; and a light reflection layer disposed on at least the bottom surface and covering the light diffusion pattern layer.

In the aforementioned light guide plate, the light reflection layer is further disposed on the side surfaces.

Compared with the prior art, the present invention has obvious advantages and beneficial effects. As can be seen from the above technical solutions, in order to achieve the aforementioned object of the invention, the main technical contents of the present invention are as follows:

The invention proposes a manufacturing method of a light guide plate, which includes the following steps: first, a film is provided, and a transfer material layer is provided on the film. Then provide a light guide plate forming machine, the light guide plate forming machine has a mold cavity, then configure the film in the light guide plate forming machine, and make at least part of the transfer material layer in the mold cavity, and finally form a light guide plate body in the mold cavity At the same time, the transfer material layer is transferred on the light guide plate body.

In this embodiment, the transfer material layer is, for example, a light diffusion pattern layer. Alternatively, the step of forming the transfer material layer includes, for example, forming a light reflection layer on the film, and then forming a light diffusion pattern layer on the light reflection layer.

The light guide plate body, for example, has a light exit surface, a bottom surface, at least one light incident surface and multiple side surfaces. The light incident surface and the side surface are respectively adjacent to the bottom surface and the light exit surface. The light diffusion pattern layer is, for example, transferred on the bottom surface, and the light reflection layer is, for example, transferred on the bottom surface. Alternatively, the light-reflecting layer is, for example, transferred onto the sides.

In addition, the method of arranging the film in the light guide plate molding machine is, for example, using a tape winding mechanism to roll the film so that at least part of the transfer material layer is located in the mold cavity. The transfer material layer has a plurality of pattern blocks, for example, and one of the pattern blocks is located in the mold cavity after the film is rolled.

The present invention further provides a light guide plate, which is mainly composed of a light guide plate body and a transfer material layer. The light guide plate body has a light exit surface, a bottom surface, at least one light incident surface and multiple side surfaces, and the light incident surface and the side surfaces are respectively adjacent to the bottom surface and the light exit surface. The transfer material layer is arranged at least on the bottom surface.

In this embodiment, the transfer material layer and the light guide plate body are, for example, integrally formed. The transfer material layer is, for example, a light diffusion pattern layer. Alternatively, the transfer material layer is, for example, composed of a light diffusion pattern layer and a light reflection layer. The light diffusion pattern layer is arranged, for example, on the bottom surface. For example, the light reflection layer is arranged at least on the bottom surface and covers the light diffusion pattern layer. In addition, the light reflection layer is arranged on the side surface, for example.

To sum up, in the light guide plate and its manufacturing method of the present invention, a film with a transfer material layer is firstly provided, and then the transfer material layer is transferred onto the light guide plate while the light guide plate is being formed. Therefore, not only the manufacturing process and cost of the light guide plate are greatly simplified, but also the increase of the overall thickness of the light guide plate caused by the reflective sheet in the prior art can be avoided. At the same time, the light guide plate manufactured according to the present invention can have high reproducibility, and the film is transported in the form of tape to increase the process speed.

It can be seen from the above that the present invention relates to a method for manufacturing a light guide plate, which includes the following steps: firstly, a film is provided, and a transfer material layer is provided on the film, and then a light guide plate forming machine is provided, and the light guide plate forming machine has a The mold cavity, and then configure the film in the light guide plate molding machine, and make at least part of the transfer material layer in the mold cavity, and finally form a light guide plate body in the mold cavity. The above transfer material layer is transferred on the light guide plate body.

With the above technical solution, the light guide plate and its manufacturing method of the present invention have at least the following advantages:

The manufacturing method of the light guide plate of the invention simplifies the manufacturing process and reduces the cost, and at the same time improves the replicability of the manufactured light guide plate; the light guide plate of the invention reduces the thickness of the light guide plate and reduces the possibility of light leakage from the light guide plate.

To sum up, the light guide plate with special structure and its manufacturing method of the present invention has many advantages and practical value mentioned above, and there is no similar structural design and method published or used in similar products and manufacturing methods. It is indeed an innovation, and it has greatly improved in product structure, manufacturing method or function, and has made great progress in technology, and has produced easy-to-use and practical effects, and is more than the existing light guide plate and its The manufacturing method has multiple enhanced effects, so it is more suitable for practical use, and has wide application value in the industry. It is a novel, progressive and practical new design.

The above description is only an overview of the technical solutions of the present invention. In order to understand the technical means of the present invention more clearly and implement them according to the contents of the description, the preferred embodiments of the present invention and accompanying drawings are described in detail below.

Description of drawings

FIG. 1 is an assembly diagram of a conventional backlight module.

FIG. 2 is a flow chart of manufacturing a light guide plate according to a preferred embodiment of the present invention.

3A and 3B are schematic diagrams of two roll-to-roll films used in the present invention.

FIG. 4 is a schematic cross-sectional view of the light guide plate of the present invention during molding.

FIG. 5 is a schematic perspective view of the light guide plate of the present invention.

FIG. 6 is a schematic cross-sectional view of the light guide plate in FIG. 5 .

