KR101478052B1 - A stamper for injection moulding a hybrid light guide panel with incorcorated led lenses - Google Patents

Abstract

The present invention relates to a stamper for injection molding a hybrid light guide plate with integrated LED lenses. The stamper according to the present invention comprises an upper stamper installed in an upper mold and a lower stamper installed in a lower mold. The upper stamper includes an upper surface layer, an upper insulation layer, an upper stamper body and multiple upper lens cores. The upper surface layer, the upper insulation layer and the upper stamper body are attached by an adhesive layer, respectively. The lower stamper includes a lower surface layer, a lower insulation layer, a lower stamper body and multiple lower lens cores. The lower surface layer, the lower insulation layer and the lower stamper body are attached by an adhesive layer, respectively. One end of each upper lens core is fixed to the upper stamper body, and the other end is exposed to the inside of a cavity in which a hybrid light guide plate is formed by penetrating through the upper insulation layer and the upper surface layer. The exposed other end of the upper lens core has a shape corresponding to an upper part of an LED lens. One end of each lower lens core is fixed to the lower stamper body, and the other end is exposed to the inside of the cavity in which the hybrid light guide plate is formed by penetrating through the lower insulation layer and the lower surface layer. The exposed other end of the lower lens core has a shape corresponding to a lower part of the LED lens.

Description

A STAMPER FOR INJECTION MOLDING A HYBRID LIGHT GUIDE PANEL WITH INCORCORATED LED LENSES [0001] The present invention relates to a stamper for injection molding a hybrid light guide plate,

The present invention relates to a stamper for injection molding of a light guide plate, and more particularly, to a stamper for injection molding of a light guide plate, in which LEDs are arranged directly underneath, that is, LEDs are arranged in a plane on a substrate, The present invention relates to a stamper for injection molding a hybrid light guide plate integrated with a light guide plate.

2. Description of the Related Art Recently, liquid crystal displays (LCDs) have been widely used in various display devices such as monitors and TVs, in order to improve the sharpness of the screen and to reduce the thickness of the device. Since such a liquid crystal display can not emit light by itself, a backlight unit (BLU) having a separate light source is required. Conventionally, a cold cathode fluorescent lamp (CCFL) has been used as a light source used in such a backlight unit. However, due to the structure of a cold cathode fluorescent lamp, there are limitations in manufacturing a thin display device, Light Emitting Diode (LED), which is a light source, is widely used as a light source.

The backlight unit has a direct type and an edge type in accordance with the manner in which the LEDs are arranged. The direct type is a type in which the LEDs are arranged in a planar manner below the backlight unit. In the edge type, Are disposed at the edge, that is, the edge, of the backlight unit light guide plate. In the case of the direct type, the LEDs are arranged evenly from the center to the side of the display screen to uniformly maintain the brightness of the entire screen, and the local dimming backlight control is easy, while the thickness of the backlight unit, There is a limit in reducing the thickness of the antenna. In the case of the edge type, the thickness of the device can be made more slimmer than the direct type, but the quantity of the LED to be used can be increased and the light emitted from the LED is scattered through the light guide plate. There is a difficulty in making.

Also, in the case of the direct-type type, in order to reduce the number of LEDs required and to improve the light orientation, the LED lenses are mounted on the respective LEDs. A large amount of LED lenses are installed on the respective LEDs. The manufacturing period is lengthened, and some of the LED lenses may not be aligned with the corresponding LEDs correctly, or the LED lens may be detached from the position.

On the other hand, LED has been widely used for lighting in recent years due to its low power consumption and long life span, and the use of LED lamps is increasing its use range. There have been various attempts to reduce the thickness of the product by securing the uniformity of luminance in the backlight unit and the LED illumination lamp as described above. Therefore, it is necessary to develop a light guide plate that combines the advantages of the edge type and the advantages of the direct type, and it is necessary to develop a method of easily performing the injection molding.

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and it is an object of the present invention to provide a light guide plate capable of making the overall light luminance of the display screen more uniform, facilitating local dimming control, And to provide a stamper which can be injection-molded at a low cost.

