KR20110094803A - Method of manufacturing light guide plate having serration - Google Patents

Abstract

PURPOSE: A method for manufacturing a light guide plate with a serration unit is provided to prevent film deformation due to heating. CONSTITUTION: A release film is attached to the rear side of a transfer film(S110). A serration unit is formed on the transfer film according to the shape of the outer circumference of a pattern roller while the transfer film passes through a rotating pattern roller(S120). A protective film is attached onto the top of the transfer film(S130). The rear side of the transfer film is attached to a side of a horizontally laminated light guide plate by eliminating the release film(S140).

Description

Manufacturing method of light guide plate including a serration part {Method of Manufacturing Light Guide Plate Having Serration}

The present invention relates to a method of manufacturing a light guide plate including a serration part, and more particularly, it is possible to minimize the dark area according to the light exit angle characteristics of the LED, to prevent film deformation due to heat generation, The present invention relates to a method of manufacturing a light guide plate including a serration part that can form a serration part on a light incident surface without deformation.

In general, a liquid crystal display (LCD) does not emit light by itself, and thus a separate surface light source unit is mainly installed on the rear of the LCD. In addition, the backlight unit (BLU) is a part of the liquid crystal display device that allows the light incident on the LCD panel from the surface light source unit to uniformly illuminate the entire LCD screen so that characters or images can be viewed on the LCD. The backlight unit is generally composed of a composite of a light source, a reflecting plate, a light guide plate, a diffusion plate, and a prism sheet.

One of the components of the backlight unit, a light guide plate (LGP), is a display component for performing brightness and uniform illumination of the backlight unit. Light Emitting Diode (LED) serves to uniformly transmit light incident from a light source such as an LCD to an entire surface of a display device such as a liquid crystal display.

Since all types of LCD panels require the use of a surface light source device, the uniformity of the entire screen and the amount of light transmitted by the brightness (luminance, cd / m²) and uniformity (%) Is determined. Such a surface light source unit requires a high level of technology to realize thin, light, high brightness, low power, and uniformity.

Recently, liquid crystal displays are used in not only small display products such as mobile phones or PDAs but also large display products such as large TVs or electronic bulletin boards to secure product competitiveness in various aspects such as light weight, thinness, low power, high brightness, and durability. Criteria for quality demanded by consumers are gradually increasing.

However, the backlight unit used in liquid crystal display devices having a size such as TVs and monitors is being changed from a cold cathode fluorescent lamp (CCFL), which is a linear light source, to an LED light source, which is a point light source, due to thinning, low power consumption, and environmental problems. However, there is a problem in that manufacturing cost increases when using a plurality of LED light source, low brightness when the number of LED light source is configured low, and many dark areas that do not give visual information to the display panel in some section beyond the incident angle of the light source There was a problem that occurred. In addition, when the LED light source is increased, there are a number of problems such as film deformation, product cost increase, power consumption increase and film aging, and difficulty in thinning due to deformation due to the high heat generation caused by the use of the LED light source.

In addition, since the conventional light guide plate for a small backlight unit is manufactured through injection, it was possible to manufacture by using the core of the serration part in the mold, but in the case of the large light guide plate which cannot be injected, the processing of the serration part became a problem while using an extruded light guide plate. .

1 is an explanatory diagram schematically showing a method of processing a serration part of a large light guide plate for a TV and a monitor possible in the prior art. As shown in FIG. 1, in order to form the serration portion 20 on the side surface of the large light guide plate 10 according to the related art, a plurality of light guide plates 10 are stacked, and then the side surfaces of the stacked large light guide plates are bite. The cutting method using a cutting tool such as) was used. However, according to the related art, since the cutting is performed using a cutting tool, a mirror treatment such as a post-processing process, that is, a fine polishing, must be performed, and when a serration portion is formed on a large light guide plate, the light guide plate is processed during the process. There was a problem that it is deformed by heat and physical force. In addition, according to the prior art, it is not only a difficult process to form a serration portion on the side of the light guide plate, but also a fine process is impossible, and a defective rate is high, thereby increasing the price of the product.

The present invention has been made in view of the above, an object of the present invention is to provide a method for manufacturing a light guide plate including a serration portion that can minimize the dark area according to the light emission angle characteristics even if the number of LEDs are used less. It is to provide.

Another object of the present invention is to provide a method of manufacturing a light guide plate including a serration part capable of preventing deformation of the film due to heat generation.

