JP3521956B2 - Method of manufacturing light guide for backlight unit - Google Patents
Method of manufacturing light guide for backlight unitInfo
- Publication number
- JP3521956B2 JP3521956B2 JP13312194A JP13312194A JP3521956B2 JP 3521956 B2 JP3521956 B2 JP 3521956B2 JP 13312194 A JP13312194 A JP 13312194A JP 13312194 A JP13312194 A JP 13312194A JP 3521956 B2 JP3521956 B2 JP 3521956B2
- Authority
- JP
- Japan
- Prior art keywords
- light guide
- layer
- backlight unit
- diffusion
- core
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Landscapes
- Light Guides In General And Applications Therefor (AREA)
- Liquid Crystal (AREA)
Description
【発明の詳細な説明】
【０００１】
【産業上の利用分野】本発明は、バックライトユニット
用導光体の製造方法に関する。
【０００２】
【従来の技術】液晶表示装置用のバックライトユニット
の主たる部分は、光源からの光を拡散面（パネル）全面
に照射させるための導光板と、拡散量増加のための拡散
板と、発光量増加のための反射板、とから成る。これら
の部品は、異なる製造方法によって個別に製造され、そ
の後に組み立てられる。すなわち、具体的には、導光板
は、例えばＰＭＭＡ材料の射出成形により形成され、拡
散板は、ＰＣ、ＰＥＴ、ＰＭＭＡ等の材料から成るシー
ト材の積層により形成され、反射板は、ＰＣ、ＰＥＴ等
の材料から成るシート材や銀フィルムのシート材で構成
される。そして、このように個別に製造された３つの部
品は、接着や溶着等により一体化接合され、これによ
り、バックライトユニットの主たる部分が出来上がる。
【０００３】
【発明が解決しようとする課題】しかるに、上記従来の
製造方法にあっては、３つの部品を個別に製造するので
合理的・経済的でなく、また、組立工程における接着・
接合作業が結構面倒であり、また、その際に異物の混入
といった事態が起きる虞れがあった。そこで、このよう
な従来の不都合を良好に克服し得る合理的・経済的なバ
ックライトユニット用導光体の形成方法を提供すること
をその課題する。
【０００４】
【課題を解決するための手段】上記課題を解決するため
に本発明に係るバックライトユニット用導光体の製造方
法は、金型コアの移動により隙間空間を形成し該隙間空
間に成形材料を射出成形するというステップを繰り返
し、反射面層及び拡散面層の少なくとも一方と、導光体
層とを含んで成る導光体を一体形成することを構成上の
特徴とする。
【０００５】
【作用】金型コアの移動により、隙間空間が形成され、
該隙間空間に成形材料を射出成形し、これを繰り返すこ
とにより、反射面層及び拡散面層の少なくとも一方と、
導光体層とを含んで成る導光体が、安全且つ確実にそし
て容易に一体形成される。
【０００６】
【実施例】以下、本発明の実施例を図面を参照して説明
する。図１は、本実施例における射出成形状態を略示す
る要部側面断面図である。同図において、P.L.線よりも
上側は、固定側（キャビティ側）の金型であり、下側
は、可動側（コア側）の金型であり、可動側の金型のコ
ア部分１１は、部分的に移動（通称コアバックあるいは
コアスライド）し得るように構成されている。
【０００７】このような構造を有する本実施例の金型を
用いて行う射出成形工程につき、図１に従って以下簡単
に説明する。先ず、図１（Ａ）に示すように、可動側の
コア１１上面の平板状の隙間空間には、射出シリンダ
（図示せず）内での加熱溶融によって流動状態となっ
た、例えばＰＭＭＡ樹脂材料（例えば、旭化成（株）製
の商品名デルペット８０ＮＲ）が射出（供給）され、そ
して、それが冷却・固化されることにより、導光体層１
３が形成される。
【０００８】次いで、コアの移動（コアバック）によ
り、射出成形されたばかりの導光体層１３の下面側に
は、薄板状の隙間空間が形成される。そして、図１
（Ｂ）に示すように、この薄板状の隙間空間には、反射
層形成のための材料（例えば、ＰＣやＰＥＴ等、例え
ば、鐘淵化学工業（株）製のＪＰ５０００ ＯＶ（ＰＣ
／ＰＥＴアロイ））が射出（供給）され、そして、それ
が冷却・固化されることにより、反射層１５が形成さ
れ、従って、一体化された二層（導光体層１３及び反射
層１５）から成る導光体１９が出来上がる。
【０００９】尚、反射層形成の代わりに、拡散材を含む
ＰＣやＰＭＭＡ等を射出成形することにより、拡散層１
７を形成し、従って、別の二層（導光体層１３及び拡散
