JP2010076274A - Manufacturing method of light guide plate, and light guide plate - Google Patents

Manufacturing method of light guide plate, and light guide plate Download PDF

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JP2010076274A
JP2010076274A JP2008247468A JP2008247468A JP2010076274A JP 2010076274 A JP2010076274 A JP 2010076274A JP 2008247468 A JP2008247468 A JP 2008247468A JP 2008247468 A JP2008247468 A JP 2008247468A JP 2010076274 A JP2010076274 A JP 2010076274A
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sheet
plate material
light guide
plate
guide plate
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JP5571891B2 (en
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Junji Kato
純二 加藤
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Toyo Machinery and Metal Co Ltd
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Toyo Machinery and Metal Co Ltd
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Priority to JP2008247468A priority Critical patent/JP5571891B2/en
Priority to CN200980133197.3A priority patent/CN102131625A/en
Priority to PCT/JP2009/065170 priority patent/WO2010035610A1/en
Priority to KR1020107028922A priority patent/KR101612573B1/en
Priority to TW98131289A priority patent/TWI438510B/en
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    • 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
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00663—Production of light guides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/22—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of both discrete and continuous layers
    • B32B37/223—One or more of the layers being plastic
    • B32B37/226—Laminating sheets, panels or inserts between two continuous plastic layers
    • 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
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B29C2045/0079—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping applying a coating or covering
    • 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
    • B29C45/0084—General arrangement or lay-out of plants
    • 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
    • B29C45/40—Removing or ejecting moulded articles
    • B29C45/42—Removing or ejecting moulded articles using means movable from outside the mould between mould parts, e.g. robots

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a light guide plate, in which the productivity is improved by automating conventional manual operation. <P>SOLUTION: A transparent plate B is formed using a cavity molded by a fixed mold 10 and a movable mold 8 of an injection molding machine 1 and then, the plate B stuck inside the cavity is discharged, and taken out while sucked by a removing device 30. The plate B taken out is placed on a prescribed placing position b on a first protective sheet 20 by the removing device 30, and is transported as it is placed on the first protective sheet 20 unwound from a first sheet roll 22. On the surface of the plate B so transported, a second protective sheet 21 is placed that is unwound from a second sheet roll 23, with the first protective sheet 20 and the second protective sheet 21 stuck to each face of the plate B. Thereafter, the plate B stuck with the first and the second protective sheet 20, 21 is cut into a prescribed size with the blade 31 of a cutting device 27, so that the light guide plate is automatically manufactured. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

本発明は、携帯電話等に備えた液晶パネル等の表示パネルに採用される導光板の製造方法に関し、特に射出成形機で成形された透光性を有する板材の表面に、特殊なシートを貼り付けることで均一に面発光させることができる導光板の製造方法及び導光板に関する。   The present invention relates to a method of manufacturing a light guide plate employed in a display panel such as a liquid crystal panel provided in a mobile phone or the like, and in particular, a special sheet is attached to the surface of a light-transmitting plate material formed by an injection molding machine. It is related with the manufacturing method and light guide plate of a light guide plate which can carry out surface emission uniformly by attaching.

近年、比較的小型化された液晶の表示モニターには、光を均一に面発光する導光板が採用されている。こうした導光板には、アクリル樹脂製の板材の一方面においては光を反射させる集光パターンが、他方面には正面に光を集めて輝度を向上させる拡散パターンが設けられている。   2. Description of the Related Art In recent years, a light guide plate that uniformly emits light is used for a relatively small liquid crystal display monitor. Such a light guide plate is provided with a light condensing pattern for reflecting light on one surface of an acrylic resin plate material, and a diffusion pattern for collecting light on the front surface to improve luminance on the other surface.

ところで、導光板を製造する際には、一般的に射出成形機が採用されているのだが、近年の導光板を成形する際の１サイクルの成形サイクル時間は１３秒〜１５秒程かかっており、さらなる成形サイクル時間の短縮化が望まれている。その一方で、金型のキャビティで成形された導光板の一部として用いられる板材は、射出成形機で成形されるに際し、板材と一緒に、成形ロスとなるスプルー形成部（スプルーに対応して形成される部分）やランナー形成部（ランナーに対応して形成される部分）が板材と共に一体に形成された状態で取り出されることから、これら成形ロスとなるスプルー形成部及びランナー形成部を取り除くための除去作業を行なう必要がある。そして、こうした除去作業や除去作業後には、不良品であるか否かなどの検査作業が行なわれ、さらに検査作業後には、板材の両面に設けられた集光パターンと拡散パターンの表面に対し、ごみや傷が付かないよう保護シートが貼着される。なお、こうした検査作業や保護シートの貼り付け作業は、熟練したオペレータ等によって手作業や目視により人員により行なわれていることが実情となっている。   By the way, when a light guide plate is manufactured, an injection molding machine is generally employed. However, in recent years, a molding cycle time for forming a light guide plate takes about 13 seconds to 15 seconds. Further reduction of molding cycle time is desired. On the other hand, the plate material used as a part of the light guide plate formed in the cavity of the mold is formed with an injection molding machine together with the plate material to form a sprue forming portion (corresponding to the sprue). In order to remove the sprue forming portion and runner forming portion that become molding loss because the portion formed) and the runner forming portion (portion formed corresponding to the runner) are taken out in a state of being integrally formed with the plate material. Need to be removed. And after such removal work and removal work, inspection work such as whether it is a defective product is performed, and further after the inspection work, on the surface of the condensing pattern and the diffusion pattern provided on both sides of the plate material, A protective sheet is attached to prevent dust and scratches. Note that it is a fact that such inspection work and protective sheet pasting work are performed manually or visually by a skilled operator or the like by personnel.

