CN115097557A - Diffusion plate manufacturing method and diffusion plate - Google Patents
Diffusion plate manufacturing method and diffusion plate Download PDFInfo
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- CN115097557A CN115097557A CN202210705072.0A CN202210705072A CN115097557A CN 115097557 A CN115097557 A CN 115097557A CN 202210705072 A CN202210705072 A CN 202210705072A CN 115097557 A CN115097557 A CN 115097557A
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- 238000000034 method Methods 0.000 claims abstract description 29
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Images
Classifications
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/02—Diffusing elements; Afocal elements
- G02B5/0268—Diffusing elements; Afocal elements characterized by the fabrication or manufacturing method
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/02—Diffusing elements; Afocal elements
- G02B5/0205—Diffusing elements; Afocal elements characterised by the diffusing properties
- G02B5/021—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/02—Diffusing elements; Afocal elements
- G02B5/0205—Diffusing elements; Afocal elements characterised by the diffusing properties
- G02B5/0236—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place within the volume of the element
- G02B5/0242—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place within the volume of the element by means of dispersed particles
Abstract
The application discloses diffuser plate manufacturing method and diffuser plate belongs to the technical field of diffuser plate manufacturing, and the method comprises the following steps: forming a first surface structure on the inner side wall of one side of an injection mold, and forming a second surface structure on the inner side wall of the other side of the injection mold to obtain a diffusion plate mold; and injecting a diffusion plate material into the diffusion plate mold, and performing injection molding to form the diffusion plate with the concave-convex structure on the surface. This application is through pouring into the diffusion plate mould that has first surface texture and second surface texture with diffusion plate material into to obtain the surface and have concave-convex structure's diffuser plate, solved and to have concave-convex structure's problem through diffuser plate cutting technique processing formation surface, avoided because of using the diffusion to cut appearance defects such as deckle edge and foreign matter that the technique brought.
Description
Technical Field
The present disclosure relates to diffuser plate manufacturing technologies, and particularly to a diffuser plate and a method for manufacturing the same.
Background
In the related art, the diffusion plate is mainly manufactured by the following steps: (1) mixing materials; (2) proportioning; (3) mixing and stirring; (4) hot melting extrusion, namely extruding, cooling and molding through a die; (5) rolling to press film; (6) laminating and eliminating static; (7) cutting and processing; (8) cleaning and drying; (9) and (6) blanking.
However, the cutting technique according to (7) can only process a regular planar structure, and cannot process a planar uneven structure by the cutting technique.
Content of application
The present disclosure provides a method for manufacturing a diffusion plate and a diffusion plate, which aims to solve the technical problem that a concave-convex structure cannot be formed on the surface of the diffusion plate by using a cutting technique.
In order to achieve the above object, the present application provides a method for manufacturing a diffusion plate, including:
forming a first surface structure on the inner side wall of one side of an injection mold, and forming a second surface structure on the inner side wall of the other side of the injection mold to obtain a diffusion plate mold;
and injecting a diffusion plate material into the diffusion plate mold, and performing injection molding to form the diffusion plate with the concave-convex structure on the surface.
In one embodiment, the forming of the first surface structure on the inner sidewall of one side of the injection mold includes:
and forming the first surface structure corresponding to the drying lines on the inner side wall of one side of the injection mold.
In an embodiment, the forming a basking pattern on an inner side wall of one side of an injection mold to obtain the first surface structure includes:
and forming the first surface structure corresponding to the drying lines on the inner side wall on one side of the injection mold through chemical corrosion.
In an embodiment, the forming of the second surface structure on the other side inner sidewall of the injection mold includes:
and forming the second surface structure corresponding to the mesh points and/or the microstructures on the inner side wall on the other side of the injection mold.
In an embodiment, the forming a dot and a microstructure on the inner side wall of the other side of the injection mold to obtain the second surface structure includes:
and forming the second surface structure corresponding to the mesh points and/or the microstructures on the inner side wall of the other side of the injection mold through chemical corrosion or laser processing.
In one embodiment, the diffuser plate material comprises, in mass fraction:
95 to 99.9 percent of high-fog high-brightness high-fluidity plastic particles and 0.1 to 5 percent of diffusant.
In one embodiment, the melt flow rate of the high-haze high-brightness high-fluidity plastic particles is greater than or equal to 40cm 3 /min。
In one embodiment, the diffusion agent is a silicon-based diffusion agent.
