Background technology
In the development of flat-panel screens, the size of display maximizes and is one of important trend.Therefore, be large scale development, provide the manufacturing technology of the large-scale backlight module of display floater backlight also to become the center of gravity of research and development in response to flat-panel screens.
In the backlight liquid crystal display module, be commonly called as optical brightening membrane (the BrightnessEnhancement Film of prismatic lens; BEF) be considerable spare part in the backlight module now.So, optical brightening membrane is quite expensive, in a backlight module, the cost of optical brightening membrane account for whole backlight module cost about 40%.At present, in the manufacturing technology of optical brightening membrane, normally utilize roller to carry out the making of the surface micro-structure of optical brightening membrane.
Please refer to Fig. 1, it is the device schematic diagram when illustrating general making optical brightening sheet.When making optical brightening membrane 114, provide roller 100 earlier, wherein convex with the broached-tooth design 104 of several proper alignment on the side surface 102 of the cylinder of roller 100, and be provided with groove 106 between adjacent two broached-tooth designs 104.Then, roller 100 levels are pressed on the surface 116 of polymer material layer 108, and make the surface 102 of roller 100 and surface 116 fluid-tight engagement of polymer material layer 108.Then, scroll wheel 100, the broached-tooth design 106 on the surface 102 of roller 100 is transferred on the surface 116 of polymer material layer 108, wherein the broached-tooth design 106 on the roller 100 produces groove 112 on the surface 116 of polymer material layer 108, and the groove 106 on the roller 100 then produces broached-tooth design 110 on the surface 116 of polymer material layer 108.
At present, when making roller 100, groove 106 is produced with the surface 102 at roller 100 in the surface 102 that normally utilizes diamond cutter to cut roller 100, and then limits broached-tooth design 104 on the surface 102 of roller 100.Yet along with the maximization of the size of flat-panel screens, the size of the size of backlight module and interior optical brightening membrane thereof also increases day by day, so the size of roller 100 is also thereupon towards the trend development that maximizes.Thus, the processing capacity of little groove 106 on the surface 102 of roller 100 certainly will significantly increase, and process time is also more and more longer.Add, the architectural feature on the surface 102 of roller 100 is quite trickle.
Because in traditional manufacturing technology, be to adopt single cutter to be carried out little ditch groove cutting of roller surface, so not only can't reduce process time in the face of more and more a large amount of minute groove processing, the abrasion speed of diamond cutter also heightens.Therefore, not only bad for volume production, more cause the cost of manufacture of roller to improve.And, because the quick abrasion of diamond cutter more can influence the uniformity of little groove structure of roller surface, and then influence the making of optical brightening membrane.
Summary of the invention
Therefore, the object of the present invention is to provide a kind of processing unit (plant) of roller micro groove, be provided with rough turn cutter and shaving tool on its tool rest simultaneously, successively to carry out processing, so can reduce the loss of shaving tool with groove.
Another object of the present invention is to provide a kind of processing unit (plant) of roller micro groove, increase the service life of its shaving tool, therefore can reduce the processing cost of roller micro groove.
Another purpose of the present invention is to provide a kind of processing method of roller micro groove, it utilizes rough turn cutter to remove lot of materials with the rough little groove that forms on roller surface earlier, utilize shaving tool to come the surface of this little groove of refine again, therefore the abrasion that can slow down shaving tool, and the processing reliability of the little groove of elevator wheel significantly, and can improve the structural precision of little groove.
A further object of the present invention is to provide a kind of processing method of roller micro groove, it can be under same cutting passage, finish simultaneously and remove lot of materials to form the refine of little groove and little flute surfaces, therefore can reduce the cutting passage widely, and can reduce the cutting time that roller is processed, but and then the working (machining) efficiency of the little groove of elevator wheel.
According to above-mentioned purpose of the present invention, a kind of processing unit (plant) of roller micro groove is proposed, comprise at least: a tool rest, wherein a side of this tool rest is provided with the first cutter fixing port and the second cutter fixing port at least; One rough turn cutter is fixedly arranged in the first cutter fixing port; And one shaving tool be fixedly arranged in the second cutter fixing port, wherein rough turn cutter and shaving tool can cut the surface of a roller simultaneously.
According to a preferred embodiment of the present invention, the material of above-mentioned rough turn cutter is different with the material of shaving tool.According to another preferred embodiment of the present invention, aforesaid shaving tool is a diamond cutter.