Still another object of the present invention is to provide a method of manufacturing a light guide plate including a serration part which can easily form a serration part on a large light guide plate and which has excellent work efficiency.

The above and other objects of the present invention can be achieved by the present invention described below.

Method of manufacturing a light guide plate including a serration portion according to the present invention provided to achieve the above object is a step of supplying a transfer film to which a release film is bonded to the rear (S110); Forming a serration part on an upper surface of the transfer film according to a shape of an outer circumferential surface of the pattern roller while the supplied transfer film passes through a rotating pattern roller (S120); Attaching a protective film to an upper surface of the transfer film on which the serration is formed (S130); Attaching the rear surface of the transfer film on which the serration part is formed to the side of at least one light guide plate stacked horizontally while removing the release film (S140); And, the transfer film formed with the serration portion is cut to match the side thickness of the light guide plate while the light guide plate attached to the side of the transfer film formed with the serration portion passes through at least one cutter installed according to the thickness of the light guide plate (S150). It characterized in that it includes;

Here, the step S120, the step of applying the adhesive means on the upper surface of the transfer film (S122); Supplying resin to the pattern roller from a resin supply device (S124); Forming a serration part having a predetermined thickness on an upper surface of the transfer film by a scriber spaced apart from the pattern roller (S126); And hardening the serration part (S128).

In addition, in the step S128, it is preferable to cure the serration part with an ultraviolet curing device or a heater.

In the step S140, the press roller is rotated in contact with one surface of the laminated light guide plate, it is preferable to press the transfer film formed with the serration portion attached to one surface of the laminated light guide plate.

Here, the bonding means is preferably a transparent adhesive layer.

In addition, the pattern roller may be embossed or embossed teeth are formed along the circumferential surface.

Likewise, the serration portion preferably has a sawtooth shape of an embossed or intaglio at regular intervals.

According to the method of manufacturing a light guide plate including a serration part according to the present invention, it is possible to minimize the dark area according to the light emission angle characteristics of the LED, and to prevent the deformation of the film due to heat generation, the light incident surface of the large light guide plate The serration part can be easily provided without deformation. In addition, the light guide plate including the serration part can be easily and economically manufactured by using the continuous process.

1 is an explanatory diagram schematically showing a method of processing a serration portion of a large light guide plate for a TV and a monitor possible according to the prior art;
2 is a flowchart illustrating a manufacturing method of a light guide plate including a serration part according to the present invention;
Figure 3 (a) is a schematic diagram showing a process of forming a serration portion using an embossed pattern roller,
Figure 3 (b) is a schematic diagram showing a process of forming a serration portion using the intaglio pattern roller,
Figure 4 (a) is a schematic diagram showing a manufacturing method of a light guide plate 200 including a serration portion manufactured using the embossed pattern roller of Figure 3 (a), and
FIG. 4B is a configuration diagram schematically illustrating a method of manufacturing a light guide plate including a serration part manufactured by using the engraved pattern roller of FIG. 3B.

The above objects, features and other advantages of the present invention will become more apparent by describing the preferred embodiments of the present invention in detail with reference to the accompanying drawings. Hereinafter, a manufacturing method of a light guide plate including a serration part according to an exemplary embodiment of the present invention will be described in detail with reference to the accompanying drawings.

2 is a flowchart illustrating a manufacturing method of the light guide plate 200 including the serration part 120 according to the present invention. FIG. 3 (a) illustrates the serration part 120 using an embossed pattern roller 130 ′. Figure 3 (b) is a schematic diagram showing the formation process, Figure 3 (b) is a schematic diagram showing the process of forming the serration portion 120 using the intaglio pattern roller 130 ″, Figure 4 (a) is A schematic diagram illustrating a method of manufacturing the light guide plate 200 including the serration part 120 manufactured using the embossed pattern roller 130 ′ of 3 (a), and FIG. FIG. 2 schematically illustrates a method of manufacturing the light guide plate 200 including the serration part 120 manufactured using the engraved pattern roller 130 ″.

2 to 4 (b), the manufacturing method of the light guide plate 200 including the serration part 120 according to the present invention is as follows. Looking at one by one, supplying the transfer film 125 to which the release film 128 is adhered on the rear surface (S110), while the supplied transfer film 125 passes through the rotating pattern roller 130 of the pattern roller 130 According to the shape of the outer circumference of the serration portion 120 is formed on the upper surface of the transfer film 125 (S120), the serration portion 120 is formed on the upper surface of the transfer film 125, the protective film 152 Attaching the back surface of the transfer film 125 on which the serration part 120 is formed while removing the release film 128 (S130) to the side surface of at least one light guide plate 200 which is horizontally stacked ( S140, the light guide plate 200 having the transfer film 125 having the serration part 120 formed thereon passes through the at least one cutter 185 installed according to the thickness of the light guide plate 200, and the serration part 120. ) Formed transfer film 125 is cut to match the side thickness of the light guide plate (200) (S150).