According to an aspect of the present invention, there is provided a stamper for injection molding a hybrid light guide plate integrally formed with LED lenses. The stamper includes an upper stamper mounted on an upper mold, And a lower stamper. The upper stamper includes an upper skin layer, an upper heat insulating material layer, an upper stamper body, and a plurality of upper lens cores, and the upper surface skin layer, the upper heat insulating material layer, and the upper stamper body are bonded together by an adhesive layer. The lower stamper includes a lower skin layer, a lower heat insulating material layer, a lower stamper body, and a plurality of lower lens cores, and the lower skin layer, the lower heat insulating material layer, and the lower stamper body are respectively adhered by an adhesive layer. One end of each of the upper lens cores is fixed to the upper stamper body and the other end passes through the upper heat insulating material layer and the upper surface skin layer so as to be exposed in the cavity in which the hybrid light guide plate is molded and the other end of the exposed upper lens core is made of LED And has a shape corresponding to the upper portion of the lens. One end of each of the lower lens cores is fixed to the lower stamper body and the other end passes through the lower heat insulating material layer and the lower surface skin layer to be exposed in the cavity in which the hybrid light guide plate is molded and the other end of the exposed lower lens core And has a shape corresponding to the lower portion of the LED.

The upper surface layer and the lower surface skin layer may be formed of any one of nickel, copper alloy, .

The upper insulating layer and the lower insulating layer may be made of a polymer insulating film.

The upper stamper body and the lower stamper body may be made of steel.

Meanwhile, the LED lens may be a top emitter type, a side emitter type, or a hybrid type in which a top emitter type and a side emitter type are mixed.

By using the stamper according to the present invention, a hybrid light guide plate in which LED lenses are integrally formed can be injection-molded in a large amount in a short time. By using such a hybrid light guide plate for a product such as a backlight unit of a display device or an LED flat- It is possible to reduce the number of LEDs and uniform brightness of the entire screen, thereby preventing the occurrence of screen stains, obtaining a clearer screen, and making the product thickness thinner than the conventional direct type. In addition, since the LED light is integrally integrated with the hybrid light guide plate, it is possible to shorten the production period of the product such as the backlight unit and the LED flat panel lamp, to reduce the manufacturing cost, and the LED lens to be arranged to be shifted from the corresponding LED , It is possible to prevent the LED lens from being displaced from its position.

1 is a plan view of a hybrid light guide plate in which LED lenses are injection-molded using a stamper according to a preferred embodiment of the present invention.
2 is a cross-sectional view taken along the line I-I 'in FIG.
3 is a schematic partial cross-sectional view of a stamper for injection molding an integrated hybrid light guide plate according to a preferred embodiment of the present invention.

Hereinafter, a heat-insulating core for injection molding according to the present invention will be described in detail with reference to the accompanying drawings, which are illustrative and do not limit the present invention.

FIG. 1 is a plan view of a hybrid light guide plate 40 in which LED lenses 42 are injection-molded using a stamper according to a preferred embodiment of the present invention, and FIG. 2 is a cross- Sectional view taken along the line I-I 'of FIG. 1, showing a state in which the hybrid light guide plate 40 is mounted on the LED substrate 52 on which the LEDs 51 are mounted.

As shown in the figure, a hybrid light guide plate 40 in which LED lenses 42 are injection-molded by injection molding using a stamper (10 and 20 in FIG. 3) according to a preferred embodiment of the present invention includes a LED substrate 52 A light guide portion 41 formed in a flat plate shape and an LED lens 42 positioned on each of the LEDs 51. The hybrid light guide plate 40 is mounted on the LEDs 51, The light guiding portion 41 and the LED lenses 42 may be integrally formed by injection molding by melting a resin such as PMMA, PC, PS or the like. The hybrid light guide plate 40, which is integrally manufactured in this way, is disposed on the LEDs 51 arranged in a direct-lowering shape, and can constitute, for example, a backlight unit or an LED flat panel lamp. In FIG. 1, 24 LED lenses 42 are integrated into the hybrid light guide plate 40, which is an example, and the quantity and arrangement of the LED lenses 42 will vary depending on the type of product and the like.