According to purpose of the present invention, a kind of processing method of roller micro groove is proposed, the processing unit (plant) of one roller micro groove is provided, and wherein the processing unit (plant) of this roller micro groove comprises a tool rest at least, and a side of tool rest is provided with a rough turn cutter and a shaving tool at least; One roller is provided, is arranged on before the aforementioned side of tool rest, so that rough turn cutter and shaving tool are over against roller; Utilize rough turn cutter pair roller to carry out at least one first cutting step, form at least one first little groove with a surface at roller; And pair roller carry out at least one second the cutting step, form at least one second little groove on the surface of roller to utilize the roughing tool tool, utilize the surface of at least one first little groove of shaving tool refine simultaneously.
According to a preferred embodiment of the present invention, the cutting-in of above-mentioned rough turn cutter is greater than the cutting-in of shaving tool.
The specific embodiment
The present invention discloses a kind of processing unit (plant) and processing method of roller micro groove.In order to make narration of the present invention more detailed and complete, can be with reference to the accompanying drawing of following description and cooperation Fig. 2 to Fig. 4.
Please refer to Fig. 2, it is the schematic perspective view that illustrates according to the processing unit (plant) of a kind of roller micro groove of a preferred embodiment of the present invention.In an example embodiment, the processing unit (plant) 200 of roller micro groove can limit little groove structure in order to carry out machining on the surface of a roller 226 (asking earlier with reference to Fig. 3), wherein this roller 226 can be the making blooming piece, optical brightening membrane for example, blooming piece processing roller.The processing unit (plant) 200 of roller micro groove mainly comprises tool rest 202 and at least two cutters, for example rough turn cutter 204 and shaving tool 206, and wherein the nose radius of these cutters is all inequality.For example, the nose radius of rough turn cutter 204 is bigger than the nose radius of shaving tool 206.The same side of tool rest 202 is provided with several cutter fixing ports, cutter fixing port 208 and 210 for example, wherein the quantity of these cutter fixing ports is the number of cutters corresponding to the processing unit (plant) 200 of roller micro groove, therefore these cutters can correspondingly respectively be installed in the cutter fixing port on the same side of tool rest 202, thereby these cutters are to be arranged on the tool rest 202 in mode side by side.For example, rough turn cutter 204 is inserted and secured on respectively among cutter fixing port 208 and 210 with shaving tool 206, and is the shape that is arranged side by side.When the processing unit (plant) 200 of the little groove of operated roller comes pair roller 226 to carry out surperficial little groove processing, be that this roller 226 is arranged on these cutters, the dead ahead of for example rough turn cutter 204 and shaving tool 206, therefore these cutters cut processing in the surface of pair roller simultaneously, and can shorten process time.
In one embodiment, the material of these cutters is identical, and for example rough turn cutter 204 is identical with the material of shaving tool 206, and wherein rough turn cutter 204 all can be diamond cutter with shaving tool 206.In further embodiments, the material of all cutters of the processing unit (plant) 200 of roller micro groove is all inequality each other, for example rough turn cutter 204 adopts the carbon steel cutter, and shaving tool 206 then adopts diamond cutter, the accuracy of the roller micro groove structure of being cut to guarantee.Because diamond cutter is quite expensive, but has high rigidity, therefore rough turn cutter 204 adopts non-diamond cutter, and under the situation of shaving tool 206 employing diamond cutters, can take into account the accuracy of cost and roller micro groove structure.In other embodiments, when the processing unit (plant) of roller micro groove comprised cutter more than three, cutter that can a part adopted identical materials, and the cutter of another part then adopts different materials.
Optionally, shown in the example embodiment of Fig. 2, tool rest 202 can further comprise pedestal 212 and 216 and sliding part 218, wherein cutter fixing port 208 is arranged in the pedestal 212, and 210 of cutter fixing ports are arranged in another pedestal 216, and these cutter fixing ports 208 and 210 all are positioned at the same side of tool rest 202.Thereby the rough turn cutter 204 that is arranged in cutter fixing port 208 is arranged on the pedestal 212, and the shaving tool 206 that is arranged in cutter fixing port 210 then is arranged on another pedestal 216.Pedestal 212 is provided with chute 214 at least, and sliding part 218 is embedded in the chute 214 of pedestal 212, and wherein sliding part 218 can be with respect to the slip of pedestal 212 travel directions 222.218 of sliding parts include slide rail 220, and this slide rail 220 is embedded in the bottom of pedestal 216 and combines with pedestal 216, wherein pedestal 216 can slide along slide rail 220, thus, makes pedestal 216 to carry out the slip of other direction 224 with respect to another pedestal 212.And because slide rail 220 is embedded at the bottom of pedestal 216, therefore when the slip of sliding part 218, mean that the pedestal 216 that combines with slide rail 220 also can be along with the slip of sliding part 218 with respect to the slip of pedestal 212 travel directions 222 with respect to pedestal 212 travel directions 222.In this example embodiment, direction 222 is different from direction 224, and direction 222 is preferably vertical with direction 224.Therefore, in this embodiment, the fixed-site of rough turn cutter 204 on tool rest 202 is motionless, and the position of shaving tool 206 on this tool rest 202 can be adjusted but not maintain static, and therefore can carry out the fine setting of position to shaving tool 206.So, in other embodiments, change all can be adjusted in the position of all cutters on tool rest.
