CN111439010A

CN111439010A - Optical function board and preparation method thereof

Info

Publication number: CN111439010A
Application number: CN202010372417.6A
Authority: CN
Inventors: 黄海涛; 刘晓东; 朱新远
Original assignee: Nantong Chuangyida New Material Co ltd
Current assignee: Nantong Chuangyida New Material Co ltd
Priority date: 2020-05-06
Filing date: 2020-05-06
Publication date: 2020-07-24

Abstract

The invention provides an optical function plate and a preparation method thereof, wherein the optical function plate comprises a light emitting layer, a main body layer and a light entering layer which are sequentially connected, the main body layer comprises a base body and a plurality of micropore structures positioned in the base body, and the distribution density of the micropore structures is gradually reduced along the direction from the center of the base body to the outer edge. The invention adopts the expandable polystyrene as the base material of the main body layer, so that the prepared optical function plate has a foaming micropore structure, and simultaneously, the particle size of pores in the foaming base material layer, the thickness of the base material layer and the processing uniformity are controlled by controlling the processing temperature, the extrusion amount, the extrusion linear speed and other parameters of the main body layer extruder and adjusting the content of expandable polystyrene particles in the processing process of the plate; the process is simple, the used materials are few, the raw material consumption and the production cost can be reduced, and a new idea is provided for the light weight of the optical function plate.

Description

Optical function board and preparation method thereof

Technical Field

The invention relates to the technical field of backlight and illumination, in particular to an optical function plate and a preparation method thereof.

Background

The optical sheet is widely applied to liquid crystal display, L ED lighting and imaging display systems, and by means of chemistry or physics, when light encounters two media with different refractive indexes (densities) in the traveling path, the physical phenomena of refraction, reflection and scattering are generated, the light coupled into the sheet is reflected and refracted, and a linear light source or a point light source is converted into a surface light source, so that the effect of homogenizing the light source is realized.

At present, the base material of the optical plate is generally made of plastics such as PMMA/PC/PE/PS, but the optical plate has the defects of insufficient diffusibility, poor light homogenizing effect and heavy quality due to single material.

Disclosure of Invention

The invention aims to solve the following problems to a certain extent: how to provide an optical function board with higher uniformity and brightness, lower power consumption and lighter weight.

In order to solve the above problems, the present invention provides an optical function plate, which is manufactured by in-mold co-extrusion in an extruder, and includes a light emitting layer, a main body layer and a light entering layer, which are connected in sequence, where the main body layer includes a base body and a plurality of microporous structures located in the base body, and the distribution density of the microporous structures is gradually reduced along the direction from the center of the base body to the outer edge.

Optionally, the pore size of the microporous structure is 5-100 μm.

Optionally, the thickness of the light emitting layer and the light incident layer accounts for 9% -11% of the total thickness of the optical functional plate.

Optionally, the total thickness of the optical function plate is 0.8-3.0 mm.

Optionally, a plurality of microstructures with preset shapes are arranged on one surface of the light emergent layer, which faces away from the main body layer, and/or one surface of the light incident layer, which faces away from the main body layer.

Optionally, the preset shape includes at least one of a prism shape, a quadrangular pyramid shape, a semi-sphere shape, a triangular frustum shape, a triangular pyramid shape, a cone frustum shape, and a sand grinding shape.

Another objective of the present invention is to provide a method for manufacturing an optical function board, so as to provide an optical function board with high uniformity and brightness, low power consumption, and lighter weight.

In order to achieve the purpose, the technical scheme of the invention is realized as follows:

a method for preparing an optical function plate, which is used for preparing the optical function plate, and comprises the following steps:

respectively feeding the light-emitting layer mixed material, the main body layer mixed material and the light-entering layer mixed material into three extruders, wherein the main body layer mixed material comprises expandable polystyrene or a mixture of the expandable polystyrene and polystyrene;

respectively melting the mixed materials in the three extruders, and then co-extruding in a die to form a composite board, wherein the melting temperature of the mixed material of the light emitting layer and the light incident layer is 5-15 ℃ higher than that of the mixed material of the main layer;

and performing edge cutting treatment on the composite board according to a preset size, and then performing dust removal, cooling and shaping to obtain the optical function board.

Optionally, after the preset mixed materials in the three extruders are melted and then co-extruded in the die to form a composite board, the method further includes the following steps:

and hot-pressing the upper surface and/or the lower surface of the composite board to form corresponding microstructures through a roller with a microstructure in a preset shape engraved on the surface.