Here, in the step S120, the step of applying the adhesive means 145 by the adhesive means supply device 140 provided on the upper surface of the transfer film 125 (S122), embossed 130 from the resin supply device 110 ′) Or the resin 115 is supplied to the intaglio pattern roller 130 ″ (S124), and the serration part 120 having a predetermined thickness is provided by the scriber 118 spaced apart from the pattern roller 130. ) Is formed on the upper surface of the transfer film 125 (S126), and curing the serration unit 120 (S128).

Herein, the resin 115 may be made of a polycarbonate (PC) substrate having excellent heat resistance or a polymethyl methacrylate (PMMA) having excellent refractive index.

In order to attach the serration part 120 to the light guide plate 200, the transfer film 125 may be formed of a film including an adhesive polymer, and in consideration of optical characteristics, a transparent adhesive layer ( It may be configured to include (not shown).

The material of the transfer film 125 is not particularly limited, it is preferable to use a thin transparent plastic film.

The transferred transfer film 125 is continuously moved by the rotation of the feed roller 190. The transfer film 125 passes through the pattern roller 130 on the movement path, wherein the serration part 120 is formed according to the shape of the outer circumferential surface of the pattern roller 130. In addition, the serration unit 120 is cured by a curing device 155 provided separately, in the present invention, it is preferable to cure with an ultraviolet curing device or a heater.

3 (a) and 3 (b) show an embossed pattern roller 130 'and an intaglio pattern roller 130' used as the pattern roller 130, respectively. The embossed pattern roller 130 ′ is formed by protruding embossed tooth blades along the circumferential surface, and the engraved pattern roller 130 ″ means formed by engraving the depressed tooth teeth along the circumferential surface.

The serration portion 122 generated by the rotation of the embossed 130 ′ or the intaglio pattern roller 130 ″ is provided with a continuous serrated protrusion having an engraved or embossed shape at a predetermined interval.

In this case, an infrared coating layer may be further included between the transfer film 125 and the release film 128.

The infrared coating layer functions to prevent deformation of the serration part 120 due to heat generated from the light source. For example, when the infrared coating layer is disposed on the transfer film 125 and provided between the transfer film 125 and the light guide plate 200, the filtering effect of the infrared coating layer among the light of a wide wavelength incident from the light source is filtered. As a result, only the light in the infrared wavelength range is incident into the light guide plate 200, so that the amount of heat generated by the incident light is significantly reduced. Therefore, the deformation of the serration unit 120 due to the heat generation can be prevented by reducing the amount of heat generated by the light that affects the light guide plate 200 without affecting the optical effect.

In addition, the protective film 152 is attached to the upper surface of the serration portion 120 in order to prevent contamination and damage of the serration portion 120 formed on the upper portion of the transfer film 125. The protective film 152 may be provided from a protective film supply roller 150 provided separately in the manufacturing process.

Thereafter, the transfer film 125 having the protective film 152 attached thereto may be provided to be wound on the winding roller 160 to be bonded to the light guide plate, and may be provided to be bonded to the light guide plate in a continuous process.

By the process described above, a process of preparing the transfer film 125 having the serration part 120 formed thereon and bonding the transfer film 125 to the light guide plate 200 is performed.

4 (a) and 4 (b), while the transfer film 125 having the serration part 120 unwound and supplied from the winding roller 160 is transferred, the protection film recovery roller 157 rotates. The protective film 152 is separated by the release film, the release film 128 is separated by the rotation of the release film recovery roller 170, and is supplied to one surface of the laminated light guide plate 200. At this time, in order to reliably attach the serration part 120 to the side of the light guide plate 200, the adhesive means 145 is applied from the adhesive means supply device 140. The adhesive means 145 may be a transparent adhesive layer.

Subsequently, when the transfer film 125 having the serration part 120 is transferred to one surface of the light guide plate 200 on which the serration part 120 is stacked, one surface of the serration part 120 is rotated in contact with the press roller 175 and pressed. It is securely bonded. Since the transfer film 125 on which the serration part 120 is formed is continuously supplied, it is necessary to cut it to the size of the light guide plate 200. Therefore, by providing a separate cutter at the end of the laminated light guide plate 200 to cut one surface of the transfer film 125 vertically.