層１７）から成る導光体１９を形成することもできる。
また、コアバックに加えてコアスライドを行うことによ
り、図２に示すように、導光体層２３の底面のみならず
側面にも反射層２５（あるいは拡散層２７）を具える導
光体２９を形成することもできる。更に、導光体層ない
し導光体の形状としては、平板状のものに何ら限定され
ず、例えば、図３に示すような導光体層３３の上面に反
射層３５（又は拡散層３７）を具えるＶブロック状の断
面の導光体３９や、図示しないが凹状、凸状、Ｕ状、片
（両）くさび状の断面のものが採用可能である。
【００１０】以上説明したように、本実施例において
は、導光体層の射出成形後に、反射層（又は拡散層）を
射出成形するべく、金型内における部分的なコアバック
（あるいはコアスライド）により、順序よく金型内で各
層部分に対応する寸法の隙間空間を形成し、この隙間空
間に各層の材料を射出成形することにより、導光体層と
別の層とを一体的に有して成る導光体を、極めて容易且
つ安価に形成することが可能になる。
【００１１】すなわち、従来の拡散層や反射層（あるい
はそれらに相当する部材）を個別に形成するための設備
や工程が全く不要となり、それらを導光体形成用の金型
１式に集約して、著しく簡素化された組立工程を介し
て、導光体を容易に製造することができ、そして、同一
の工程中で多層形成できるために、ゴミ等の異物の混入
を簡単に回避することができ、歩留まりが著しく向上
し、これにより、低コストのバックライトユニットを市
場にタイムリーに供給することができる。
【００１２】尚、本発明に従って形成されるこのような
二層構造の導光体が、従来の事後的接着・溶着タイプの
ものと比較して、性能において何ら遜色ない（あるいは
それ以上の性能を有する）ことが実験的に認められた。
ところで、本発明は、上記二層構造に限定されるもので
はなく、二以上の層から成る導光体にも適用できる。す
なわち、例えば、図４に示すように、拡散層４７、導光
体層４３、及び反射層４５をこの順序で有して成る三層
構造の導光体４９を形成しようとする場合、本発明に従
って、例えば、先ず、拡散層４７、次いで、導光体層４
３、そして、反射層４５、という順序で射出成形するべ
く、コアバック（及びコアスライド）を適宜行ってから
射出成形を行うのを繰り返すことにより、実施・実現可
能である。
【００１３】
【発明の効果】以上説明したように本発明によれば、特
別な組立工程や設備が不要であり、異物混入等が起きに
くい、合理的・経済的な導光体をタイムリーに供給する
ことが可能になる。Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a light guide for a backlight unit. 2. Description of the Related Art A main part of a backlight unit for a liquid crystal display device includes a light guide plate for irradiating light from a light source to the entire diffusion surface (panel) and a diffusion plate for increasing the amount of diffusion. And a reflector for increasing the amount of light emission. These parts are individually manufactured by different manufacturing methods and then assembled. That is, specifically, the light guide plate is formed by, for example, injection molding of a PMMA material, the diffusion plate is formed by laminating sheet materials made of a material such as PC, PET, PMMA, etc., and the reflection plate is formed by PC, PET And a silver film sheet material. Then, the three components manufactured individually as described above are integrally joined by bonding, welding, or the like, whereby a main portion of the backlight unit is completed. [0003] However, in the above-mentioned conventional manufacturing method, three parts are separately manufactured, so that it is not rational and economical.
