TWI551904B - Method for manufacturing edge-lighting light guide plate - Google Patents

Description

Side-entry light guide plate manufacturing method

The present invention relates to a method of fabricating a light guide plate, and more particularly to a method of fabricating a side-entry light guide plate.

With the development of technology for portable electronic products, the thickness of related products is moving toward a lighter and thinner direction. Most electronic products are still displayed through a liquid crystal display screen, and the light source of the liquid crystal display screen depends on the backlight module. A common backlight module is generally composed of a light guide plate and an array of light sources.

Please refer to FIG. 1A. FIG. 1A is a schematic view showing the processing of a conventional cold-pressing extrusion molding technology for a light guide plate. In the conventional light guide plate extrusion molding technology, the roll 100 is first torn off the protective film 102 by a roller, and the light guide pattern is pressed by the pattern pressing wheel 103, and then rerolled by the roller 104. The light guide plate 101 is coated with the protective film 102, and then the material is collected.

The rolled light guide plate 101 is then transported to the cutting line for die-cutting and cutting, so that it is in a half-break state, for example, as shown in FIG. 1B, and FIG. 1B is a conventional light-guide plate cold material for die-cutting and cutting. Processing schematic. Through the die 106 (or the die template, the first drawing shows the punching direction), The light guide plate 101 and the upper protective film 105 thereof are cut, but the lower protective film 105' is not cut, so that the light guide plate 101 is easily removed when assembled later. Finally, the panel assembly factory is further assembled on the assembly line, and the light guide plates 101 are removed for assembly.

In FIG. 1A, the cold pressing line (the line forming the light guiding pattern) and the assembly line (the line for removing the light guiding plate 101 on the web 100 for assembly) can coordinately define the front side of the light guiding plate as the winding material 100. Inside or outside. Taking the inner surface of the coil 100 as the front surface, that is, the light-emitting surface as an example, if the backlight module designer designs the light guiding pattern to be located on the front surface of the light guide plate, the pattern pressing wheel 103 is as shown in FIG. 1A, and the winding direction of the coil 100 is rotated. The rotation of the web 100 is opposite to the direction of rotation of the pattern pressing wheel 103. Go below.

However, even though the cold-pressing line and the assembly line have been instructed by the designer to carry out division of labor and cooperation, but the actual mass production is due to the fine division of labor, and a slight carelessness may result in a large amount of scrapping of the back-end working point due to the negligence of the front-end working point. .

Therefore, how to effectively solve this problem is an important research and development project of current light guide plates and backlight modules using the same, and has become an urgent target for improvement in related fields.

Accordingly, the present invention provides a method for manufacturing a side-entry light guide plate, which integrates various work stations, particularly cross-factory and inter-company cooperation methods, thereby improving the yield of the terminal product.

In one embodiment, the present invention provides a method for manufacturing a side-lit light guide plate for manufacturing a light guide plate having a light guiding pattern on a front or a back surface for providing light provided by a light source assembled on a side of the light guide plate. The front side of the light guide plate is uniformly led out, and the method for manufacturing the side-entry light guide plate includes the following steps. In the design stage of the light guiding pattern, a light guide plate layout is provided. The light guide plate layout includes an outer size data and a light guiding pattern of the light guiding plate, and a light source is assembled on the side of the light guiding plate, adjacent to the front or the back of the light guiding plate, if the light source is in close proximity On the front side of the light guide plate, the mirror processing mark is marked. In the mold making stage, according to the size data and the size of the material, define the pattern of the mold. If there is a mirroring mark, the mirror will be turned over and the knife template will be made. If there is no mirror processing For the mark, the knife template is directly created according to the die layout. In the light guiding pattern processing stage, the pattern mold is made according to the light guiding pattern, and the light guiding pattern is transferred to the material by the pattern mold. In the cutting stage of the die, the material is cut together with the light guiding pattern by a knife template to form a light guide plate.

According to an embodiment of the invention, the knife template has a die, and the light guide plate is formed by one punch.

According to an embodiment of the invention, the material is an optical grade plastic coil.

According to an embodiment of the invention, the pattern mold is a roller.

An embodiment of the present invention provides a method for manufacturing a light guide plate, which integrates manufacturing methods of each stage of the light guide plate to promote communication between different work sites, thereby improving the yield of the terminal product.