Alternatively, the amount of the surfactant, in parts by weight,

the components of the light emitting layer mixture comprise: 72-95% of polystyrene, 4-10% of siloxane light diffusant, 0.1-2% of ultraviolet absorbent, 0.1-2% of light stabilizer, 0.1-2% of antioxidant, 0.2-2% of antistatic agent and 0.5-10% of toughening agent;

the components of the main body layer mixing material comprise: 48-99% of expandable polystyrene, 0-39.0% of polystyrene, 0.1-2% of ultraviolet absorbent, 0.1-2% of light stabilizer, 0.1-2% of antioxidant, 0.2-2% of antistatic agent and 0.5-5% of toughening agent;

the light incident layer mixture comprises the following components: 57-90% of polystyrene, 9-30% of siloxane light diffusant, 0.1-2% of ultraviolet absorbent, 0.1-2% of light stabilizer, 0.1-2% of antioxidant, 0.2-2% of antistatic agent and 0.5-5% of toughening agent.

Optionally, the extruders corresponding to the light emitting layer mixture and the light incident layer mixture both include a vacuum exhaust device, and a vacuum degree of the vacuum exhaust device is-0.08 to 0.1 Mpa.

Compared with the prior art, the optical function plate and the preparation method thereof provided by the invention have the following advantages:

(1) according to the invention, the plurality of microporous structures are arranged in the main body layer, and the position distribution of the microporous structures is limited, so that the number of the microporous structures is smaller at the position on the substrate closer to the light emitting layer or the light entering layer, and thus, the microporous structures are beneficial to the diffusion of light spots, and the light guiding property of the optical function plate is enhanced; meanwhile, the problems that the main body layer is poor in binding force with the light emitting layer and the light incident layer and is easy to fall off due to the fact that the microporous structure in contact with the light incident layer or the light emergent layer is too much are solved, and the stability of the whole structure of the optical function plate is improved.

(2) The invention adopts the expandable polystyrene as the base material of the main body layer, so that the prepared optical function plate has a foaming micropore structure, and simultaneously, the particle size of pores in the foaming base material layer, the thickness of the base material layer and the processing uniformity are controlled by controlling the processing temperature, the extrusion amount, the extrusion linear speed and other parameters of the main body layer extruder and adjusting the content of expandable polystyrene particles in the processing process of the plate; the process is simple, the used materials are few, the raw material consumption and the production cost can be reduced, and a new idea is provided for the light weight of the optical function plate.

Drawings

Fig. 1 is a schematic flow chart of a method for manufacturing an optical functional plate according to an embodiment of the present invention;

FIG. 2 is a schematic structural diagram of an optical function board according to an embodiment of the present invention;

fig. 3 is a second schematic structural diagram of an optical function board according to an embodiment of the invention.

Description of reference numerals:

1-light emitting layer, 2-main body layer, 21-matrix, 22-micropore structure, 3-light incident layer and 4-microstructure.

Detailed Description

It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict.

It should be noted that all directional indicators (such as upper, lower, left, right, front and rear … …) in the embodiment of the present invention are only used to explain the relative position relationship between the components, the motion situation, etc. in a specific posture, and if the specific posture is changed, the directional indicator is changed accordingly, and the connection may be a direct connection or an indirect connection. In addition, the terms "comprising," "including," "containing," and "having" are intended to be non-limiting, i.e., that other steps and other ingredients can be added that do not affect the results. Materials, equipment and reagents are commercially available unless otherwise specified.

In addition, although the invention has described the forms of S1, S2, S3 and the like for each step in the preparation, the description is only for the convenience of understanding, and the forms of S1, S2, S3 and the like do not represent the limitation of the sequence of each step.

In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail below.

Referring to fig. 2 and 3, an embodiment of the present invention provides an optical functional board, which is manufactured by in-mold co-extrusion through an extruder, and includes a light emitting layer 1, a main body layer 2, and a light incident layer 3, which are connected in sequence, where the main body layer 2 includes a base 21 and a plurality of microporous structures 22 located in the base 21, and the distribution density of the microporous structures 22 gradually decreases along a direction from the center of the base 21 to the outer edge.