In one embodiment, the diffuser plate die size is no greater than 55 inch.
According to the diffuser plate manufacturing method provided by the embodiment of the application, a first surface structure is formed on the inner side wall of one side of an injection mold, and a second surface structure is formed on the inner side wall of the other side of the injection mold, so that a diffuser plate mold is obtained; and injecting a diffusion plate material into the diffusion plate mold, and performing injection molding to form the diffusion plate with the concave-convex structure on the surface. From this, this application is through forming first surface texture and second surface texture respectively on two inside walls of injection mold, pour into the diffuser plate material and treat its cooling back into, alright with the surface of first surface texture and second surface texture rendition diffuser plate, obtain the diffuser plate that the surface has concave-convex structure, the problem that can't cut technical processing through the diffuser plate and form the surface and have concave-convex structure has been solved, avoid cutting the technique and make appearance defects such as deckle edge and foreign matter appear in the diffuser plate, and simultaneously, haze and transmissivity have been improved, thereby the influence to demonstration optics and luminance has been reduced, in addition, the diffuser plate of moulding plastics can also improve homogeneity and LED top facula scheduling problem through the site structure and the density of adjustment second surface.
Drawings
FIG. 1 is a schematic flow chart illustrating a method for manufacturing a diffuser plate according to a first embodiment of the present invention;
FIG. 2 is a schematic flow chart of a diffusion plate manufacturing method according to a second embodiment of the present invention
FIG. 3 is a view showing a first surface structure of a diffuser plate mold according to the present invention;
FIG. 4 is a view showing a second surface structure of the diffuser plate mold according to the present invention;
FIG. 5 is a basque pattern corresponding to a first surface structure of a diffuser plate mold according to the present application;
fig. 6 is a dot and/or microstructure diagram corresponding to the second surface structure of the diffuser plate mold according to the present application.
The implementation, functional features and advantages of the object of the present application will be further explained with reference to the embodiments, and with reference to the accompanying drawings.
Detailed Description
It should be understood that the specific embodiments described herein are merely illustrative of and not restrictive on the broad application.
In the prior art, raw materials for manufacturing the diffusion plate are injected into a die, and after the raw materials are extruded and formed, the raw materials are required to be cut to obtain the required appearance. However, the diffusion plate formed by cutting in the prior art has the following defects:
1. the existing diffusion plate has low relative haze and transmittance, influences display optics and brightness, needs to be used by increasing current and consumes more electricity;
2. the existing diffusion plate has large thermal shrinkage and thermal deformation, and the dimensional tolerance and the planeness of the diffusion plate are large in the high-temperature reliability process, so that the optical display is influenced.
3. The existing diffusion plate adopts a cutting technology, only a plane regular framework can be processed, and the diffusion plate with a concave-convex structure or a curved surface structure on the surface cannot be formed;
4. the existing diffuser plate cutting technology is easy to have appearance defects such as burrs, foreign matters, black and white points, processing scratches and the like.
5. The light guide plate is cut by using an extrusion-molded plate, the raw material and the surface structure are shaped and fixed, and the optics cannot be adjusted subsequently according to individual requirements.
The application provides a solution, a first surface structure is formed on the inner side wall of one side of an injection mold, a second surface structure is formed on the inner side wall of the other side of the injection mold, and a diffusion plate mold is obtained; and injecting a diffusion plate material into the diffusion plate mold, and performing injection molding to form the diffusion plate with the concave-convex structure on the surface. From this, this application is through forming first surface texture and second surface texture respectively on two inside walls of injection mold, and after pouring into the diffuser plate material and treating its cooling, alright with first surface texture and the surface of second surface texture rendition diffuser plate, obtain the diffuser plate that the surface has concave-convex structure, have following beneficial effect:
1. injecting a diffusion plate material into a diffusion plate die to form a diffusion plate with a concave-convex structure or a curved surface structure on the surface;
2. after the diffusion plate material is injected into the diffusion plate die, the diffusion plate can be integrally formed through injection molding, and the diffusion plate does not need to be processed by using a cutting technology, so that appearance defects such as burrs, foreign matters, black and white spots, scratches and the like caused by the cutting technology can be avoided;
3. the high-haze high-brightness high-fluidity plastic particles are adopted, so that the haze and the transmittance are improved, and the influence on optical display and brightness is reduced;
4. the problems of uniformity, light spots above the LED and the like can be improved by adjusting the dot structure and the density of the second surface, so that the LED cost can be reduced;
5. adopts high temperature resistant silicon series diffusant which is not easy to yellow after molding.