上記導光板の製造方法に係わる技術として特許文献１には、比較的板厚の薄い導光板を製造するに際し、その成形サイクル時間を短縮するために、キャビティ形成面を冷却媒体流路に流される冷却媒体により冷却し、この冷却媒体流路とは別の冷却媒体流路を、キャビティ形成面を冷却する冷却媒体流路よりも低温に冷却することで、射出速度の高速化を図った小型導光板の射出圧縮成形方法が開示されている。   As a technique related to the method of manufacturing the light guide plate, Patent Document 1 discloses that when a light guide plate having a relatively thin thickness is manufactured, the cavity forming surface is caused to flow through the cooling medium flow path in order to shorten the molding cycle time. Cooling with a cooling medium, a cooling medium flow path different from the cooling medium flow path is cooled to a temperature lower than that of the cooling medium flow path for cooling the cavity forming surface, thereby reducing the injection speed. An optical plate injection compression molding method is disclosed.

また、特許文献２には、金型の間に形成されるキャビティ形成部内で導光板の成形を行なう成形金型に関し、スプルブッシュとその周囲に配設されたキャビティ形成部を冷却する冷却媒体流路とをそれぞれ独立させることで、スプルーを細くしてもキャビティ内の溶融樹脂の冷却収縮に対応させて保圧を維持しながら圧縮成形するができ、成形ロスとなるランナー形成部やスプルー形成部の比率を減らすことで歩留まりの向上や成形サイクル時間の短縮化を向上することが可能な導光部の成形金型が開示されている。   Further, Patent Document 2 relates to a molding die that molds a light guide plate in a cavity forming portion formed between the molds, and a cooling medium flow for cooling the sprue bush and the cavity forming portion disposed around the same. By making the paths independent of each other, even if the sprue is narrowed, it can be compression-molded while maintaining the holding pressure corresponding to the cooling shrinkage of the molten resin in the cavity, and the runner forming part and sprue forming part that cause molding loss There has been disclosed a light guide molding die that can improve the yield and shorten the molding cycle time by reducing the ratio.

特許第４０４４６０８号公報Japanese Patent No. 4044608 特許第４０４７９１７号公報Japanese Patent No. 4047917

前述した特許文献１及び特許文献２においては、何れにおいても導光板の製造効率を向上することを目的とした技術ではあるが、成形サイクル時間を短縮化するだけでは、導光板の生産性を飛躍的に向上することは難しい。すなわち、１サイクルの成形サイクル時間は１５秒前後要することが一般的でもあり、たとえ射出速度を高速化したり、成形ロスとなるスプルー形成部の容積を小さくしたところで、若干成形サイクル時間が短縮するのみで大幅に導光板の生産効率を向上することを達成することは難しい。   In both of Patent Document 1 and Patent Document 2 described above, the technology aims to improve the manufacturing efficiency of the light guide plate. However, the productivity of the light guide plate is greatly improved only by shortening the molding cycle time. It is difficult to improve. In other words, the molding cycle time for one cycle is generally about 15 seconds. Even if the injection speed is increased or the volume of the sprue forming portion that causes molding loss is reduced, the molding cycle time is only slightly shortened. It is difficult to achieve a significant improvement in the light guide plate production efficiency.

本発明は、上記課題を解決するものであり、導光板を製造するに際し、射出成形機等で成形される成形サイクル時間の短縮を図るのではなく、従来熟練者等により手作業で行なわれきた人為的作業を自動化し、導光板を製造する際の生産性を向上させた導光板の製造方法及びそれにより製造された導光板を提供することを目的とする。   SUMMARY OF THE INVENTION The present invention solves the above-mentioned problems, and has been carried out manually by skilled workers and the like rather than reducing the molding cycle time formed by an injection molding machine or the like when manufacturing a light guide plate. It is an object of the present invention to provide a light guide plate manufacturing method and a light guide plate manufactured thereby by automating human work and improving productivity when manufacturing the light guide plate.

請求項１に係る導光板の製造方法は、
加熱シリンダ内に設けたスクリューを回転させながら後退させて溶融樹脂の計量を行い、該計量工程後に前記スクリューを前進させて前記加熱シリンダの先端に装着した射出ノズルから、固定ダイプレートに固定された固定金型と進退可能に設けられた可動ダイプレートに固定された可動金型とにより、型閉時に形成されたキャビティに前記溶融樹脂を射出して透明な板材を成形し、該板材の上下面にシートを貼着して導光板を製造する方法であって、
前記板材を射出成形機に備えた前記固定金型と前記可動金型からなるキャビティで成形した後、
前記キャビティ内に張り付いた板材を排出して、該排出された板材を取り出し装置で取り出し、
前記板材の下面を第１のシートロールから水平方向に巻きだされてきた底面シートの上面の所定載置位置に載置した後、
第１のシートロールから巻きだされてくる底面シートに載置されていることで搬送されてくる前記板材の上面に、第２のシートロールから巻きだされてきた上面シートを載置して、該上面シートと底面シートを前記板材に貼着させ、
前記上面シートと底面シートが貼着された水平方向に搬送される板材に対し、切断装置に設けた切刃を鉛直方向にスライドさせて所定サイズに切断することを特徴とする。 A method of manufacturing a light guide plate according to claim 1 is as follows:
The screw provided in the heating cylinder is rotated while retracted to measure the molten resin, and after the metering step, the screw is advanced and fixed to the fixed die plate from the injection nozzle attached to the tip of the heating cylinder. By using a fixed mold and a movable mold fixed to a movable die plate provided so as to be able to move forward and backward, the molten resin is injected into a cavity formed when the mold is closed to form a transparent plate material, and the upper and lower surfaces of the plate material A method of manufacturing a light guide plate by attaching a sheet to a sheet,
After molding the plate material in a cavity comprising the fixed mold and the movable mold provided in an injection molding machine,
The plate material stuck in the cavity is discharged, and the discharged plate material is taken out by a take-out device,
After placing the lower surface of the plate material at a predetermined placement position on the upper surface of the bottom sheet that has been wound in the horizontal direction from the first sheet roll,
Place the top sheet unwound from the second sheet roll on the upper surface of the plate material that is conveyed by being placed on the bottom sheet unwound from the first sheet roll, Adhering the top sheet and bottom sheet to the plate,
A cutting blade provided in a cutting device is slid in a vertical direction and cut to a predetermined size with respect to a plate material conveyed in a horizontal direction to which the top sheet and the bottom sheet are adhered.