Specifically, the optical function board is manufactured by co-extrusion in an extruder die, the main body layer 2 is positioned between the light emitting layer 1 and the light entering layer 3, and the whole structure is a three-layer composite integrated structure. And because the main body layer 2 takes Expandable Polystyrene (EPS) particles as main raw materials, a plurality of microcellular structures 22 can be generated by foaming in the preparation process, the foamed microcellular structures 22 can enable light rays to be refracted, reflected and scattered in different directions, so that the traveling route of the light rays is changed, the effect of optical diffusion is realized by fully dispersing incident light rays to generate optical diffusion, the effects of uniform diffusion and defect covering of the light rays entering the board can be further improved, and the using amount of a diffusing agent and the main materials can be reduced. However, the strength of the main body layer 2 is reduced to some extent by the inclusion of the plurality of pore structures 22, and the pore structures 22 also affect the bonding force between the main body layer 2 and the light exit layer 1 and the light entrance layer 3.

Here, the distribution density of the microporous structures 22 gradually decreases along the direction from the center of the substrate 21 to the outside, that is, the number of the microporous structures 22 distributed in the substrate 21 is smaller as the substrate layer 2 and the light incident layer 3 are closer.

Therefore, in the embodiment of the invention, the plurality of microporous structures 22 are arranged in the main body layer 2, and the positions of the microporous structures 22 are limited, so that the positions of the substrate 21 closer to the light emitting layer 1 or the light entering layer 3 are smaller in the number of the microporous structures 22, which not only ensures that the microporous structures 22 can be beneficial to the diffusion of light spots, but also enhances the light guiding performance of the optical function plate; meanwhile, the problems that the main body layer 2 is poor in binding force with the light emitting layer 1 and the light incident layer 3 and is easy to fall off due to the fact that the microporous structures 22 in contact with the light incident layer 3 or the light emitting layer 1 are too many are solved, and the stability of the whole structure of the optical function board is improved.

The base material of the light emergent layer 1 and the base material of the light incident layer 3 both comprise one or more of polymethyl methacrylate (PMMA), Polystyrene (PS), Polycarbonate (PC), Polyethylene (PE) and polypropylene (PP); the substrate of the body layer 2 comprises expandable polystyrene or a mixture of expandable polystyrene and polystyrene.

In the preparation process, the melting temperature of the light inlet layer mixed material and the light outlet layer mixed material in the mold is limited to be 5-15 ℃ higher than that of the main body layer mixed material, and the traction speed and the pressing pressure of the plate are properly increased, so that the light inlet layer mixed material and the light outlet layer mixed material can permeate into micropores formed by the main body layer mixed material at an interface to a certain extent, multiple layers of materials at the interface can be better fused, the density of a microporous structure near the interface of the main body layer is reduced, the gradient density of the microporous structure of the main body layer is formed, and the firmness of compounding of three layers of materials is ensured.

Therefore, by arranging different raw materials, EPS is creatively introduced into the optical function board, and by utilizing the foaming property of the EPS, the microcellular structure 22 is added in the optical function board, so that the light guide performance of the EPS is improved, and meanwhile, the weight of the EPS main body layer under the same volume is far less than that of the main body layer made of PMMA/PS/PC/PE/PP. Therefore, the optical function plate with the foaming structure provided by the invention is high in light weight degree, can be operated by a mechanical arm, is convenient to transport and assemble, improves the production efficiency, saves the processing time and cost, and is beneficial to large-scale popularization.

In addition, the micro-porous structure 22 can refract, reflect and scatter light in different directions, thereby facilitating light diffusion, the aperture has great influence on the light traveling path, and the larger the aperture, the lighter the weight, but the strength of the plate is also reduced correspondingly. Therefore, in the present embodiment, it is preferable that the pore size of the microporous structure 22 is in the range of 5 to 100 μm.

Compared with a light source, the light emitting layer 1 is positioned on the uppermost layer of the optical function plate and is used as a light emitting surface, the light incident layer 3 is positioned on the lowermost layer of the optical function plate and is used as a light incident surface and is in direct contact with the light source, and the two layers belong to function layers. The main body layer 2 made of EPS is positioned in the middle of the optical function plate as a main body, and a plurality of micropore structures 22 exist, so that the main body layer is arranged as the thickest layer, the using amount of plates can be effectively reduced, the material cost is reduced, and the light and thin of the backlight module can be better realized; and the thickness of the layer of the foaming microporous structure 22 is a little larger, so that the light stroke of the foaming structure can be increased, and the uniform diffusion effect of light entering the plate is further improved. In practical production, the thickness of each layer can be flexibly adjusted within a reasonable interval range according to requirements, in the implementation of the invention, preferably, the thickness of the light emergent layer 1 and the thickness of the light incident layer 3 both account for 9% -11% of the total thickness of the optical function board, wherein the total thickness of the optical function board is 0.8-3.0 mm.

Furthermore, a plurality of microstructures 4 with preset shapes are arranged on the surface of one surface of the light emergent layer 1 departing from the main body layer 2 and/or one surface of the light incident layer 3 departing from the main body layer 2.