 Next, the laminated light guide plate 200 moves horizontally and passes through the fixed cutter 185 having a plurality of cutter blades according to the thickness intervals of the light guide plate 200.

At this time, the transfer film 125 in which the serration portion 120 is formed by the fixed cutter 185 is cut to match the thickness of each light guide plate 200, thereby completing a product.

The press roller 175 may be rotated by the roller shaft is fixed or rotated while the roller shaft is moved horizontally to press the transfer film 125, the serration portion 120 is formed.

FIG. 4A illustrates a light guide plate 200 including an intaglio serration formed by the embossed pattern roller 130 ′ of FIG. 3A, and FIG. 4B illustrates the intaglio of FIG. 3B. The light guide plate 200 including an embossed serration formed by the pattern roller 130 ″ is shown.

The material of the light guide plate 200 is not particularly limited, but it is preferable to use a polycarbonate (PC) substrate having excellent heat resistance or a poly methyl methacrylate (PMMA) substrate having excellent refractive index.

The light guide plate 200 is refracted by incident light incident from a light source (not shown) by the serration part 120 having an embossed or negative serrated shape, and when forming an infrared coating layer, the light guide plate 200 is filtered by an infrared coating layer to form a dark part. It is minimized and heat deformation can be prevented.

As described above, the manufacturing method of the light guide plate including the serration part may minimize the dark area according to the light exit angle characteristic of the LED and prevent the deformation of the film due to heat generation. Serration) can be easily provided. In addition, by using a continuous process, the light guide plate including the preparation of the serration portion or the serration portion can be easily and economically manufactured.

While preferred embodiments of the present invention have been described above, the present invention is not limited to the above-described specific embodiments. That is, those skilled in the art to which the present invention pertains can make many changes and modifications to the present invention without departing from the spirit and scope of the appended claims, and all such appropriate changes and modifications are possible. Equivalents should be considered to be within the scope of the present invention.

110: resin supply device 115: resin
120: serration part 125: transfer film
128: release film 130: pattern roller
140: bonding means supply device 145: bonding means
150: protective film supply roller 152: protective film
155: release film 157: protective film recovery roller
160: winding roller 170: release film recovery roller
175: press roller 185: fixed cutter
190: feed roller 200: light guide plate

Claims (7)

Supplying a transfer film to which a release film is adhered to a rear surface (S110);
Forming a serration part on an upper surface of the transfer film according to a shape of an outer circumferential surface of the pattern roller while the supplied transfer film passes through a rotating pattern roller (S120);
Attaching a protective film to an upper surface of the transfer film on which the serration is formed (S130);
Attaching the rear surface of the transfer film on which the serration part is formed to the side of at least one light guide plate stacked horizontally while removing the release film (S140); And,
A step in which the transfer film having the serration portion is cut to the side thickness of the light guide plate while the light guide plate having the transfer film having the serration portion attached to the side passes through at least one cutter installed according to the thickness of the light guide plate (S150); Method of manufacturing a light guide plate comprising a serration portion comprising a. The method of claim 1, wherein step S120,
Applying an adhesive means to an upper surface of the transfer film (S122);
Supplying resin to the pattern roller from a resin supply device (S124);
Forming a serration part having a predetermined thickness on an upper surface of the transfer film by a scriber spaced apart from the pattern roller (S126);
Curing the serration portion (S128); manufacturing method of a light guide plate comprising a serration portion comprising a. The method of claim 2, wherein step S128,
A method of manufacturing a light guide plate including a serration part, wherein the serration part is cured by an ultraviolet curing device or a heater. The method of claim 1,
In the step S140, the press roller is rotated in contact with one surface of the laminated light guide plate, the manufacturing method of the light guide plate including a serration portion, characterized in that for pressing the transfer film formed with the serration portion on one surface of the laminated light guide plate. . The method of claim 1,
The bonding means is a manufacturing method of the light guide plate comprising a serration portion, characterized in that the transparent adhesive layer. The method of claim 1,
The pattern roller is a manufacturing method of the light guide plate including a serration portion, characterized in that the toothed or embossed teeth are formed along the circumferential surface. The method of claim 1,
The serration portion manufacturing method of the light guide plate including a serration portion, characterized in that having a serrated embossed or intaglio at a predetermined interval.

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