請求項２に係る導光板の製造方法は、請求項１において、
前記取り出し装置には負圧を発生させることで前記板材を吸引する保持装置を備え、該保持装置の吸引力により取り出された前記板材を、前記底面シート上面の所定載置位置に載置することを特徴とする。 The method for manufacturing a light guide plate according to claim 2 is described in claim 1.
The take-out device includes a holding device that sucks the plate material by generating a negative pressure, and the plate material taken out by the suction force of the holding device is placed at a predetermined placement position on the bottom sheet upper surface. It is characterized by.

請求項３に係る導光板の製造方法は、請求項２において、
前記射出成形機とは別体に設けたシート成形加工装置に、前記第１のシートロール、前記第２のシートロール、及び前記切断装置を少なくとも備え、
前記シート成形加工装置を前記射出成形機の側部に配設し、
該射出成形機の金型のキャビティから前記板材を取り出す前記キャビティ近傍の取り出し口と、前記シート成形加工装置により前記底面シートの上面に前記板材を載置する所定載置位置とを直線的に最短距離で結ぶ仮想線上に前記取り出し装置を配設し、
前記キャビティ近傍の取り出し口から取り出された前記板材を前記所定載置位置へ最短距離で搬送するようにしたことを特徴とする。 A method of manufacturing a light guide plate according to claim 3 is described in claim 2,
The sheet molding apparatus provided separately from the injection molding machine includes at least the first sheet roll, the second sheet roll, and the cutting device,
The sheet molding apparatus is disposed on the side of the injection molding machine,
A linearly shortest distance between a take-out port near the cavity for taking out the plate material from a mold cavity of the injection molding machine and a predetermined placement position for placing the plate material on the upper surface of the bottom sheet by the sheet molding apparatus. The take-out device is arranged on a virtual line connected by a distance,
The plate material taken out from the take-out port near the cavity is conveyed to the predetermined placement position at the shortest distance.

請求項４に係る導光板の製造方法は、請求項３において、
前記射出成形機と前記シート成形加工装置との各々を交互に複数並設し、これら射出成形機の１つずつに対応付けして、その側部に前記シート成形加工装置を１つずつ配設し、前記射出成形機と前記シート成形加工装置とを１ｂｙ１で１ユニットとしてこのユニットを複数並設することで、前記導光板を並行して連続的に量産することを特徴とする。 A method for manufacturing a light guide plate according to a fourth aspect is the method according to the third aspect,
A plurality of each of the injection molding machine and the sheet molding processing apparatus are alternately arranged in parallel, and each of the injection molding machines is associated with one by one, and the sheet molding processing apparatus is disposed on the side portion one by one. Then, the light guide plate is continuously mass-produced in parallel by arranging a plurality of these units by arranging the injection molding machine and the sheet molding apparatus as one unit in 1 by 1.

請求項５に係る導光板は、請求項３又は４に記載の導光板の製造方法において、前記上面シート及び底面シートは保護シートとし、該保護シートが成形加工装置により前記板材の上下面に貼着されるものであることを特徴とする。   The light guide plate according to claim 5 is the light guide plate manufacturing method according to claim 3 or 4, wherein the top sheet and the bottom sheet are protective sheets, and the protective sheets are attached to the top and bottom surfaces of the plate material by a molding apparatus. It is characterized by being worn.

本発明によれば、導光板を製造するに際し、射出成形機で板材の成形を行った後に、この板材の上下面に保護シート等を貼着して導光板を製造する工程を、従来のように熟練者による手作業ではなくシート成形加工装置で自動的に行うことができるので、導光板の製造を短時間で行なうことができると共に、人為的な手作業により板材の上下面に傷が付いたり汚れてしまったりすることも防止することができるので、人員作業に伴う不良を低減でき、ひいては歩留まりを向上して生産効率を向上することができる。   According to the present invention, when manufacturing a light guide plate, after forming a plate material with an injection molding machine, a process of manufacturing a light guide plate by pasting a protective sheet or the like on the upper and lower surfaces of the plate material is performed as in the conventional method. In addition, it can be automatically performed by a sheet forming apparatus rather than manually by a skilled worker, so that the light guide plate can be manufactured in a short time, and the upper and lower surfaces of the plate material are scratched by manual labor. Therefore, it is possible to prevent defects caused by personnel work, thereby improving yield and improving production efficiency.