100,210,210’‧‧‧volume

101,200‧‧‧Light guide plate

102‧‧‧Protective film

103‧‧‧pattern extrusion wheel

104‧‧‧Roller

105,213,213'‧‧‧Upper protective film

105',214,214'‧‧‧ under protective film

106,154‧‧‧Model

107‧‧‧Into the knife face

108‧‧‧Non-cutting

109‧‧‧Squeezing

110‧‧‧Materials

112‧‧‧ positive

114‧‧‧Back

116‧‧‧ border

120‧‧‧ Connection surface

122‧‧‧Predetermined location

124‧‧‧Squeeze surface

130‧‧‧Light guide pattern

150‧‧‧Model layout

152‧‧‧Knife template

160‧‧‧Light source

206‧‧‧First wheel

207‧‧‧Reprinted plates

208‧‧‧second wheel

212‧‧‧Materials

Fig. 1A is a schematic view showing the processing of a conventional light guide plate extrusion molding technique.

FIG. 1B is a schematic view showing the processing of the die-cutting and cutting of the conventional light guide plate cold material.

Figure 2 is a side elevational view of the extruded material corresponding to the non-edge face in the light guide plate.

Fig. 3 is a perspective view showing an embodiment of a light guiding pattern design stage in the manufacturing method of the present invention.

Figure 4 is a schematic view showing the design of the material for designing the light guiding pattern in Figure 3.

Fig. 5A is a schematic view showing the design of an embodiment of the die making stage in the manufacturing method of the present invention.

Fig. 5B is a schematic view showing the design of an embodiment of a blade mold making stage in which the mirroring process mark is marked in the manufacturing method of the present invention.

Fig. 6 is a side elevational view showing an embodiment of a light guiding pattern processing stage in the manufacturing method of the present invention.

Fig. 7 is a perspective view showing an embodiment of a cutting stage of a die in the manufacturing method of the present invention.

Figure 8 is a perspective view showing another embodiment of the cutting process of the die in the manufacturing method of the present invention.

FIG. 9A is a perspective view showing an embodiment of the light guide plate of the present invention in an assembly process.

FIG. 9B is a perspective view showing another embodiment of the light guide plate of the present invention in an assembly process.

The spirit and scope of the present invention will be apparent from the following description of the preferred embodiments of the invention. The spirit and scope of the invention are not departed.

In view of the fact that the size of the light guide plate tends to be thinner, it will be disadvantageous for ejection ejection during processing. However, the thinned light guide plate facilitates the extrusion and cutting of the cold material. Considering that when the extrusion and cutting are performed, the die will cause edge extrusion of the punched object, thereby causing the extrusion having an uneven surface. Therefore, the manufacturing method of the present invention integrates the light guide plate, the light source setting position, the light guiding pattern, and the die, which not only promotes communication between the work sites, but also avoids problems caused by the extrusion.

Based on years of practical experience and long-term efforts, the inventor of this case analyzed the processing details of each work site of the light guide plate production process, and found out the factors of the large defect rate of the terminal products as follows: First, multiple light guide plate patterns may be designed in the transverse direction of one coil. In terms of width, therefore, accurate alignment must be performed during cutting to ensure that the light guiding pattern designed on the light guide plate is normally displayed in the visual area of the screen. Therefore, in the stamping and cutting process, the accuracy is shifted a little, which will cause poor optical uniformity.

Please see FIG. 1B again. In the prior art, if the processing precision of the automatic punching machine is to be ensured, at least the direction of the web 100 and the cutting direction of the die 106 must be fixed. For example, if the machine is designed to feed the roll 100 counterclockwise, the die 106 is uniformly pressed (from top to bottom). However, if According to the designer's requirements, if the coil 100 is arbitrarily adjusted to roll out the feed clockwise or change the cutter die to the upper punching (from bottom to top), each time the important parts of the machine are adjusted or reorganized, tolerances will be generated, which will affect the processing. Precision.