As shown in Figure 3, in this example embodiment, roller 226 is arranged on the dead ahead of rough turn cutter 204 and shaving tool 206, carry out Surface Machining in order to rough turn cutter 204 and 206 while of shaving tool pair roller 226, thereby direction 222 indications are preferably the direction of vertically advancing or vertically retreating towards roller 226 for shaving tool 206.In addition, rough turn cutter 204 is on tool rest 202 with shaving tool 206 and is arranged side by side, thus direction 224 indications be preferably for shaving tool 206 towards rough turn cutter 204 side direction are vertically advanced or side direction vertically retreats direction.
In certain embodiments, when the processing unit (plant) of roller micro groove comprises cutter more than three, tool rest 202 can comprise several pedestals 216 that a pedestal 212, several sliding parts 218 and quantity and sliding part 218 are identical, wherein pedestal 212 is provided with the identical chute 214 of quantity and pedestal 216 and sliding part 218, and sliding part 218 correspondence respectively is embedded in these chutes 214.Each sliding part 218 includes a slide rail 220, and these slide rails 220 are then corresponding respectively to be embedded in the bottom of pedestal 216, and each pedestal 216 can slide along slide rail 220, as the tool rest configuration of above-mentioned example embodiment.In the same manner, each sliding part 218 can be with respect to the slip of pedestal 212 travel directions 222, and makes the slip of each pedestal 216 with respect to pedestal 212 travel directions 222, and each pedestal 216 can carry out the slip of other direction 224 with respect to another pedestal 212.Wherein, direction 222 is different from direction 224, and direction 222 is preferably vertical with direction 224.Similarly, pedestal 212 is equipped with a cutter fixing port with each pedestal 216, and these cutter fixing ports all are positioned at the same example of tool rest 202, is provided with and is fixed in these cutter fixing ports and each cutter is corresponding respectively.By the design of sliding part slidably 218 with pedestal 216, make that being located at every on the pedestal 216 can adjust the location to cutter separately, and the different purposes of cutting can be provided, more can shorten the cutting time.
Yet more noticeable is that in other embodiments of the invention, the tool rest of the processing unit (plant) of roller micro groove can be single base construction, and is not equipped with the relatively-movable pedestal in several positions.
Please referring again to Fig. 2 and Fig. 3, in this example embodiment, be separately fixed at rough turn cutter 204 and shaving tool 206 in the cutter fixing port 208 and 210 of tool rest 202 for the object of desiring to process, for example roller 226, have a cutting-in respectively, the cutting-in of wherein rough turn cutter 204 is greater than the cutting-in of shaving tool 206.In one embodiment, each cutter all has cutting-in, and the cutting-in of each cutter is all inequality.In a preferred embodiment, have the cutter of big cutting-in, its nose radius is bigger; And the cutter with less cutting-in, its nose radius is less.
In a preferred embodiment, all cutters of the processing unit (plant) of roller micro groove are sizes of the cutting-in that has according to each cutter, arrange and be docile and obedient preface.Generally speaking, in a tool rest, the cutter that first pair roller carries out machining is arranged on first of all cutter fixing ports, and the cutting-in of being located at the cutter of this first cutter fixing port is maximum in all cutters; The cutting-in that is arranged on the cutter in second the cutter fixing port that is next to first cutter fixing port then is inferior big in all cutters; All the other cutters are provided with in regular turn according to above-mentioned rule.For example, as Fig. 2 and shown in Figure 3, in rough turn cutter 204 and shaving tool 206, the nose radius of rough turn cutter 204 is big and cutting-in is bigger, and therefore rough turn cutter 204 is arranged in first cutter fixing port 208 of tool rest 202; On the other hand, the nose radius of shaving tool 206 is less and cutting-in is less, so shaving tool 206 is arranged in the next cutter fixing port 210 of first cutter fixing port 208 of tool rest 202.In a preferred embodiment, the cutter that has minimum cutting-in in these cutters is preferably the employing diamond cutter, in order to the surface of accurately repairing established little groove.