さらに、キャビティ近傍の取り出し口から取り出された板材は、シート成形加工装置の所定載置位置へ短い距離で搬送することができるので、透明な板材に塵や埃などの微細なごみが付着してしまう前に、板材の表面を保護シートで保護することができ、より歩留まりを向上することができる。しかも、シート成形加工装置により保護シートの貼着工程を自動的に行うことから、導光板を製造する際の貼着工程時間を短縮化することができ、生産効率を向上することができる。   Furthermore, since the plate material taken out from the take-out port near the cavity can be transported to a predetermined mounting position of the sheet forming apparatus at a short distance, fine dust such as dust and dirt adheres to the transparent plate material. Before, the surface of a board | plate material can be protected with a protective sheet, and a yield can be improved more. Moreover, since the protective sheet sticking process is automatically performed by the sheet forming apparatus, the sticking process time for manufacturing the light guide plate can be shortened, and the production efficiency can be improved.

さらに、板材を成形する射出成形機とシート成形加工装置を１ｂｙ１とする１ユニットを複数並設することで、導光板の量産を行なうことができると共に、各シート成形加工装置で製造されてきた複数の導光板が同じ方向から排出させることができるから、排出後に行なわれる導光板のロボットや人員による梱包作業を簡単且つ短時間で効率よく行うことが可能になる。   Furthermore, the light guide plate can be mass-produced by arranging a plurality of one unit having 1 by 1 as an injection molding machine for molding a plate material and a sheet molding processing apparatus, and a plurality of units manufactured by each sheet molding processing apparatus. Since the light guide plates can be discharged from the same direction, it is possible to carry out the packing work by the robot and personnel of the light guide plate performed after the discharge easily and efficiently in a short time.

以下、本発明を実施するための最良の形態としての実施例を図１、図２により以下に説明する。もちろん、本発明は、その発明の趣旨に反しない範囲で、実施例において説明した以外の構成のものに対しても容易に適用可能なことは説明を要するまでもない。   The best mode for carrying out the present invention will be described below with reference to FIGS. Needless to say, the present invention can be easily applied to configurations other than those described in the embodiments without departing from the spirit of the invention.

図１は本発明の一例である、射出成形機、シート成形加工装置等を構成するユニットが複数並設された状態を上方から視た概略構成図、図２はシート成形加工装置の構成を示す正面図である。図１に示すように、射出成形機１とシート成形加工装置２との１つずつは取り出し装置３の１つを含みこれらを１ユニット４として並設され、取り出し装置３は射出成形機１とシート成形加工装置２との間を結ぶようにして配設されている。   FIG. 1 is an example of the present invention, and is a schematic configuration diagram showing a state in which a plurality of units constituting an injection molding machine, a sheet molding processing apparatus and the like are arranged in parallel, and FIG. 2 shows a configuration of the sheet molding processing apparatus It is a front view. As shown in FIG. 1, each of the injection molding machine 1 and the sheet molding apparatus 2 includes one take-out device 3, which is arranged in parallel as one unit 4, and the take-out device 3 is connected to the injection molding machine 1. It arrange | positions so that between the sheet forming processing apparatuses 2 may be tied.

射出成形機１には、型締めユニット５と射出ユニット６を備えており、型締めユニット５には、可動ダイプレート７に固定された可動金型８、固定ダイプレート９に固定された固定金型１０、固定金型１０に対し可動金型８を進退させ型開閉を行うためのトグルリンク機構等が構成されている。   The injection molding machine 1 includes a mold clamping unit 5 and an injection unit 6. The mold clamping unit 5 includes a movable mold 8 fixed to a movable die plate 7 and a fixed mold fixed to a fixed die plate 9. A toggle link mechanism for opening and closing the mold by moving the movable mold 8 forward and backward with respect to the mold 10 and the fixed mold 10 is configured.

射出ユニット６には、粒状の原料である樹脂（ペレット）が投入されるホッパ１１を有し、このホッパ１１からその下方に設けられた筒型の加熱シリンダ１２内に粒状の樹脂が自重により落下して投入されるようになっており、加熱シリンダ１２内に供給され熱で可塑化された溶融樹脂は、加熱シリンダ１２内に設けた図示しないスクリューが回転されながら後退されることにより計量され、計量工程後には前記スクリューを前進させて加熱シリンダ１２の先端に装着した射出ノズル１３から、固定金型１０と可動金型８とにより型閉時に形成されるキャビティに、溶融樹脂を射出して成形体たる板材Ｂが成形される。なお、本実施例における射出成形機１では、キャビティで成形される板材Ｂは導光板に用いられるものであるため透明体であり、この透明な板材Ｂの各面（上下面）には集光パターンと拡散パターンが設けられており、集光パターンと拡散パターンの表面に後述する保護シートが貼着され導光板が製造される。   The injection unit 6 has a hopper 11 into which resin (pellet) as a granular raw material is charged, and the granular resin falls into the cylindrical heating cylinder 12 provided below the hopper 11 by its own weight. The molten resin supplied into the heating cylinder 12 and plasticized by heat is weighed by retreating a screw (not shown) provided in the heating cylinder 12 while being rotated, After the metering step, the screw is advanced and injected from the injection nozzle 13 attached to the tip of the heating cylinder 12 into a cavity formed by the fixed mold 10 and the movable mold 8 when the mold is closed, and then molded. A body plate B is formed. In addition, in the injection molding machine 1 in the present embodiment, the plate material B formed by the cavity is a transparent body because it is used for the light guide plate, and light is condensed on each surface (upper and lower surfaces) of the transparent plate material B. A pattern and a diffusion pattern are provided, and a protective sheet, which will be described later, is attached to the surface of the light collection pattern and the diffusion pattern to manufacture a light guide plate.