The joining operation is quite troublesome, and at that time, there is a possibility that a situation such as mixing of foreign matter may occur. Accordingly, it is an object of the present invention to provide a reasonable and economical method of forming a light guide for a backlight unit, which can effectively overcome such conventional inconveniences. In order to solve the above-mentioned problems, a method of manufacturing a light guide for a backlight unit according to the present invention comprises forming a clearance space by moving a mold core, and forming the clearance space in the clearance space. The step of injection molding the molding material is repeated, and a light guide including at least one of the reflection surface layer and the diffusion surface layer and the light guide layer is integrally formed. A clearance space is formed by the movement of the mold core.
Injection molding a molding material in the gap space, by repeating this, at least one of the reflective surface layer and the diffusion surface layer,
A lightguide comprising a lightguide layer is integrally formed safely, reliably and easily. Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a side sectional view of a main part schematically showing an injection molding state in this embodiment. In the figure, the upper side of the PL line is a mold on the fixed side (cavity side), the lower side is a mold on the movable side (core side), and the core portion 11 of the movable side mold is It is configured to be able to partially move (commonly called a core back or core slide). The injection molding process performed using the mold of the present embodiment having such a structure will be briefly described below with reference to FIG. First, as shown in FIG. 1 (A), for example, a PMMA resin material which has been in a fluidized state due to heating and melting in an injection cylinder (not shown) is provided in a flat clearance space on the upper surface of the movable core 11. (For example, Delpet 80NR (trade name, manufactured by Asahi Kasei Corporation)) is injected (supplied) and then cooled and solidified to form the light guide layer 1.
3 is formed. Next, by the movement of the core (core back), a thin plate-shaped gap space is formed on the lower surface side of the light guide layer 13 that has just been injection molded. And FIG.
As shown in (B), a material for forming the reflective layer (for example, PC or PET, for example, JP5000 OV (PC
/ PET alloy)) is injected (supplied), and is cooled and solidified to form the reflective layer 15, and therefore, two integrated layers (the light guide layer 13 and the reflective layer 15) Is formed. In addition, instead of forming the reflection layer, PC, PMMA or the like containing a diffusion material is injection-molded to form the diffusion layer 1.
7, so that a light guide 19 consisting of another two layers (light guide layer 13 and diffusion layer 17) can also be formed.
In addition, by performing the core slide in addition to the core back, as shown in FIG. 2, the light guide 29 including the reflection layer 25 (or the diffusion layer 27) on the side surface as well as the bottom surface of the light guide layer 23. Can also be formed. Further, the shape of the light guide layer or the light guide is not limited to a flat plate shape, but may be, for example, a reflective layer 35 (or a diffusion layer 37) on the upper surface of the light guide layer 33 as shown in FIG. A light guide 39 having a V-block-shaped cross section and a concave, convex, U-shaped, or single (both) wedge-shaped cross section (not shown) can be employed. As described above, in this embodiment, after the light guide layer is injection-molded, a partial core back (or core slide) in a mold is formed in order to injection-mold the reflection layer (or diffusion layer). ), A gap space having a dimension corresponding to each layer portion is formed in order in the mold, and the material of each layer is injection-molded into the gap space, thereby integrally having the light guide layer and another layer. It is possible to extremely easily and inexpensively form a light guide composed of the above. In other words, there is no need for any equipment or process for individually forming the conventional diffusion layer and reflection layer (or members corresponding thereto), and these are integrated into a mold for forming a light guide. Therefore, the light guide can be easily manufactured through a significantly simplified assembly process, and since it can be formed in multiple layers in the same process, it is possible to easily avoid the intrusion of foreign substances such as dust. And the yield is remarkably improved, whereby a low-cost backlight unit can be supplied to the market in a timely manner. It should be noted that such a two-layered light guide formed according to the present invention is not inferior in performance as compared with a conventional post-adhesion / welding type light guide (or has a higher performance). Experimentally).
By the way, the present invention is not limited to the above two-layer structure, but can be applied to a light guide composed of two or more layers. That is, for example, as shown in FIG. 4, when a light guide 49 having a three-layer structure including the diffusion layer 47, the light guide layer 43, and the reflection layer 45 in this order is to be formed, the present invention is applied. For example, first, the diffusion layer 47 and then the light guide layer 4
3. Then, in order to perform the injection molding in the order of the reflection layer 45, it is possible to implement and realize by repeating the injection molding after appropriately performing the core back (and the core slide). As described above, according to the present invention, there is no need for a special assembling step or equipment, and a reasonable and economical light guide can be provided in a timely manner, in which foreign substances are hardly mixed. It becomes possible to supply.