Referring again to Fig. 2, Fig. 2 is a side elevational view of the extruded material corresponding to the non-into-blade surface of the light guide plate. When the die 106 (or the die plate, the drawing of FIG. 2 mainly shows the punching direction), the light guide plate 101 is punched from top to bottom, and the opposite positions of the light guide plate 101 corresponding to the cutting position of the die 106 can be divided into two. The cutting face 107 and the non-edge face 108. When the die 106 cuts the light guide plate 101, the extrudate 109 is actually generated on the non-cutting surface 108, and the extrudate 109 will cause the surface of the light guide plate 101 to have an uneven surface. However, these extrudates 109 are not easily noticeable at the time of punching, and are difficult to be improved. In particular, it is considered that the die 106 is to be punched into a semi-punching state. If excessive punching, the thickness and cost of the protective film are required. increase. Further, the position of the knife-increasing surface 107 is caused to affect whether the light-emitting diode light source is surely close to the light side as the design value. For example, the light-emitting diode light source may not be flattened due to the squeeze material 109 relationship. The side of the light guide plate 101.

In summary, the present invention provides a side-by-side light guide plate manufacturing method for manufacturing a light guide plate having a light guiding pattern on the front or back side, and a light guiding pattern for assembling the side surface of the light guide plate. The light provided by the light source is uniformly led out from the front surface of the light guide plate, and the manufacturing method of the side-entry light guide plate includes the following steps in different stages.

In the design stage of the light guiding pattern, a light guide plate layout is provided. The light guide plate layout includes the outer size information and the light guiding pattern of the light guiding plate, and when the light source is assembled on the side of the light guiding plate, the light source is located adjacent to the light guiding plate. On the front or back side, if the light source is located next to the front side of the light guide plate, mark the mirroring mark.

In the mold making stage, according to the size data and the size of the material, define the pattern of the mold. If there is a mirroring mark, the mirror will be turned over and the knife template will be made. If there is no mirror processing For the mark, the knife template is directly created according to the die layout.

In the light guiding pattern processing stage, the pattern mold is made according to the light guiding pattern, and the light guiding pattern is transferred to the material by the pattern mold.

In the cutting stage of the die, the material is cut together with the light guiding pattern by a knife template to form a light guide plate.

Since the production processes at different stages are completed by different work sites, it is particularly likely to be completed by means of cross-plant and inter-company cooperation. The above steps will integrate the production process and improve the yield. Next, the following description will further explain the details of the different stages.

Please refer to FIG. 3, which is a perspective view of an embodiment of a light guiding pattern design stage in the manufacturing method of the present invention. In the production process, the light guide plate 200 is finally removed from the material 110 after cutting. Therefore, at the beginning of the processing process of the light guide plate 200, the layout of the light guide plate must be designed first, and the layout of the light guide plate includes the dimensions and guides of the light guide plate 200. Light pattern. In addition, in this stage, the design of the light guide plate layout can be performed on the design drawing, and then the design drawing content is realized on the material 110, wherein the material 110 can be an optical grade plastic coil material. In order to make the details of this stage easy to understand, the following description will be described in conjunction with material 110.

Designing a light guide plate layout on the material 110, wherein the material 110 has Front side 112 and back side 114. The boundary 116 of the light guide plate 200 is designed, wherein the boundary 116 is used to define the outer dimensions of the light guide plate 200, including the length and width of the light guide plate 200. Therefore, when the design of the boundary 116 is completed, the position and size of the light guide plate 200 on the material 110 can be defined. When the material 110 needs to be cut to form the light guide plate 200, a die (not shown) is aligned with the boundary 116 for cutting. However, the boundary 116 drawn in the figure is the position corresponding to the cutting of the material 110 by the die, which is not necessarily the physical line on the material 110 (for example, it may be the data in the design drawing). Narration.

Next, a light guiding pattern is defined on the material 110. Please refer to FIG. 4, which is a schematic diagram of the design of the material for designing the light guiding pattern in FIG. The light guiding pattern 130 is used to assist the light guide plate 200 to uniformly guide the light. In FIG. 4, the light guiding pattern 130 is designed on the front side 112 of the material 110 and is located within the boundary 116 of the light guiding plate 200. However, the light guiding pattern 130 can also be designed on the back side of the material 110 (see FIG. 3), and is also located in the boundary 116 of the light guide plate 200.