次に、図２によりシート成形加工装置について説明する。同図に示すシート成形加工装置２は、射出成形機１で成形された板材Ｂの下面には底面シートたる第１の保護シート２０を、上面には上面シートたる第２の保護シート２１を貼着し、その後に所定サイズに切断されるものであり、これらの作業工程は自動化されており、第１の保護シート２０の巻き回された第１のシートロール２２、第２の保護シート２１の巻き回された第２のシートロール２３、上下に並設された一対の第１，第２の誘導ローラ２４，２５、搬送ローラ郡２６、及び第１の保護シート２０と第２の保護シート２１が各面に貼着された板材Ｂを切断する切断装置２７等を備えている。なお、第１，第２のシートロール２２，２３及びローラ２４，２５，２６は回転自在に支持されており、図示しない回転駆動手段としてのモータを駆動源として第１の保護シート２０が搬送（図２に示す左側から右方向へ）される。   Next, the sheet forming apparatus will be described with reference to FIG. In the sheet molding apparatus 2 shown in the figure, a first protective sheet 20 as a bottom sheet is pasted on the lower surface of the plate B formed by the injection molding machine 1, and a second protective sheet 21 as a top sheet is pasted on the upper surface. It is worn and then cut into a predetermined size. These work steps are automated, and the first sheet roll 22 and the second protection sheet 21 wound with the first protection sheet 20 are wound. The wound second sheet roll 23, a pair of first and second guide rollers 24 and 25 arranged in parallel above and below, a conveying roller group 26, and the first protective sheet 20 and the second protective sheet 21. Is provided with a cutting device 27 and the like for cutting the plate material B adhered to each surface. The first and second sheet rolls 22 and 23 and the rollers 24, 25 and 26 are rotatably supported, and the first protective sheet 20 is conveyed by using a motor as a rotation driving means (not shown) as a drive source ( (From left to right in FIG. 2).

図１に示す取り出し装置３は、射出成形機１の金型のキャビティで成形された板材Ｂをキャビティ近傍の取り出し口ａから取り出し、シート成形加工装置２の所定載置位置ｂに載置することができ、この取り出し装置３には、板材Ｂをキャビティ近傍の取り出し口ａから取り出すため、負圧により板材Ｂを吸着する保持装置を備え、保持装置で取り出し口ａから吸引された板材Ｂは、図２に示す、第１の保護シート２０の上面の所定載置位置ｂに搬送され載置される。なお、取り出し装置３は、図１に示している可動金型８が後退されている型開き状態においては、キャビティ近傍の取り出し口ａと第１の保護シート２０の上面の所定載置位置ｂとを直線的に最短距離で結んだ仮想線Ｘ上に配設されており、取り出し装置３により板材Ｂをキャビティ近傍の取り出し口ａから所定載置位置ｂへと短い距離で搬送することができるようになっている。   The take-out device 3 shown in FIG. 1 takes out the plate material B molded in the mold cavity of the injection molding machine 1 from the take-out port a in the vicinity of the cavity and places it on the predetermined placement position b of the sheet molding apparatus 2. In order to take out the plate material B from the takeout port a near the cavity, the takeout device 3 includes a holding device that adsorbs the plate material B by negative pressure, and the plate material B sucked from the takeout port a by the holding device is: 2 is conveyed and placed at a predetermined placement position b on the upper surface of the first protective sheet 20 shown in FIG. In the mold open state in which the movable mold 8 shown in FIG. 1 is retracted, the take-out device 3 has a take-out port a near the cavity and a predetermined placement position b on the upper surface of the first protective sheet 20. Are arranged on a virtual line X that is linearly connected at the shortest distance so that the plate material B can be conveyed by the take-out device 3 from the take-out port a near the cavity to the predetermined placement position b at a short distance. It has become.

次に、射出成形機で成形された板材に保護シートを貼着して導光板を製造するその工程について説明する。射出成形機１のキャビティ近傍の取り出し口ａに有する射出成形機１で成形の終えた板材Ｂは、取り出し装置３の保持装置により吸引して保持され、シート成形加工装置２の第１のシートロール２２から巻きだされて、第１の誘導ローラ２４を通過してきた第１の保護シート２０の上面の所定載置位置ｂに載置される。   Next, the process of manufacturing a light guide plate by attaching a protective sheet to a plate material molded by an injection molding machine will be described. The sheet material B that has been molded by the injection molding machine 1 at the take-out port a in the vicinity of the cavity of the injection molding machine 1 is sucked and held by the holding device of the take-out device 3, and the first sheet roll of the sheet molding processing device 2 is held. 22, and is placed at a predetermined placement position b on the upper surface of the first protective sheet 20 that has passed through the first guide roller 24.

続いて、第２のシートロール２３から第２の誘導ローラ２５を介して巻きだされてきた第２の保護シート２１は、第１の保護シート２０に載置された板材Ｂの上面に載置された後、第２の搬送ローラ２５、搬送ローラ郡２６等によって第１の保護シート２０と第２の保護シート２１が剥離することがないよう板材Ｂの各面に確実に貼着されてゆく。   Subsequently, the second protective sheet 21 unwound from the second sheet roll 23 via the second guide roller 25 is placed on the upper surface of the plate material B placed on the first protective sheet 20. After that, the first protective sheet 20 and the second protective sheet 21 are securely adhered to each surface of the plate material B by the second transport roller 25, the transport roller group 26, etc. .