When the light emitting layer 1, the main body layer 2 and the light entering layer 3 are co-extruded into the optical function board through the extruder die, the plurality of microstructures 4 in the preset shapes are pressed on the upper surface and/or the lower surface of the optical function board, so that the surface of the optical function board is in a non-smooth structure, the interference problem caused by matching liquid crystal glass can be avoided, a certain air layer is reserved, and the brightening effect of the optical function board is improved.

The preset shape comprises at least one of a prism shape, a quadrangular pyramid shape, a semi-sphere shape, a triangular frustum shape, a triangular pyramid shape, a cone shape, a conical frustum shape and a sand grinding mold, and can be selected according to actual needs. The area and height of the bottom surface of the microstructure 4 with the preset shape can be set at will, and in the embodiment of the invention, the height range of the microstructure 4 relative to the surface of the light incident layer 3 or the surface of the light emitting layer 1 is 0.1-20 μm.

Referring to fig. 1, another embodiment of the present invention provides a method for manufacturing an optical functional plate, which includes the following steps:

s1, respectively feeding the light emergent layer mixed material, the main body layer mixed material and the light incident layer mixed material into three extruders, wherein the main body layer mixed material comprises expandable polystyrene or a mixture of expandable polystyrene and polystyrene; setting the extruder to preset parameters, wherein the preset parameters comprise metering pump pressure, feeding rate, host rotating speed and extrusion temperature;

s2, respectively melting the mixed materials in the three extruders, and then co-extruding in a die to form a composite board, wherein the melting temperature of the mixed material of the light emergent layer and the melting temperature of the mixed material of the light incident layer are both 5-15 ℃ higher than that of the mixed material of the main layer;

and S3, trimming the composite board according to a preset size, and then removing dust, cooling and shaping to obtain the optical function board.

Specifically, in step S1, parameters such as the temperature of the extruder, the pressure of the metering pump, the feeding rate, the rotating speed of the host and the like are set, then the preset mixed materials are weighed according to the respective proportions and uniformly mixed in the mixer, and are put into material ports corresponding to the extruders, and the three extruders work simultaneously to enable the materials in the molten state in the extruders to be compounded in the die and then extruded into a whole through the die ports, so that the optical function plate with the multilayer structure is prepared, that is, the optical function plate is prepared by in-die co-extrusion of the extruders.

The light-emitting layer comprises the following mixed materials in parts by weight: 72-95% of polystyrene, 4-10% of siloxane light diffusant, 0.1-2% of ultraviolet absorbent, 0.1-2% of light stabilizer, 0.1-2% of antioxidant, 0.2-2% of antistatic agent and 0.5-10% of toughening agent;

the main body layer mixing material comprises the following components: 48-99% of expandable polystyrene, 0-39.0% of polystyrene, 0.1-2% of ultraviolet absorbent, 0.1-2% of light stabilizer, 0.1-2% of antioxidant, 0.2-2% of antistatic agent and 0.5-5% of toughening agent;

the components of the light incident layer mixture comprise: 57-90% of styrene, 9-30% of siloxane light diffusant, 0.1-2% of ultraviolet absorbent, 0.1-2% of light stabilizer, 0.1-2% of antioxidant, 0.2-2% of antistatic agent and 0.5-5% of toughening agent.

In addition, the content of the diffusing agent in the light incident layer 3 is greater than that in the light emitting layer 1. The light emitting layer 1 is used as a light emitting surface, the effect of shielding the middle layer foaming microporous structure 22 can be achieved by adding the dispersing agent, and meanwhile, the light emitting angle can be adjusted by the dispersing agent, so that the fineness and the uniformity of a picture are ensured. The light incident layer 3 is used as a light incident surface, and a dispersing agent is added to diffuse an incident light source into the plate, so that light reflection is reduced, a point light source is converted into a surface light source, and the brightness of a picture is uniform. The light emitting layer 1 and the light incident layer 3 have different functions of the diffusant, so that the dosage of the diffusant is adjusted according to different purposes, the reaction accuracy can be further improved, and the optical effect of the prepared optical function board is improved.

Ultraviolet absorbers, light stabilizers, antioxidants, antistatic agents and toughening agents are used in the mixed materials, the ultraviolet absorbers are used for preventing ultraviolet rays from aging the plates, and the light stabilizers are used for eliminating or slowing down photochemical reaction possibility and preventing or delaying the process of light aging; the antioxidant is used for preventing the plate from aging due to oxygen, the antistatic agent can reduce static electricity, and the toughening agent can reduce the brittleness of the plate; the additives are conventional substances for production, and can be selected according to requirements in actual production.