For the sake of reference, the light guide plate 40 is referred to as a hybrid light guide plate in the present specification, the light guide plate is provided in the case of an edge type in a general backlight unit and the light guide plate is not usually provided in a direct type. The light guide plate 40 is integrally formed with the LED lenses 42 and is disposed on the LEDs 51 disposed directly under the light guide plate 40 so that the light guide plate 40 has a combination of a direct under type and an edge type, It is called the hybrid light guide plate 40 because it can be used.

The LED substrate 52 is a substrate in the form of a bar or a plate and LEDs 51 are arranged on the substrate 51. The hybrid light guide plate 40 is hermetically mounted on the substrate to form a hybrid light guide plate 40 The LEDs 51 inside the LEDs 51 can be protected from the external environment. The hybrid light guide plate 40 may be used for a backlight unit used in a liquid crystal display device, an apparatus using an LED flat light or the like, or other devices.

Various lens types may be used as the above-described LED lens 42. The lens emissive type may be a top emitting type described in Patent Application No. 10-2013-0101070 filed on Aug. 26, 2013, Side emitting type or hybrid type LED lenses may be used, and other lens types may be applied. The above Patent Application No. 10-2013-0101070 is incorporated herein by reference.

By doing so, it is possible to reduce the number of LEDs required for a product such as a backlight unit or an LED flat panel lamp, improve luminance uniformity compared to the conventional direct type or edge type, Though it is possible to obtain a clear screen, the thickness of the product can be made more slimmer than the conventional direct type. In addition, since the LED lenses 42 are integrally integrated with the hybrid light guide plate 40 according to the present invention, the manufacturing time of the products such as the backlight unit and the LED flat panel lamp can be shortened, It is possible to prevent the LED lenses 42 from being displaced from the corresponding LEDs 51 and to prevent the LED lenses 42 from being displaced from their positions.

3, a schematic cross-sectional view of the stamper 10 and 20 for injection molding the hybrid light guide plate 40, in which the LED lenses 42 are integrally formed, is partially shown in FIG. .

3, the stamper according to the preferred embodiment of the present invention includes an upper stamper 10 provided on an upper mold (not shown) and a lower stamper 20 provided on a lower mold (not shown) .

The upper stamper 10 includes the upper skin layer 11, the upper heat insulating material layer 13 and the upper stamper body 14 sequentially from the cavity 30 in which the product is molded, and the upper skin layer 11, The layer 13 and the upper stamper body 14 are adhered to each other by the adhesive layer 12. The upper stamper 10 includes a plurality of upper lens cores 15. One end of each of the upper lens cores 15 is fixed to the upper stamper body 14 by fixing bolts The other end of the upper lens core 15 passes through the upper heat insulating layer 13 and the upper surface skin layer 11 and is exposed in the cavity 30 in which the hybrid light guide plate 40 is molded and the exposed upper lens core 15 And the molten resin is injected into the cavity 30 to form a shape of the upper surface of the hybrid light guide plate 40 together with the upper surface skin layer 11. [

The lower stamper 20 sequentially forms the lower skin layer 21, the lower heat insulating material layer 23 and the lower stamper body 24 from the cavity 30 in which the product is molded, as in the upper stamper 10 described above The lower skin layer 21, the lower heat insulating material layer 23 and the lower stamper body 24 are adhered to each other by the adhesive layer 22. A plurality of lower lens cores 25 are arranged on the lower stamper 20 at positions facing the upper lens core 15 of the upper stamper 10. Each of the lower lens cores 25 has one end The other end of the lower lens core 25 is fixed to the lower stamper body 24 by a fixing bolt (not shown) or the like and passes through the lower heat insulating material layer 23 and the lower surface skin layer 21 so that the hybrid light guide plate 40 The other end of the exposed lower lens core 25 has a shape corresponding to the lower portion of the LED lens so that when the molten resin is injected into the cavity 30, The shape of the lower surface of the hybrid light guide plate 40 is formed.