100: Backlight module 110: Light guide plate

112: concave-convex pattern 120: light source

130: reflector 140: optical film

S1: Light incident surface S2: Bottom surface

S3: Light exit surface 200: Film

210a, 210b: transfer material layer 212: light reflection layer

214: Light diffusion pattern layer 250: Light guide plate forming machine

260: mold cavity 280: light guide plate body

290: Tape take-up mechanism 300: Light guide plate

B: pattern block S4: light exit surface

S5: bottom surface S6: light incident surface

S7: Side S10, S20, S30, S40: Steps

Detailed ways

In order to further explain the technical means and effects of the present invention to achieve the intended purpose of the invention, the specific implementation, structure and manufacturing method of the light guide plate and its manufacturing method proposed according to the present invention will be described below in conjunction with the accompanying drawings and preferred embodiments. , steps, features and effects thereof are described in detail below.

Please refer to FIG. 2 , which is a flow chart of manufacturing a light guide plate according to a preferred embodiment of the present invention, and FIG. 3A and FIG. 3B are schematic diagrams of two kinds of tape-and-roll films used in the present invention.

Please refer to FIG. 2 and FIG. 3A , the manufacturing method of the light guide plate of the present invention is to provide a film 200 with a transfer material layer 210 a on the film 200 (step S10 ). The film 200 is, for example, a roll film, and its material is, for example, polyester (PET).

3A and 3B, the transfer material layer 210a on the film 200 can have a plurality of pattern blocks B (as shown in Figure 3A), or the transfer material layer 210b on the film 200 can also be distributed in a continuous strip (Figure 3B). In the subsequent description, the transfer material layer 210 a having a plurality of pattern blocks B will be taken as an example for introduction.

Referring to FIG. 3A , the method of forming the transfer material layer 210 a on the film 200 is, for example, printing. The step of forming the transfer material layer 210 a includes, for example, firstly forming a light reflection layer 212 on the film 200 . Next, a light diffusion pattern layer 214 is formed on the light reflection layer 212 . Wherein, the pattern of the light diffusion pattern layer 214 is, for example, regular dots, irregular dots, or other patterns that are optimally designed to produce the best light diffusion effect. The material of the light diffusion pattern layer 214 is, for example, thermal transfer ink. The material of the light reflection layer 212 is, for example, a highly reflective material suitable for transfer.

Of course, the step of forming the transfer material layer 210a may also only include forming the light reflection layer 212, or only include forming the light diffusion pattern layer 214, depending on the requirements of product design.

Please refer to FIG. 4 , which is a schematic cross-sectional view of the light guide plate of the present invention during molding. Referring to FIG. 2 and FIG. 4 , a light guide plate forming machine 250 is provided (step S20 ). The light guide plate molding machine 250 is, for example, an injection molding machine. The light guide plate molding machine 250 has a mold cavity 260 . After that, the film 200 formed with the transfer material layer 210a (shown in FIG. 3A ) is placed in the light guide plate molding machine 250 (step S30), and a pattern block B of the transfer material layer 210a is positioned in the mold cavity 260 Inside. Finally, the light guide plate material is injected into the mold cavity 260 to injection mold a light guide plate body 280 (step S40 ). During the injection molding process of the light guide plate body 280 , the transfer material layer 210 a leaves the film 200 and is transferred onto the light guide plate body 280 , so that the transfer material layer 210 a and the light guide plate are integrally formed. .

In addition, the film 200 is disposed in the light guide plate molding machine 250 by using a tape winding mechanism 290, for example, and the film 200 is rolled by the tape winding mechanism 290 to position a pattern block B of the transfer material layer 210a on the Inside the mold cavity 260. After each light guide plate body 280 is injection-molded, the film 200 is rolled, so that the next pattern block B of the transfer material layer 210 a is positioned in the mold cavity 260 . If the transfer material layer 210b as shown in FIG. 3B is used, the winding mechanism 290 rolls the film 200 so that the unused portion of the transfer material layer 210b is positioned in the mold cavity 260 .

Of course, the film 200 is not limited to the roll-type film, nor is it limited to be conveyed by the tape-reel mechanism 290 , but the film 200 can be sent into the mold cavity 260 one by one by various conveying mechanisms. Alternatively, a plurality of mold cavities 260 are designed in the light guide plate molding machine 250 to perform injection molding of a plurality of light guide plate bodies 280 at one time.

Please refer to FIG. 5 , which is a schematic perspective view of the light guide plate of the present invention, and FIG. 6 is a schematic cross-sectional view of the light guide plate in FIG. 5 . Please refer to FIG. 5 and FIG. 6 , the light guide plate 300 of the present invention is mainly composed of the light guide plate body 280 and the transfer material layer 210a. The appearance of the light guide plate body 280 is, for example, wedge-shaped, flat-shaped or other forms. In this embodiment, a flat light guide plate is taken as an example, but it is not intended to limit the present invention.