In step S2, after the mixed materials in the three extruders are melted, the mixed materials are extruded into a die to be compounded and extruded to form a composite board, that is, the uniformly stirred mixed light emitting layer mixed material, main layer mixed material and light incident layer mixed material are respectively fed to corresponding feed ports to be melted at high temperature; compounding the light emergent layer mixed material, the main body layer mixed material and the light incident layer mixed material in a molten state in a die and extruding the multilayer substrate through a die discharge port, and the method specifically comprises the following steps:

selecting a corresponding die according to a four-layer extrusion process, installing an extruder head, and checking the integrity of extrusion equipment and each rotating part; adjusting the temperature control meter to the working temperature, heating the cylinder mould, and keeping the temperature for 20-30 minutes after the temperature reaches a set value; the three extruder hoppers respectively correspond to the light emitting layer 1, the main body layer 2 and the light entering layer 3, and respectively feed the uniformly stirred light emitting layer mixed material, main body layer mixed material and light entering layer mixed material to the feed ports of the corresponding substrates; replacing filter meshes of each machine, sequentially turning on a metering pump, rotating a screw motor, setting parameters of pressure, feeding speed and rotating speed of the metering pump, allowing the plastic material to pass through a machine barrel and be plasticized, extruding by an extruder, and cleaning a die lip; and adjusting parameters such as a metering pump, a main line speed, pressure and the like to start extrusion.

Because each layer uses plastic materials with different materials, the temperature settings of the three extruders corresponding to related materials have certain difference, the extruders corresponding to the light emitting layer mixed material and the light incident layer mixed material both comprise a vacuum exhaust device, and the preset parameters also comprise vacuum degree, in the embodiment of the invention, the vacuum degree is preferably-0.08 to 0.1 Mpa.

Since the base material of the main layer 2 comprises EPS and PS, the temperature of co-extrusion needs to be controlled to increase the bonding force between the two, and the extrusion speed and the extrusion amount need to be set to match the temperature, so as to allow the foamed cellular structure 22 to be uniformly and controllably produced.

In the embodiment of the present invention, in order to realize that the distribution density of the microporous structure 22 in the main body layer 2 is gradually reduced along the direction from the center of the substrate 21 to the outer edge, the melting temperature of the light emitting layer mixed material and the melting temperature of the light entering layer mixed material are both set to be 5-15 ℃ higher than the melting temperature of the main body layer mixed material, so that the light entering layer mixed material and the light emitting layer mixed material can permeate into micropores formed by the main body layer mixed material at the interface to a certain extent, and on one hand, the microporous structure near the interface of the main body layer (that is, the microporous structure is filled by the light layer mixed material and the light entering layer mixed material) can be reduced, thereby forming the gradient density of; on the other hand, the multilayer materials at the interface can be better fused, and the firmness of compounding of the three layers of materials is ensured.

The extrusion temperature of the main body layer 2 needs to be controlled, the overall control temperature tends to increase gradually, and the traction pressure, the traction speed, the linear speed and the extrusion amount which are matched with the width and the thickness need to be set. In the embodiment of the invention, the temperature of the first zone blanking zone is 130-. The extrusion amount is generally 220-250kg/h, the thickness of the extruded sheet is generally 1.2-1.5mm, and the pressure of the drawing roll is 0.3-0.5 MPa. When the width is 650 plus 850mm, the linear velocity is 3.0-3.8m/min, and the traction velocity is 3.06-3.86 m/min; when the width is 850-1050mm, the linear velocity is 2.5-3.0m/min, and the traction velocity is 2.56-3.06 m/min; when the width is 1050-; when the width is 1250-1500mm, the linear velocity is 1.5-2.0m/min, and the drawing speed is 1.56-2.06 m/min. In actual production, the method can be selected according to requirements.

In step S3, the composite board is subjected to edge cutting treatment according to a preset size, and then subjected to dust removal and cooling setting, so as to obtain the optical function board, which specifically comprises:

according to production requirements, the width and the thickness of the plate are adjusted by a lower cutter, and the stacking between rollers is adjusted; and (3) removing dust after trimming the composite board, gradually conveying the composite board to the rear section of a production line through a conveying device, and gradually cooling and shaping in traction to obtain the optical function board.

Certainly, in order to facilitate storage and transportation, the rear section cutting unit of the production line can be cut into a second preset size, and the second preset size is grabbed, stacked and stacked by a mechanical arm, cleaned, packaged and warehoused immediately.