【図面の簡単な説明】
【図１】図１は、本実施例における射出成形状態を略示
する要部側面断面図である。
【図２】図２は、底面及び側面に反射層（拡散層）を具
える導光体の一例を示す側面断面図である。
【図３】図３は、Ｖブロック状断面の導光体の一例を示
す図である。
【図４】図４は、三層構造から成る導光体の一例を示す
図である。
【符号の説明】
１１…コア（部分）
１３、２３、３３、４３…導光体層
１５、２５、３５、４５…反射層
１７、２７、３７、４７…拡散層
１９、２９、３９、４９…導光体BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side sectional view schematically showing a main part of an injection molding state according to the present embodiment. FIG. 2 is a side cross-sectional view illustrating an example of a light guide having a reflective layer (diffusion layer) on a bottom surface and a side surface. FIG. 3 is a diagram illustrating an example of a light guide having a V-block-shaped cross section. FIG. 4 is a diagram illustrating an example of a light guide having a three-layer structure. [Description of Signs] 11 cores (portions) 13, 23, 33, 43 light guide layers 15, 25, 35, 45 reflective layers 17, 27, 37, 47 diffusion layers 19, 29, 39, 49 … Light guide
───────────────────────────────────────────────────── フロントページの続き (56)参考文献 特開 平７−120605（ＪＰ，Ａ) 特開 平７−110409（ＪＰ，Ａ) 特開 平６−160638（ＪＰ，Ａ) 実開 平２−104325（ＪＰ，Ｕ) (58)調査した分野(Int.Cl.7，ＤＢ名) G02F 1/13357 ──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-7-120605 (JP, A) JP-A-7-110409 (JP, A) JP-A-6-160638 (JP, A) 104325 (JP, U) (58) Field surveyed (Int. Cl. 7 , DB name) G02F 1/13357
Claims (1)
該隙間空間に成形材料を射出成形するというステップを
繰り返し、反射面層（１５：２５：３５：４５）及び拡
散面層（１７：２７：３７：４７）の少なくとも一方
と、導光体層（１３：２３：３３：４３）とを含んで成
る導光体（１９：２９：３９：４９）を一体形成するこ
とを特徴とする、バックライトユニット用導光体の製造
方法。(57) [Claims 1] A step of forming a clearance space by moving a mold core and injecting a molding material into the clearance space is repeated, and the reflection surface layer (15:25:35: 45) and a light guide (19: 29: 39: 49) comprising at least one of a diffusion surface layer (17: 27: 37: 47) and a light guide layer (13: 23: 33: 43). A method of manufacturing a light guide for a backlight unit, comprising:
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP13312194A JP3521956B2 (en) | 1994-06-15 | 1994-06-15 | Method of manufacturing light guide for backlight unit |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP13312194A JP3521956B2 (en) | 1994-06-15 | 1994-06-15 | Method of manufacturing light guide for backlight unit |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH086021A JPH086021A (en) | 1996-01-12 |
| JP3521956B2 true JP3521956B2 (en) | 2004-04-26 |
Family
ID=15097287
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP13312194A Expired - Fee Related JP3521956B2 (en) | 1994-06-15 | 1994-06-15 | Method of manufacturing light guide for backlight unit |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3521956B2 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR100313246B1 (en) * | 1999-11-26 | 2001-11-07 | 구본준, 론 위라하디락사 | Apparatus of Fabricating Light Guide and Method thereof |
| DE10224267A1 (en) * | 2002-05-31 | 2003-12-11 | Kostal Leopold Gmbh & Co Kg | Fiber optic light guide body (FOLGB) for decoupling has a surface for decoupling rays of light coupled into the FOLGB and a diffuser layer for even light density near this surface |
| KR101192949B1 (en) | 2003-09-30 | 2012-10-18 | 미츠비시 레이온 가부시키가이샤 | Flowability improver for engineering plastics, thermoplastic resin compositions containing the same, and molded articles of the compositions |
-
1994
- 1994-06-15 JP JP13312194A patent/JP3521956B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JPH086021A (en) | 1996-01-12 |
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