続いて、第１の保護シート２０及び第２の保護シート２１が貼着された板材Ｂは、第１，第２の誘導ローラ２４，２５、搬送ローラ郡２６等によりさらに水平方向（図２に示す左方向）へ誘導され、所定の切断位置ｃに到達されると、回転駆動手段が停止され、この状態で、切断装置２７に構成される切刃３１が鉛直方向に降下されて所定サイズに切断されることで導光板の製造が完了する。そして、こうした動作を繰り返し行なうことで導光板の製造が繰り返し行なわれる。   Subsequently, the plate material B to which the first protective sheet 20 and the second protective sheet 21 are adhered is further horizontal (see FIG. 2) by the first and second guide rollers 24 and 25, the transport roller group 26, and the like. When the predetermined cutting position c is reached, the rotational driving means is stopped, and in this state, the cutting blade 31 configured in the cutting device 27 is lowered in the vertical direction to a predetermined size. Cutting the light guide plate is completed. Then, the light guide plate is repeatedly manufactured by repeating such an operation.

以上のように本実施例によれば、加熱シリンダ１２内に設けたスクリューを回転させながら後退させて溶融樹脂の計量を行い、計量工程後にスクリューを前進させて加熱シリンダ１２の先端に装着した射出ノズル１３から、固定ダイプレート９に固定された固定金型１０と進退可能に設けられた可動ダイプレート７に固定されたか可動金型８とにより型閉時に形成されたキャビティに溶融樹脂を射出するなどして、集光パターンと拡散パターンとが表面に設けられた透明な板材Ｂを成形した後、キャビティに張り付いた板材Ｂを、進退可能なイジェクトピン等により排出させ、キャビティ近傍の取り出し口ａから排出された板材Ｂを取り出し装置３で吸引して取り出し、取り出された板材Ｂの下面を、第１のシートロール２２から巻きだされて、第１の誘導ローラ２４により挟み込まれながら水平方向に送り出されてきた第１の保護シート（底面シート）２０の上面の所定載置位置ｂに載置した後、第１のシートロール２２から巻きだされてくる第１の保護シート２０に載置されていることで搬送されてくる板材Ｂの上面に、第２のシートロール２３から、第２の誘導ローラ２５に挟み込まれながら巻きだされてきた第２の保護シート（上面シート）２１を載置し、一方面に接着材の塗布されている、第１の保護シート２０及び第２の保護シート２１を板材Ｂの各面に貼着させ、水平方向に搬送されてきた第１の保護シート２０と第２の保護シート２１とが貼着された板材Ｂに対し、切断装置２７に設けた切刃３１を自動的に鉛直方向にスライド作動させて、所定サイズに切断して導光板を製造するので、射出成形機１による板材Ｂの成形後において、従来人員で行なわれていた、板材Ｂの上下面に第１の保護シート２０及び第２の保護シート２１を貼着して導光板を製造する工程をシート成形加工装置２により自動化できるので導光板の製造を短時間で行なうことができ、さらに、人為的な手作業により保護シート２０，２１を貼着する作業を行なわないことから、板材Ｂの表面に傷が付いたり汚れてしまったりすることも防止することができる。よって、人員作業に伴う不良を抑えて、歩留まりを向上させ、導光板の生産効率を向上させることができる。   As described above, according to the present embodiment, the screw provided in the heating cylinder 12 is moved backward while rotating to measure the molten resin, and after the measuring step, the screw is advanced to be injected at the tip of the heating cylinder 12. Molten resin is injected from the nozzle 13 into a cavity formed when the mold is closed by the fixed mold 10 fixed to the fixed die plate 9 and the movable mold 8 fixed to the movable die plate 7 or movable mold 8. After forming a transparent plate B having a condensing pattern and a diffusion pattern on the surface, the plate B attached to the cavity is discharged by an eject pin or the like that can be moved back and forth, and a takeout port near the cavity The board material B discharged from a is sucked and taken out by the take-out device 3, and the lower surface of the taken-out board material B is unwound from the first sheet roll 22. Then, after being placed at a predetermined placement position b on the upper surface of the first protective sheet (bottom sheet) 20 that has been fed out in the horizontal direction while being sandwiched by the first guide roller 24, it is wound from the first sheet roll 22. From the second sheet roll 23, the sheet is wound while being sandwiched between the second guide rollers 25 on the upper surface of the plate material B that is conveyed by being placed on the first protective sheet 20. The second protective sheet (upper surface sheet) 21 is placed, and the first protective sheet 20 and the second protective sheet 21, which are coated with an adhesive on one surface, are adhered to each surface of the plate material B. The cutting blade 31 provided in the cutting device 27 is automatically slid in the vertical direction with respect to the plate material B on which the first protective sheet 20 and the second protective sheet 21 that have been conveyed in the horizontal direction are adhered. Let's cut it to a certain size Since the optical plate is manufactured, the first protective sheet 20 and the second protective sheet 21 are pasted on the upper and lower surfaces of the plate material B, which has been conventionally performed by personnel after the formation of the plate material B by the injection molding machine 1. Since the process of manufacturing the light guide plate can be automated by the sheet forming apparatus 2, the light guide plate can be manufactured in a short time, and further, the work of attaching the protective sheets 20 and 21 manually is not performed. Therefore, it is possible to prevent the surface of the plate material B from being scratched or soiled. Therefore, it is possible to suppress defects due to personnel work, improve yield, and improve the production efficiency of the light guide plate.