The inventive concept of the present application is further illustrated below with reference to some specific embodiments.
Referring to fig. 1, in an embodiment of the present invention, a method for manufacturing a diffuser plate includes the following steps:
and step S10, forming a first surface structure on the inner side wall of one side of the injection mold, and forming a second surface structure on the inner side wall of the other side of the injection mold to obtain the diffusion plate mold.
Specifically, the diffuser plate mold comprises: the injection molding device comprises a mold body, wherein an injection molding space is arranged in the mold body, and the injection molding space is provided with a first inner side wall and a second inner side wall which are opposite; the first inner side wall is provided with a first surface structure matched with one side surface of the diffusion plate, and the second inner side wall is provided with a second surface structure matched with the other side surface of the diffusion plate.
The diffuser plate mold can be a thermoplastic injection mold, a thermosetting plastic injection mold, a movable injection mold, a fixed injection mold, and the like. Referring to fig. 3 and 4, the diffuser plate mold includes an upper mold 10 and a lower mold 20, the upper mold 10 having a first groove on a lower surface thereof, and the lower mold 20 having a second groove on an upper surface thereof. The upper die 10 and the lower die 20 are assembled to form a die body, and the two grooves are assembled to form an injection molding space. It will be appreciated that the first recess has a first surface structure on the top wall of the recess and the second recess has a second surface structure on the bottom wall of the recess.
In this embodiment, the first surface structure and the second surface structure are concave-convex structures formed in two side walls of the injection mold as required, so that a diffusion plate mold having concave-convex structures in the two side walls is obtained. The concave-convex structures in the two side walls of the diffusion plate mould can be surface structures corresponding to sun grains, net points or microstructures. If a micro-convex structure should be formed on the back surface of the diffuser plate, a second surface structure corresponding to the micro-convex structure should be formed on the groove bottom wall of the second groove of the lower mold 20.
Wherein, the concave-convex structure can be formed on the two inner side walls of the injection mould through chemical corrosion or laser processing. For example, a chemical substance having an etching function such as nitric acid or sulfuric acid is used to determine the position of the concave-convex structure on the inner side wall of the injection mold, and then the chemical substance such as nitric acid or sulfuric acid is used to etch the surface of the inner side wall, thereby obtaining the diffusion plate mold.
And step S20, injecting a diffusion plate material into the diffusion plate mold, and performing injection molding to form the diffusion plate with the concave-convex structure on the surface.
In the embodiment, a diffusion plate mold is obtained by forming a first surface structure on the inner side wall of one side of an injection mold and forming a second surface structure on the inner side wall of the other side of the injection mold; the diffusion plate mould is used for injecting the diffusion plate material, so that the first surface structure and the second surface structure are transferred to the diffusion plate, injection molding is carried out to form the diffusion plate with the concave-convex structure on the surface, the diffusion plate with the concave-convex structure on the surface can be obtained, the problem that the concave-convex structure on the surface cannot be formed through processing of a diffusion plate cutting technology is solved, appearance defects such as burrs, foreign matters and the like caused by the use of the diffusion cutting technology are avoided, the relative haze and the transmittance of the diffusion plate are improved, the influence on display optics and brightness is reduced, and the consumption on electricity is reduced.
In one embodiment, in a specific implementation, a diffuser plate material is injected into the diffuser plate mold, and the diffuser plate material comprises, in mass fraction:
95 to 99.9 percent of high-fog high-brightness high-fluidity plastic particles and 0.1 to 5 percent of diffusant.
The plastic particles are raw materials for storing, transporting and processing plastic in a semi-finished product form, and belong to the class of high polymer materials. Haze refers to the cloudy or cloudy appearance of the interior or surface of a transparent or translucent material due to light diffusion, expressed as a percentage of the ratio of the amount of diffused light to the amount of light transmitted through the material. Highlight is a diffuse transmittance, i.e., the ratio of the amount of light transmitted through the sample (lumineus Flux) to the amount of light impinging on the sample, expressed as a percentage. The high fluidity is Melt Flow Rate (MFR), which is used to indicate the fluidity index when processing plastic materials, i.e. the number of grams (g) of plastic particles that are melted into plastic fluid within a certain time (10 minutes) under a certain temperature and pressure (different standards of various materials) and then Flow out through a circular tube with a diameter of 2.1 mm. The larger the value, the better the processing fluidity of the plastic material, and the worse the processing fluidity.