According to the preparation method of the optical function board provided by the invention, the prepared optical function board has the foaming microporous structure 22 by adopting the expandable polystyrene as the base material of the main body layer 2, meanwhile, the particle size of pores in the foaming base material layer, the thickness of the base material layer and the processing uniformity are controlled by controlling the processing temperature, the extrusion amount, the extrusion linear speed and other parameters of the main body layer extruder and adjusting the content of expandable polystyrene particles in the processing process of the board, and meanwhile, the problems of poor bonding force and easy peeling of the expandable polystyrene material and other materials are avoided.

Compared with the traditional optical function board, the preparation method of the optical function board provided by the invention has the advantages of simple process, less material consumption, capability of reducing raw material consumption and production cost, and capability of highly combining the expandable polystyrene and the styrene to introduce the foaming material into the optical function board, thereby providing a new idea for light weight of the optical function board. Meanwhile, the optical function board prepared by the invention can further improve the uniform diffusion and defect covering effects of light rays entering the board by utilizing the micropore structures 22 in the main body layer 2, and the diffusion components are added in the light emergent layer 1 and the light incident layer 3, so that the light incident quantity of the light incident surface and the light emergent uniformity of the light emergent surface can be increased, meanwhile, a better shielding effect is achieved on the micropore structures 22 in the middle main body layer, the light emergent display effect is enhanced, and the application environment in backlight and illumination products is expanded. .

Further, the method for preparing an optical function board provided by the present invention, before performing post-processing on the composite board in step S3, further includes the steps of:

and S4, hot-pressing the upper surface and the lower surface of the composite board to form corresponding microstructures 4 through a roller with the surface engraved with the microstructures 4 in the preset shape.

The roller is generally a roller with the surface engraved with the microstructure 4 in the preset shape, the composite board is placed on a workbench, and the roller rolls to hot press the upper surface and/or the lower surface of the composite board into the microstructure 4 in the preset shape. Of course, the composite board can also be placed between the upper roller and the lower roller, and the upper surface and/or the lower surface of the composite board is hot-pressed into the composite board with the microstructure 4 with the preset shape by rotating the upper roller and the lower roller.

The steps S1, S2, S3 and S4 are integrally manufactured on line, so that the equipment investment and the process loss of processing and treating the single materials respectively are reduced, the manpower investment and the product operation reject ratio are reduced, and the production automation efficiency is improved.

Therefore, the plurality of microstructures 4 in the preset shape are pressed on the upper surface and/or the lower surface of the optical function plate, light is better refracted and reflected when passing through, the uniform diffusion effect of light is increased, the interference problem caused by matching liquid crystal glass can be avoided, and the brightening effect of the optical function plate is improved.

The invention will be further illustrated with reference to the following specific examples. It should be understood that these examples are for illustrative purposes only and are not intended to limit the scope of the present invention. The following examples are examples of experimental procedures not specified under specific conditions, generally according to the conditions recommended by the manufacturer. Unless otherwise indicated, percentages and parts are by weight.

Example 1

The embodiment provides a method for preparing an optical function board, which comprises the following steps:

1) preparing materials: drying the plastic particles needed by the light emitting layer 1, the main body layer 2 and the light entering layer 3 at 50-60 ℃ for 2-4 hours, mixing the plastic particles and the additive according to a certain ratio, and uniformly stirring in a mixer to form a mixed material for later use;

the mixed material of the light emergent layer comprises the following components in parts by weight: 84.7 percent of PS, 8.0 percent of siloxane light diffusant, 0.2 percent of ultraviolet absorbent, 0.2 percent of light stabilizer, 0.4 percent of antioxidant, 0.5 percent of antistatic agent and 6 percent of toughening agent; the main layer mixed material comprises the following components in parts by weight: 97.7 percent of EPS, 0.2 percent of ultraviolet absorbent, 0.2 percent of light stabilizer, 0.4 percent of antioxidant, 0.5 percent of antistatic agent and 1.0 percent of toughening agent; the light entering layer mixed material comprises the following components in parts by weight: 80.7% of PS, 13.0% of siloxane light diffusant, 0.2% of ultraviolet absorbent, 0.2% of light stabilizer, 0.4% of antioxidant, 0.5% of antistatic agent and 5% of toughening agent.