Please refer to Fig. 4, it is the enforcement schematic diagram that illustrates according to the processing method of a kind of roller micro groove of a preferred embodiment of the present invention, and please in the lump with reference to Fig. 2 and Fig. 3.In an example embodiment, can provide the processing unit (plant) 200 of roller micro groove earlier.Simultaneously, roller 226 is provided, and the side surface that makes roller 226 is over against the rough turn cutter 204 and shaving tool 206 of the processing unit (plant) 200 of roller micro groove, and wherein the distance between the side surface of shaving tool 206 and roller 226 is slightly less than the distance between the side surface of rough turn cutter 204 and roller 226.Because the spacing of desiring to be limited between roller 226 lip-deep adjacent two grooves 232 and 234 228 is common much smaller than the distance 230 between rough turn cutter 204 and the shaving tool 206, therefore in one embodiment, 204 pairs of rollers 226 that roll fast of rough turn cutter carry out the several cutting, and after forming little groove 232 of several thick tool blanks on roller 226 side surfaces, being located at shaving tool 206 after the rough turn cutter 204 just begins the surface of little groove 232 of first formation is cut, and the surface of this little groove 232 of refine, and then finish the complete little groove 234 of structure.Because the cutting-in of rough turn cutter 204 is greater than shaving tool 206, and the nose radius of rough turn cutter 204 is greater than the nose radius of shaving tool 206, therefore utilize rough turn cutter 204 to remove lot of materials on the surface local zone of roller 226 earlier, only have little groove 232 of blank and on roller 226 surfaces, form, this only has little groove 232 of blank to utilize shaving tool 206 finishing impressions subsequently again, and this little groove 232 of only having blank is accomplished the little groove 234 that meets desired structure.Thus, can reduce the consume of shaving tool 206, and can prolong the service life of shaving tool 206, more can reduce the manufacture craft cost.In addition, because during little groove 234 of roller 226 is made, most manufacture craft is the most of material in the required roller material that removes when utilizing rough turn cutter 204 to remove to form little groove 234 simultaneously in the time, come refine only to have a surface of little groove 232 of blank with utilizing shaving tool 206, therefore can shorten the manufacture craft time widely.
In another embodiment, when if the spacing of required roller micro groove equals distance 230 between rough turn cutter 204 and the shaving tool 206, then form on roller 226 surfaces and only have behind little groove 232 of blank utilizing rough turn cutter 204 to carry out a cutting step, the back to back step of cutting together down can be utilized shaving tool 206 to come this little groove 232 of refine simultaneously and finishes little groove 234, and utilizes rough turn cutter 204 to form another on roller 226 surfaces only to have little groove 232 of blank.
At last, after rough turn cutter 204 was finished the cutting process of whole roller 226, the follow-up shaving tool 206 that promptly utilizes separately cut, and finishing the surperficial refine of the still unfinished little groove 232 in the place ahead, and finished all the little grooves 234 on the roller 226.Therefore, from the foregoing description as can be known, each little groove that meets desired structure needs to cut through at least two roads that at least two different cutters are carried out.
By above-mentioned example embodiment as can be known, an advantage of embodiments of the invention is exactly because be provided with rough turn cutter and shaving tool simultaneously on the tool rest of the processing unit (plant) of roller micro groove, successively to carry out the processing with groove, so can reduce the loss of shaving tool.
By above-mentioned example embodiment as can be known, another advantage of embodiments of the invention is exactly because increase the service life of the shaving tool of the processing unit (plant) of roller micro groove, therefore can reduce the processing cost of roller micro groove.
By above-mentioned example embodiment as can be known, the another advantage of embodiments of the invention is exactly because the processing method of roller micro groove is to utilize rough turn cutter to remove lot of materials with the rough little groove that forms on roller surface earlier, utilize shaving tool to come the surface of this little groove of refine again, therefore the abrasion that can slow down shaving tool, and the processing reliability of the little groove of elevator wheel significantly, and can improve the structural precision of little groove.
By above-mentioned example embodiment as can be known, an advantage again of embodiments of the invention is exactly because the processing method of roller micro groove can be under same cutting passage, finish simultaneously and remove lot of materials to form the refine of little groove and little flute surfaces, therefore can reduce the cutting passage widely, and can reduce the cutting time that roller is processed, but and then the working (machining) efficiency of the little groove of elevator wheel.
Though disclosed the present invention in conjunction with an above preferred embodiment; yet it is not in order to limit the present invention; anyly be familiar with this operator in this technical field; without departing from the spirit and scope of the present invention; can be used for a variety of modifications and variations, thus protection scope of the present invention should with enclose claim was defined is as the criterion.