In this embodiment, the material of the diffuser plate comprises 95% -99.9% of high-haze high-brightness high-fluidity plastic particles and about 0.1% -5% of a diffuser, wherein the melt flow rate of the high-haze high-brightness high-fluidity plastic particles is greater than or equal to 40cm 3 10min, therefore, its 1mm thickness optical properties are: 99.9 percent of haze, 30 to 85 percent of light transmittance and 50 to 80 percent of light diffusivity, and the adopted diffusant is a high-temperature resistant silicon diffusant, so that the diffuser plate is not easy to yellow after being molded. Therefore, the diffusion plate mold is obtained by forming a first surface structure on the inner side wall of one side of an injection mold and forming a second surface structure on the inner side wall of the other side of the injection mold; the diffusion plate with the size below 55inch can be obtained by injecting diffusion plate material into the diffusion plate die, and the light guide plate has tighter molecular structure and smaller contractibility by injection molding, thereby preventing high temperature from generating optical displayHave an influence. And through the diffusion plate mould, the surface structure of the diffusion plate can be diversified and shaped in a special shape, and appearance defects such as burrs, foreign matters and the like caused by the diffusion cutting technology are avoided.
Further, based on the first embodiment, the present application provides a second embodiment of a method for manufacturing a diffuser plate, and referring to fig. 2, fig. 2 shows a schematic flow chart of the second embodiment of the method for manufacturing a diffuser plate.
In this embodiment, step S10 includes:
and S101, forming the first surface structure corresponding to the drying lines on the inner side wall of one side of the injection mold.
Referring to fig. 5, in the present embodiment, the pattern-coating process refers to a process of treating a surface of a mold, which can enhance the appearance and texture of a plastic part, so that the product has a variety of or a new design, mainly uses a corrosive chemical solution, such as nitric acid, sulfuric acid, etc., to react with the mold, and controls the reaction process to obtain various effects. The main process for obtaining the sun print comprises the following steps: 1. cleaning the mould, namely cleaning oil stains on the mould; 2. detecting the surface of the mold; 3. protecting the area without line sunning and being not corroded by the liquid medicine; 4. transferring the corrosion-resistant wax to the surface of a mould by adopting DTT (draw textured transfer) paper to form patterns; 5. preparing a liquid medicine, corroding the pattern area, and exposing patterns on the surface of the mold; 6. and adjusting the surface gloss of the die. Through the operation steps, the diffusion plate die with the sunning patterns on the inner side wall can be obtained, the inner side wall with the sunning patterns in the surface structure is used as a first surface structure, and the first surface structure is matched with one side surface of the diffusion plate.
And S102, forming the second surface structure corresponding to the mesh points and/or the microstructures on the inner side wall of the other side of the injection mold.
Referring to fig. 6, the dots and/or microstructures are roughening treatment performed on the diffuser plate to improve the diffusion effect of the light source of the diffuser plate, thereby solving the phenomena of light eyes and dark marks and improving the uniformity. The main process of forming the mesh points and/or the microstructures on the inner side wall of the other side of the injection mold by adopting laser processing comprises the following steps: putting the mirror grinding kernel into an ultra-precise laser dotting machine, inputting a pre-designed mesh point program into the ultra-precise laser dotting machine, adjusting a proper dotting parameter, and performing insertion dotting on the mirror mould kernel; the mirror surface mold core is scanned through laser focusing, and the generated high temperature is processed on the mirror surface mold core according to the pre-designed mesh point arrangement to form the semi-spherical pits which are arranged orderly one by one. Through the operation steps, the diffusion plate die with the screen dots and/or the microstructures on the inner side wall of the other side can be obtained, the inner side wall with the surface structure of the screen dots and/or the microstructures is used as a second surface structure, and the second surface structure is matched with the surface of the other side of the diffusion plate.