さらに、図１に示すように、射出成形機１とは別体にシート成形加工装置２を設け、このシート成形加工装置２には、第１の保護シート２０の巻き取られた第１のシートロール２２、第２の保護シート２１の巻き取られた第２のシートロール２３、及び切断装置２７等を備え、射出成形機１の側部（横側）に前記シート成形加工装置２を配設し、射出成形機１で板材Ｂを取り出すキャビティ近傍の取り出し口ａと、第１の保護シート２０の上面に板材Ｂを載置する所定載置位置ｂとを直線的に最短距離で結ぶ仮想線Ｘ上に取り出し装置３０を配設したので、キャビティ近傍の取り出し口ａから取り出された板材Ｂは、シート成形加工装置２の所定載置位置ｂへ短い距離で搬送できその搬送時間を短縮することができる。そして、短い距離で搬送された板材Ｂに対して、第１の保護シート２０および第２の保護シート２１を速やかに貼着することが可能になり、透明な板材Ｂに塵や埃などの微細なごみが付着してしまう前に貼着工程を終えることができることから、製品の歩留まりをより向上することができる。しかも、シート成形加工装置２により貼着作業が自動的に行われることから、人員よる作業に比べ貼着作業を短時間で行なうことができ生産性を向上することができる。   Further, as shown in FIG. 1, a sheet forming apparatus 2 is provided separately from the injection molding machine 1, and the first sheet on which the first protective sheet 20 is wound is provided in the sheet forming apparatus 2. A roll 22, a second sheet roll 23 wound around the second protective sheet 21, a cutting device 27, and the like are provided, and the sheet molding apparatus 2 is disposed on the side (lateral side) of the injection molding machine 1. An imaginary line that linearly connects the take-out port a near the cavity from which the plate material B is taken out by the injection molding machine 1 and the predetermined placement position b where the plate material B is placed on the upper surface of the first protective sheet 20 at the shortest distance. Since the take-out device 30 is arranged on X, the plate material B taken out from the take-out port a near the cavity can be transported to a predetermined placement position b of the sheet forming apparatus 2 at a short distance, and the transport time is shortened. Can do. And it becomes possible to stick the 1st protective sheet 20 and the 2nd protective sheet 21 rapidly with respect to the board | plate material B conveyed by the short distance, and fine particles, such as dust and dust, are attached to the transparent board | plate material B. Since the adhering process can be completed before the dust is attached, the product yield can be further improved. Moreover, since the sticking work is automatically performed by the sheet forming apparatus 2, the sticking work can be performed in a shorter time than the work by the personnel, and the productivity can be improved.

さらに、板材Ｂを成形する射出成形機１とシート成形加工装置２を１ｂｙ１として取り出し装置３も含んで１ユニット４とし、このユニットを複数並設することで、導光板の量産をより達成できると共に、各ユニットのシート成形加工装置２で製造されてきた複数の導光板が同じ方向に並ぶようにして梱包位置ｄへと排出されることから、作業者等が、導光板を梱包するためにシート成形加工装置２の後方一端側の各梱包位置ｄへと移動するに際し、図１に示す矢印方向のように、直線的に短い距離で移動することができるので、短時間で効率よく梱包作業を行うことが可能になる。   Furthermore, the injection molding machine 1 and the sheet forming apparatus 2 for forming the plate material B are set as 1 by 1 and the take-out device 3 is included as one unit 4. By arranging a plurality of these units in parallel, mass production of the light guide plate can be achieved. Since the plurality of light guide plates manufactured by the sheet forming apparatus 2 of each unit are discharged to the packing position d so that they are aligned in the same direction, the operator can use the sheet to pack the light guide plates. When moving to each packing position d on the rear end side of the molding apparatus 2, it can move linearly at a short distance as shown by the arrow in FIG. It becomes possible to do.

本発明の一例の、射出成形機、シート成形加工装置等を構成するユニットが複数並設された状態を上方から視た概略構成図である。It is the schematic block diagram which looked at the state by which the unit which comprises an injection molding machine, a sheet molding processing apparatus, etc. of an example of this invention was arranged in parallel from the upper direction. 同上、シート成形加工装置の構成を示す正面図である。It is a front view which shows the structure of a sheet forming processing apparatus same as the above.

符号の説明Explanation of symbols

１ 射出成形機
４ １ユニット
７ 可動ダイプレート
８ 可動金型
９ 固定ダイプレート
１０ 固定金型
１２ 加熱シリンダ
１３ 射出ノズル
２０ 第１の保護シート（底面シート）
２１ 第２の保護シート（上面シート）
２２ 第１のシートロール
２３ 第２のシートロール
２７ 切断装置
３０ 取り出し装置
３１ 切刃
Ｂ 板材
Ｘ 仮想線
ａ 取り出し口
ｂ 所定載置位置 DESCRIPTION OF SYMBOLS 1 Injection molding machine 4 1 unit 7 Movable die plate 8 Movable metal mold 9 Fixed die plate 10 Fixed metal mold 12 Heating cylinder 13 Injection nozzle 20 First protective sheet (bottom sheet)
21 Second protective sheet (top sheet)
22 first sheet roll 23 second sheet roll 27 cutting device 30 take-out device 31 cutting blade B plate material X virtual line a take-out port b predetermined placement position

Claims (5)