The light guide plate body 280 has a light emitting surface S4 , a bottom surface S5 , two light incident surfaces S6 and two side surfaces S7 . The light incident surface S4 and the side surface S7 are respectively adjacent to the bottom surface S5 and the light emitting surface S4. The transfer material layer 210a is transferred and arranged at least on the bottom surface S5. Since the transfer material layer 210a is transferred on the bottom surface S5 when the light guide plate body 280 is formed, the transfer material layer 210a and the light guide plate body 280 can be integrally formed. Wherein, the light diffusion pattern layer 214 is, for example, transferred on the bottom surface S5 , and the light reflection layer 214 is, for example, at least transferred on the bottom surface S5 . Certainly, the light reflective layer 214 can be transferred onto the side S7. In other words, the light reflective layer 214 is, for example, transferred onto each surface of the light guide plate body 280 except the light exit surface S4 and the light incident surface S6 . In this way, light leakage can be avoided to obtain the best light utilization rate. Of course, the light reflection layer 214 may also be transferred only on the bottom surface S5.

In this embodiment, the transfer material layer 210 a is composed of, for example, a light diffusion pattern layer 212 and a light reflection layer 214 . Of course, the transfer material layer 210 a may also be only the light diffusion pattern layer 212 or only the light reflection layer 214 .

To sum up, in the light guide plate and its manufacturing method of the present invention, a transfer material layer is first printed on a film, and then the transfer material layer is transferred onto the light guide plate while the light guide plate is injection molded. . Therefore, it is possible to avoid the high skill and complicated process required for making molds in the prior art. Moreover, due to the simplification of process parameters, the reproducibility of the light guide plate can be greatly improved to obtain stable product characteristics. In addition, since the light reflection layer can be integrally formed on the light guide plate body, the cost and man-hours required for attaching the reflective sheet in the prior art are saved, and the overall thickness of the light guide plate is reduced. At the same time, the light reflection layer integrally formed on the light guide plate body can significantly improve the light leakage of the light guide plate, thereby improving the brightness of the backlight module. In addition, the application of tape and roll film also increases the process speed, thereby increasing the output of the light guide plate and reducing the cost.

The above description is only a preferred embodiment of the present invention, and does not limit the present invention in any form. Although the present invention has been disclosed as above with preferred embodiments, it is not intended to limit the present invention. Anyone familiar with this field Those skilled in the art, without departing from the scope of the technical solution of the present invention, can use the method and technical content disclosed above to make some changes or modifications to equivalent embodiments with equivalent changes, but any content that does not depart from the technical solution of the present invention, Any simple modifications, equivalent changes and modifications made to the above embodiments according to the technical essence of the present invention still fall within the scope of the technical solutions of the present invention.

Claims (11)

1. A method for manufacturing a light guide plate, characterized in that it comprises the following steps: providing a film with a transfer material layer on the film; Provide a light guide plate forming machine, the light guide plate forming machine has a mold cavity; disposing the film in the light guide plate molding machine, and making at least part of the transfer material layer in the mold cavity; and A light guide plate body is formed in the mold cavity, and the transfer material layer is transferred on the light guide plate body, so that the transfer material layer and the light guide plate are integrally formed. 2. The manufacturing method of the light guide plate according to claim 1, wherein the transfer material layer is a light diffusion pattern layer. 3. The manufacturing method of the light guide plate according to claim 1, wherein the formation of the transfer material layer comprises the following steps: forming a light reflective layer on the film; and A light diffusion pattern layer is formed on the light reflection layer. 4. The manufacturing method of the light guide plate according to claim 3, wherein the light guide plate body has a light exit surface, a bottom surface, at least one light incident surface and a plurality of side surfaces, the light incident surface and the light incident surface The side faces are respectively adjacent to the bottom surface and the light exit surface, and the light diffusion pattern layer is transferred on the bottom surface, and the light reflection layer is transferred on the bottom surface. 5. The manufacturing method of the light guide plate according to claim 4, wherein the light reflection layer is further transferred on the side surfaces. 6. The manufacturing method of the light guide plate according to claim 1, wherein the method of arranging the film in the light guide plate forming machine includes using a tape winding mechanism to roll the film so that at least part of the transfer A layer of material is located within the mold cavity. 7. The manufacturing method of the light guide plate according to claim 6, wherein the transfer material layer has a plurality of pattern blocks, and one of the pattern blocks is located in the pattern block after the film is rolled. Inside the mold cavity. 8. A light guide plate, characterized in that it comprises: A light guide plate body has a light exit surface, a bottom surface, at least one light incident surface and a plurality of side surfaces, and the light incident surface and the side surfaces are respectively adjacent between the bottom surface and the light exit surface; and A transfer material layer is disposed on at least the bottom surface, and the transfer material layer is integrally formed with the light guide plate body. 9. The light guide plate according to claim 8, wherein said transfer material layer is a light diffusion pattern layer. 10. The light guide plate according to claim 8, wherein said transfer material layer comprises: a light diffusion pattern layer, configured on the bottom surface; and A light reflection layer is disposed on at least the bottom surface and covers the light diffusion pattern layer. 11. The light guide plate according to claim 10, wherein said light reflection layer is further disposed on the side surfaces.