Please return to Figure 3. When the light guide plate 200 is formed, the light source is attached to the side of the light guide plate 200 again. When the light guide plate 200 has not been separated from the material 110, the side surface is connected to the connecting surface 120 of the material 110 and the light guide plate 200 (the surface having the shaded area in FIG. 3). Furthermore, the connecting surface 120 is used to set the surface of the light source corresponding to the light guide plate 200 after the light guide plate 200 is separated from the material 110. In addition, the connecting surface 120 is provided with a predetermined position 122 as a specific setting position of the light source on the light guide plate 200.

Then, when the light source is assembled on the side of the light guide plate 200, the light is defined. The source is located immediately adjacent to the front or back of the light guide plate 200. Here, the front or back side of the light guide plate 200 is independent of the front side 112 or the back side 114 of the material 110.

For example, when the light source is defined as being adjacent to the front surface of the light guide plate 200, the light guide plate 200 has the front surface 112 of the material 110 as the front surface (ie, the back surface of the light guide plate 200 is the back surface 114 of the material 110), wherein the front surface of the light guide plate 200 For the light surface. On the contrary, when the light source is defined as being adjacent to the back surface of the light guide plate 200, the light guide plate 200 has the back surface 114 of the material 110 as the front surface (ie, the back surface of the light guide plate 200 is the front surface 112 of the material 110), wherein the front surface of the light guide plate 200 is light-emitting. surface.

In addition, if the light source is located close to the front side of the light guide plate 200, the mirror processing mark is marked, wherein the mirror processing mark is a mark mark or a physical mark on the design drawing. In summary, this stage is to design the light guiding pattern and define the position of the light source, and then determine whether to mark the mirroring processing mark by the position of the light source.

Please refer to both Figure 5A and Figure 5B. FIG. 5A is a schematic view showing the design of an embodiment of a die making stage in the manufacturing method of the present invention, and FIG. 5B is a schematic view showing the design of an embodiment of a die making stage in which the mirroring process mark is marked in the manufacturing method of the present invention. According to an embodiment of the present invention, in the die making stage, the die layout 150 is designed and the die template 152 is formed according to the design of the die template 150. The die template 152 has a plurality of die 154, and a plurality of guides are formed by one stamping. Light board. The die layout 150 is designed to be based on the dimensions of the light guide and the dimensions of the material (see Figure 3). That is, the size of the knife template 152 corresponds to the material size, and the size of the die 154 corresponds to the light guide. Board appearance size.

The definition of the die layout 150 is as shown in FIG. 5A, and when there is a mirroring mark, the mirror layout 150 of the 5A is mirrored and turned into the die layout 150 of the 5B, and the knife is formed accordingly. Template 152. On the other hand, if there is no mirror processing mark, the blade template 152 is directly formed according to the die layout 150 of Fig. 5A. Therefore, there are two types of die layouts 150 (Figs. 5A and 5B) depending on whether or not there is a mirroring mark (or where the light source is located immediately adjacent to the front or back of the light guide plate), and the two die layouts 150 are Mirror relationship.

In addition, the actual die layout 150 does not necessarily require the missing corners as shown in FIGS. 5A and 5B. This notch is to make the manufacturing method of the present invention easier to understand, for example, FIG. 5A and FIG. 5B. The mutual mirroring relationship, and in the following description, the teachings of the manufacturing method of the present invention can be further understood through the missing corners.

Please refer to FIG. 6 again. FIG. 6 is a side view showing an embodiment of a light guiding pattern processing stage in the manufacturing method of the present invention. In the light guiding pattern, a pattern mold is first formed according to the light guiding pattern, and the light guiding pattern is transferred to the material by a pattern mold. According to an embodiment of the invention, the pattern mold is a roller.

Specifically, taking FIG. 6 as an example, the first roller 206 is coated with a reprinted plate 207, wherein the reprinted plate 207 has a pattern corresponding to the light guiding pattern. Next, the first roller 206 is used as a pattern mold to perform imprinting to transfer to form a light guiding pattern. The web 210 includes a material 212, an upper protective film 213, and a lower protective film 214 corresponding to the light guide plate layout of FIG.