2) Die matching and equipment inspection: selecting a corresponding die according to a four-layer extrusion process, installing an extruder head, and checking the integrity of extrusion equipment and each rotating part;

3.) temperature rising: adjusting the temperature control meter to the working temperature, heating the cylinder mould, and keeping the temperature for 20-30 minutes after the temperature reaches a set value;

4) extruding: the three extruder hoppers respectively correspond to the light emitting layer 1, the main body layer 2 and the light entering layer 3, and respectively feed the uniformly stirred mixture of the substrate layers to the feed ports of the corresponding substrate layers; replacing filter meshes (300 meshes and 400 meshes) of each machine, sequentially turning on a metering pump, rotating a screw motor, setting parameters such as pressure, feeding speed, rotating speed of a main machine and the like of the metering pump, allowing the plastic material to pass through a machine barrel and be plasticized, extruding the plastic material by an extruder, and cleaning a die lip; adjusting parameters such as a metering pump, a main line speed and pressure, and starting extrusion;

each extruder is divided into eight heating zones, specifically, the temperature of a blanking zone in a first zone of the extruder of the light emitting layer 1 is 170-; the temperature of a first zone blanking zone of the main body layer 2 extruder is 120-; the temperature of a blanking zone in a first zone of the light entrance layer 3 extruder is 185-plus-one, the temperature of a preheating zone in a second zone is 185-plus-one, the temperature of a heating zone in a third zone is 195-plus-one, the temperature of a glue melting zone in a fourth zone and a fifth zone is 205-plus-one, the temperature of a plasticizing zone in a sixth zone and a plasticizing zone in a seventh zone is 215-plus-one and 220-plus-one, and the temperature of a glue mixing and plasticizing zone in an eighth zone is 220.

The extruders corresponding to the light emitting layer 1 and the light entering layer 3 are provided with vacuumizing exhaust devices, the vacuum degree is controlled to be-0.08 to 0.1Mpa, and the extruder of the main layer 2 is not provided with the vacuumizing exhaust devices. In this embodiment, the preset shape is a frosted shape, and the preset conditions are as follows: the temperature of the die is 190 ℃ and 200 ℃; the temperature of the upper frosted structure roller is 100-115 ℃, the temperature of the middle frosted structure roller is 95-105 ℃, and the temperature of the mirror surface structure roller is 80-90 ℃; the pressure before the pump is 3.5 Mpa plus or minus 0.5 Mpa; on the premise of unchanging length and width, the thickness is changed by 0.1mm when the speed is normally regulated to 2.0 m/min.

5) Compounding and pressing plates: after materials in the three extruders are melted, extruding the materials into a die for compounding, and extruding a composite board through a discharge port of the die; uniformly heating and pressing the upper surface and the lower surface of the plate into the frosted microstructures 4 by using a roller with the frosted mold microstructures 4 engraved on the surface;

6) dedusting, cooling and drawing: according to production requirements, the width and the thickness of the plate are adjusted by a lower cutter, and the stacking between rollers is adjusted; removing dust after trimming the multilayer substrate, gradually conveying the plate to the rear section of a production line through a conveying device, and gradually cooling and shaping during traction;

7) cutting and packaging: the plates are gradually conveyed to a rear section cutting unit of a production line through a conveying device of the traction unit, cut into required sizes, grabbed by a mechanical arm, stacked, cleaned, packaged and warehoused.

The total thickness of the optical functional plate prepared in this embodiment is 1.5mm, wherein the thicknesses of the light emergent layer 1 and the light incident layer 3 are both 0.15mm, the thickness of the main body layer 2 is 1.2mm, and the height of the microstructure 4 is 0.1 μm.

Example 2

This example differs from example 1 in that:

in the step 1), the mixed material of the light emitting layer consists of the following components in parts by weight: 83.7% of PS, 10.0% of siloxane light diffusant, 0.2% of ultraviolet absorbent, 0.2% of light stabilizer, 0.4% of antioxidant, 0.5% of antistatic agent and 5% of toughening agent; the main layer mixed material comprises the following components in parts by weight: 57.7% of EPS, 40.0% of PS, 0.2% of ultraviolet absorbent, 0.2% of light stabilizer, 0.4% of antioxidant, 0.5% of antistatic agent and 1.0% of toughening agent; the light entering layer mixed material comprises the following components in parts by weight: 81.7% of PMMA, 12.0% of siloxane light diffusant, 0.2% of ultraviolet absorbent, 0.2% of light stabilizer, 0.4% of antioxidant, 0.5% of antistatic agent and 5% of toughening agent;

5) compounding and pressing plates: after materials in the three extruders are melted, extruding the materials into a die for compounding, and extruding a composite board through a discharge port of the die; hot-pressing the lower surface of the plate into a prismatic microstructure 4 and hot-pressing the upper surface of the plate into a frosted microstructure 4 by using a roller with prismatic and frosted microstructures 4 carved on the surface (as shown in figure 3);

the other steps and parameters were the same as in example 1.