加熱シリンダ内に設けたスクリューを回転させながら後退させて溶融樹脂の計量を行い、該計量工程後に前記スクリューを前進させて前記加熱シリンダの先端に装着した射出ノズルから、固定ダイプレートに固定された固定金型と進退可能に設けられた可動ダイプレートに固定された可動金型とにより、型閉時に形成されたキャビティに前記溶融樹脂を射出して透明な板材を成形し、該板材の上下面にシートを貼着して導光板を製造する方法であって、
前記板材を射出成形機に備えた前記固定金型と前記可動金型からなるキャビティで成形した後、
前記キャビティ内に張り付いた板材を排出して、該排出された板材を取り出し装置で取り出し、
前記板材の下面を第１のシートロールから水平方向に巻きだされてきた底面シートの上面の所定載置位置に載置した後、
第１のシートロールから巻きだされてくる底面シートに載置されていることで搬送されてくる前記板材の上面に、第２のシートロールから巻きだされてきた上面シートを載置して、該上面シートと底面シートを前記板材に貼着させ、
前記上面シートと底面シートが貼着された水平方向に搬送される板材に対し、切断装置に設けた切刃を鉛直方向にスライドさせて所定サイズに切断することを特徴とする導光板の製造方法。 The screw provided in the heating cylinder is rotated while retreating to measure the molten resin, and after the measuring step, the screw is advanced and fixed to the fixed die plate from the injection nozzle attached to the tip of the heating cylinder. By using a fixed mold and a movable mold fixed to a movable die plate provided so as to be able to move forward and backward, the molten resin is injected into a cavity formed when the mold is closed to form a transparent plate material, and the upper and lower surfaces of the plate material A method of manufacturing a light guide plate by attaching a sheet to a sheet,
After molding the plate material in a cavity comprising the fixed mold and the movable mold provided in an injection molding machine,
The plate material stuck in the cavity is discharged, and the discharged plate material is taken out by a take-out device,
After placing the lower surface of the plate material at a predetermined placement position on the upper surface of the bottom sheet that has been wound in the horizontal direction from the first sheet roll,
Place the top sheet unwound from the second sheet roll on the upper surface of the plate material that is conveyed by being placed on the bottom sheet unwound from the first sheet roll, Adhering the top sheet and bottom sheet to the plate,
A method of manufacturing a light guide plate, comprising: cutting a predetermined blade by sliding a cutting blade provided in a cutting device in a vertical direction with respect to a plate material conveyed in a horizontal direction to which the top sheet and the bottom sheet are attached. . 前記取り出し装置には負圧を発生させることで前記板材を吸引する保持装置を備え、該保持装置の吸引力により取り出された前記板材を、前記底面シート上面の所定載置位置に載置することを特徴とする請求項１記載の導光板の製造方法。   The take-out device includes a holding device that sucks the plate material by generating a negative pressure, and the plate material taken out by the suction force of the holding device is placed at a predetermined placement position on the bottom sheet upper surface. The method for manufacturing a light guide plate according to claim 1. 前記射出成形機とは別体に設けたシート成形加工装置に、前記第１のシートロール、前記第２のシートロール、及び前記切断装置を少なくとも備え、
前記シート成形加工装置を前記射出成形機の側部に配設し、
該射出成形機の金型のキャビティから前記板材を取り出す前記キャビティ近傍の取り出し口と、前記シート成形加工装置により前記底面シートの上面に前記板材を載置する所定載置位置とを直線的に最短距離で結ぶ仮想線上に前記取り出し装置を配設し、
前記キャビティ近傍の取り出し口から取り出された前記板材を前記所定載置位置へ最短距離で搬送するようにしたことを特徴とする請求項２記載の導光板の製造方法。 The sheet molding apparatus provided separately from the injection molding machine includes at least the first sheet roll, the second sheet roll, and the cutting device,
The sheet molding apparatus is disposed on the side of the injection molding machine,
A linearly shortest distance between a take-out port near the cavity for taking out the plate material from a mold cavity of the injection molding machine and a predetermined placement position for placing the plate material on the upper surface of the bottom sheet by the sheet molding apparatus. The take-out device is arranged on a virtual line connected by a distance,
3. The method of manufacturing a light guide plate according to claim 2, wherein the plate material taken out from the take-out port near the cavity is conveyed to the predetermined placement position at the shortest distance. 前記射出成形機と前記シート成形加工装置との各々を交互に複数並設し、これら射出成形機の１つずつに対応付けして、その側部に前記シート成形加工装置を１つずつ配設し、前記射出成形機と前記シート成形加工装置とを１ｂｙ１で１ユニットとしてこのユニットを複数並設することで、前記導光板を並行して連続的に量産することを特徴とする請求項３に記載の導光板の製造方法。   A plurality of each of the injection molding machine and the sheet molding processing apparatus are alternately arranged in parallel, and each of the injection molding machines is associated with one by one, and the sheet molding processing apparatus is disposed on the side portion one by one. Further, the light guide plate can be continuously mass-produced in parallel by arranging a plurality of the units by arranging the injection molding machine and the sheet molding processing apparatus as one unit in 1 by 1. The manufacturing method of the light-guide plate of description. 請求項３又は４に記載の導光板の製造方法において、前記上面シート及び底面シートは保護シートとし、該保護シートが前記シート成形加工装置により前記板材の上下面に貼着されるものであることを特徴とする導光板。   5. The light guide plate manufacturing method according to claim 3, wherein the top sheet and the bottom sheet are protective sheets, and the protective sheets are attached to the top and bottom surfaces of the plate member by the sheet forming apparatus. A light guide plate characterized by
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