A fine pattern may be formed on the surface of the upper skin layer 11 or the surface of the lower skin layer 21 in contact with the cavity 30 for uniform scattering of light and brightness of the hybrid light guide plate 40, 11) and the surface of the lower skin layer 21 can be formed. The upper skin layer 11 and the lower skin layer 21 may be made of nickel, copper alloy or aluminum alloy having good pattern processability and thermal conductivity. The upper heat insulating material layer 13 and the lower heat insulating material layer 23 may be made of polyimide A heat-resistant insulating film of a polymer type such as a film (PI film).

On the other hand, general steels can be used for the upper stamper body 14 and the lower stamper body 24, and high-strength steels are preferably used for the upper lens core 15 and the lower lens core 25 Do. The upper lens core 15 and the lower lens core 25 may be fixed to the upper stamper body 14 and the lower stamper body 24 so as to be replaceable.

The upper stamper 10 is provided in an upper mold (not shown), and the lower stamper 20 is provided in a lower mold (not shown). When the upper mold and the lower mold are in close contact with each other, A cavity 30 is formed in which the hybrid light guide plate 40 in which the LED lenses 42 and the light guide portion 41 are integrated can be formed. Thus, the hybrid light guide plate 40 is molded by injecting molten resin into the cavity 30. When the molded product is cooled and solidified, the upper mold and the lower mold are separated from each other. By doing so, the hybrid light guide plate 40 in which a plurality of LED lenses are integrated can be mass-produced in a short time, thereby enhancing cost competitiveness and quality uniformity.

As described above, the shape of the LED lens may be a top emitter type, a side emitter type, or a hybrid type in which a top emitter type and a side emitter type are mixed. The shape of the upper lens core 15, the lower lens core 25, and the like will be different depending on the shape of the LED lens.

In the stamper for molding the hybrid light guide plate 40 as shown in FIG. 1, twenty-four upper lens cores 15 and twenty-four lower lens cores 25 are arranged, which is an example, And so on.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, It is to be understood that the invention is not limited to the disclosed embodiments.

10: upper stamper 11: upper surface layer
12: adhesive layer 13: upper heat insulating material layer
14: upper stamper body 15: upper lens core
20: lower stamper 21: lower side skin layer
22: adhesive layer 23: lower insulating material layer
24: lower stamper body 25: lower lens core
30: cavity 40: hybrid light guide plate
41: light guide portion 42: LED lens
51: LED 52: LED substrate

Claims (6)

A stamper for injection molding a hybrid light guide plate integrally formed with LED lenses, wherein the stamper includes an upper stamper provided on the upper mold and a lower stamper provided on the lower mold,
Wherein the upper side skin layer, the upper side heat insulating material layer and the upper side stamper body are adhered to each other by an adhesive layer, and the upper side skin layer, the upper side heat insulating material layer, the upper side stamper body and the upper side lens cores,
The lower stamper includes a lower skin layer, a lower heat insulating material layer, a lower stamper body, and a plurality of lower lens cores, wherein the lower skin layer, the lower heat insulating material layer, and the lower stamper body are adhered to each other with an adhesive layer,
Wherein one end of each of the upper lens cores is fixed to the upper stamper body and the other end passes through the upper heat insulating material layer and the upper surface skin layer to be exposed in a cavity in which the hybrid light guide plate is molded, The end portion has a shape corresponding to the upper portion of the LED lens,
One end of each of the lower lens cores is fixed to the lower stamper body and the other end passes through the lower heat insulating material layer and the lower surface skin layer to be exposed in a cavity in which the hybrid light guide plate is molded, And the end portion has a shape corresponding to a lower portion of the LED lens.
The method according to claim 1,
Wherein a fine pattern is formed on either the surface of the upper surface layer or the surface of the lower surface layer or the surface of the upper surface layer and the surface of the lower surface layer.
The method according to claim 1,
Wherein the upper and lower skin layers are made of one of nickel, a copper alloy, and an aluminum alloy.
The method according to claim 1,
Wherein the upper heat insulating material layer and the lower heat insulating material layer are polymeric heat insulating films.
The method according to claim 1,
Wherein the upper stamper body and the lower stamper body are made of steel.
The method according to claim 1,
Wherein the LED lens is of a top emitter type, a side emitter type, or a hybrid type of a mixture of a top emitter type and a side emitter type.

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