The total thickness of the optical functional plate prepared in this embodiment is 1.2mm, wherein the thickness of the light emergent layer 1 and the light incident layer 3 is 0.13mm, the thickness of the main body layer 2 is 0.94mm, and the height of the microstructure 4 is 20 μm.

Example 3

This example differs from example 1 in that:

in the step 1), the mixed material of the light emitting layer consists of the following components in parts by weight: 72% of PS, 15% of siloxane light diffusant, 2% of ultraviolet absorbent, 2% of light stabilizer, 2% of antioxidant, 2% of antistatic agent and 10% of toughening agent; the main layer mixed material comprises the following components in parts by weight: 48% of EPS, 39% of PS, 2% of ultraviolet absorber, 2% of light stabilizer, 2% of antioxidant, 2% of antistatic agent and 5% of toughening agent; the light entering layer mixed material comprises the following components in parts by weight: 57% of PMMA, 30% of siloxane light diffusant, 2% of ultraviolet absorbent, 2% of light stabilizer, 2% of antioxidant, 2% of antistatic agent and 5% of toughening agent;

the other steps and parameters were the same as in example 1.

Example 4

This example differs from example 1 in that:

in the step 1), the mixed material of the light emitting layer consists of the following components in parts by weight: 95% of PS, 4% of siloxane light diffusant, 0.1% of ultraviolet absorbent, 0.1% of light stabilizer, 0.1% of antioxidant, 0.2% of antistatic agent and 0.5% of toughening agent; the main layer mixed material comprises the following components in parts by weight: 99% of EPS, 0% of PS, 0.1% of ultraviolet absorber, 0.1% of light stabilizer, 0.1% of antioxidant, 0.2% of antistatic agent and 0.5% of toughening agent; the light entering layer mixed material comprises the following components in parts by weight: 90% of PMMA, 9% of siloxane light diffusant, 0.1% of ultraviolet absorbent, 0.1% of light stabilizer, 0.1% of antioxidant, 0.2% of antistatic agent and 0.5% of toughening agent;

the other steps and parameters were the same as in example 1.

Although the present disclosure has been described above, the scope of the present disclosure is not limited thereto. Various changes and modifications may be effected therein by one of ordinary skill in the pertinent art without departing from the spirit and scope of the present disclosure, and these changes and modifications are intended to be within the scope of the present disclosure.

Claims

1. An optical function board is characterized by comprising a light emitting layer (1), a main body layer (2) and a light entering layer (3) which are sequentially connected, wherein the main body layer (2) comprises a base body (21) and a plurality of micropore structures (22) positioned in the base body (21), and the distribution density of the micropore structures (22) is gradually reduced along the direction from the center of the base body (21) to the outer edge.

2. The optical functional plate according to claim 1, wherein the pore size of the microporous structure (22) is 5 to 100 μm.

3. The optical functional plate according to claim 1, wherein the thickness of the light emitting layer (1) and the light entering layer (3) is 9-11% of the total thickness of the optical functional plate.

4. The optical functional plate according to claim 3, wherein the total thickness of the optical functional plate is 0.8 to 3.0 mm.

5. Optical function board according to any one of claims 1-4, characterized in that the side of the light exit layer (1) facing away from the body layer (2) and/or the side of the light entry layer (3) facing away from the body layer (2) is provided with a plurality of microstructures (4) of a predetermined shape.

6. The optical functional sheet according to claim 5, wherein the predetermined shape includes at least one of a prism type, a quadrangular pyramid type, a hemisphere type, a triangular pyramid type, a cone type, a truncated cone type, and a frosted mold.

7. A method for producing an optical functional sheet according to any one of claims 1 to 6, comprising the steps of:

8. The method for producing an optical functional sheet as claimed in claim 7, further comprising the steps of, after said melting of the mixed materials in three of said extruders and in-mold co-extrusion to form a composite sheet material:

and (3) hot-pressing the upper surface and/or the lower surface of the composite board to form a corresponding microstructure (4) through a roller with a microstructure (4) with a preset shape engraved on the surface.

9. The method for producing an optical functional sheet according to claim 7, wherein the optical functional sheet is produced by, in parts by weight,

10. The method of claim 7, wherein the extruders for the light-emitting layer mixture and the light-entering layer mixture each comprise a vacuum evacuation device having a vacuum of-0.08 to 0.1 Mpa.