In this embodiment, a first surface structure with a sun-drying texture and a second surface structure with a mesh point and/or a microstructure are respectively formed on the inner side wall of the diffusion plate through chemical corrosion or laser processing, so that a diffusion plate mold with a size not larger than 55inch is obtained, an injection molding space is arranged in the injection molding mold body, a first inner side wall and a second inner side wall are opposite in the injection molding space, the first inner side wall is provided with the first surface structure, the first surface structure is matched with one side surface of the diffusion plate, the second inner side wall is provided with the second surface structure, the second surface structure is matched with the other side surface of the diffusion plate, and the first inner side wall and the second inner side wall are both planes or curved surfaces. After obtaining the diffuser plate mould, pour into the diffuser plate mould with the diffuser plate material to can obtain the diffuser plate that the surface has concave-convex structure, solve and to have processed the problem that the formation surface has concave-convex structure through diffuser plate cutting technique, avoid because of using appearance defects such as deckle edge and foreign matter that diffusion cutting technique brought, improve the relative haze of diffuser plate and transmissivity, reduce the influence to demonstration optics and luminance, also reduced the consumption to the electricity simultaneously.
Based on the same inventive concept, the application also provides a diffusion plate which is obtained by adopting the injection molding method of the diffusion plate.
In one embodiment, the diffuser plate is no larger than 55inch in size.
In this embodiment, the diffuser plate size through diffuser plate mould injection moulding is below 55inch, also is not more than 140 centimetres, can select the diffuser plate that corresponds the size as required, has avoided because of fashioned diffuser plate size is too big, need cut apart it to the corner after cutting apart, still need carry out secondary operation, can have appearance defects such as burr and foreign matter.
The above description is only a preferred embodiment of the present application, and not intended to limit the scope of the present application, and all modifications of equivalent structures and equivalent processes, which are made by the contents of the specification and the drawings of the present application, or which are directly or indirectly applied to other related technical fields, are included in the scope of the present application.
Claims (10)
1. A method of manufacturing a diffuser plate, the method comprising:
forming a first surface structure on the inner side wall of one side of an injection mold, and forming a second surface structure on the inner side wall of the other side of the injection mold to obtain a diffusion plate mold;
and injecting a diffusion plate material into the diffusion plate mould, and performing injection molding to form the diffusion plate with the concave-convex structure on the surface.
2. The method of manufacturing a diffuser plate of claim 1 wherein said forming a first surface feature on a side inner sidewall of an injection mold comprises:
and forming the first surface structure corresponding to the drying lines on the inner side wall of one side of the injection mold.
3. The method for manufacturing a diffuser plate according to claim 2, wherein the forming of the first surface structure corresponding to the tanning pattern on the inner sidewall of one side of the injection mold comprises:
and forming the first surface structure corresponding to the suntan pattern on the inner side wall on one side of the injection mold through chemical corrosion.
4. The method as claimed in claim 2, wherein the step of forming a second surface structure on the other side inner sidewall of the injection mold comprises:
and forming the second surface structure corresponding to the mesh points and/or the microstructures on the inner side wall on the other side of the injection mold.
5. The method for manufacturing a diffusion plate according to claim 2, wherein the step of forming dots and microstructures on the inner side wall of the other side of the injection mold to obtain the second surface structure comprises:
and forming the second surface structure corresponding to the mesh points and/or the microstructures on the inner side wall of the other side of the injection mold through chemical corrosion or laser processing.
6. The method of manufacturing a diffuser plate according to claim 1, wherein the diffuser plate material comprises, in mass fraction: 95 to 99.9 percent of high-fog high-brightness high-fluidity plastic particles and 0.1 to 5 percent of diffusant.
7. The method of claim 6 wherein the high haze high brightness high flow plastic particles have a melt flow rate of 40 or more (units cm) 3 /10min)。
8. The method of manufacturing a diffusion plate according to claim 6, wherein the diffusing agent is a silicon-based diffusing agent.
9. A diffuser plate obtained by the method of injection molding according to any one of claims 1 to 5.
10. The diffuser plate as set forth in claim 9 wherein the diffuser plate is no larger than 55inch in size.
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| CN202210705072.0A CN115097557A (en) | 2022-06-21 | 2022-06-21 | Diffusion plate manufacturing method and diffusion plate |
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| CN202210705072.0A CN115097557A (en) | 2022-06-21 | 2022-06-21 | Diffusion plate manufacturing method and diffusion plate |
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