The roll 210 first detaches the upper protective film 213 and the lower protective film 214 through the tear film to expose the material 212 and perform transfer of the light guiding pattern. In Fig. 6, the light guiding pattern is designed to be the front side of the material 212, and the first roller 206 is used as a pattern mold, and the second roller 208 is used as a portion of the supporting material 212 at the time of writing. Thus, the material 212 faces the pattern mold with the front side, and the pattern mold rotates counterclockwise with the direction of rotation of the web 210.

On the other hand, if the design position of the light guiding pattern is located on the back surface of the material 212, the second roller 208 functions as a pattern mold, that is, the printing plate 207 is wrapped on the second roller 208, and the first roller 206 is used as the supporting material 212 during the writing. part. Thus, the material 212 will face the pattern mold with the back side and the pattern mold rotates in the opposite direction to the direction of rotation of the web.

After the transfer of the light guiding pattern is completed, the material 212 is coated with the additional upper protective film 213' and the lower protective film 214' for protection, and is further made into a web 210' by a roller. By this method, the light guiding pattern can be formed on the material 212 quickly and in a large amount. When the work is completed at this stage, the roll 210' can be sent to the next station for processing in the next step.

The following description will be accompanied by the drawings of Figures 7 to 9B and the related description thereof to explain the details of the cutting stage of the die cutter. As described above, the corners drawn in the drawing are to make the manufacturing method of the present invention easier to understand. It doesn't really exist.

Please refer to Figure 7 and Figure 8 at the same time. Fig. 7 is a perspective view showing an embodiment of a cutting process of a die in the manufacturing method of the present invention, and Fig. 8 is a perspective view showing another embodiment of the cutting process of the die in the manufacturing method of the present invention. The embodiments of Figures 7 and 8 are corresponding to the cutting stage of the die. In this stage, the knife template 152 cuts the material 110 together with the light guiding pattern 130 to form the light guide plate 200. According to an embodiment of the present invention, the blade die plate 152 has a plurality of die 154 to form a plurality of light guide plates 200 in one press.

The light source is disposed on the connecting surface 120 of the separated light guide plate 200, and the predetermined position 122 on the connecting surface 120 is a specific position of the light source on the light guide plate 200.

According to the foregoing, since it is necessary to reorganize the important parts of the machine when adjusting the cutting direction of the die, this will create tolerances and affect the machining accuracy. If you want to maintain the machining accuracy of the automatic punching machine, you must at least fix the direction of the coil and the cutting direction of the die.

Therefore, in the cutting stage of the die of FIGS. 7 and 8, the die templates 152 are all stamped in the same direction. Specifically, the knife template 152 having the die 154 is cut from the front side 112 of the material 110. The difference between FIG. 7 and FIG. 8 is that the light guiding pattern 130 of FIG. 7 is located on the front side 112 of the material 110, and the light guiding pattern 130 of FIG. 8 is located on the back side 114 of the material 110. In addition, the cutting mode of Fig. 7 corresponds to the marked mirroring processing mark.

As also mentioned above, when the die 154 is punched into the light guide plate 200, the extrusion will be generated on the non-entry face (see Fig. 2). However, due to the presence of the extrudate, it will be impossible to know whether the light source is actually disposed on the side of the light guide plate 200 as designed.

Please refer to FIG. 9A. FIG. 9A is a perspective view showing an embodiment of the light guide plate of the present invention in an assembly process. The embodiment is a continuation of the seventh drawing, that is, the light guide plate 200 has passed through the cutting method of the seventh figure from the material (see the 7 is separated, and the light guiding pattern 130 has been transferred to the light guide plate 200.

After the light guide plate 200 is separated from the material, since the separation mode is to cut the light guide plate 200 from the material through the die (see FIG. 7), as described above, the die will squeeze the edge of the light guide plate 200. .

The connecting surface 120 is a surface on which the light source 160 is disposed, and can be roughly divided into a predetermined position 122 and a pressing surface 124. The predetermined position 122 is a specific installation position of the light source 160, and the pressing surface 124 has a squeeze material generated by the die pressing (see Fig. 2).

The extruding causes the pressing surface 124 in the connecting surface 120 to have a relatively uneven surface, which is not easy to adhere between the light source 160 and the light guide plate 200, and also because the light source 160 cannot be flatly attached to the light guide plate 200. Light is also unfavorably transmitted into the light guide plate 200. Conversely, the predetermined position 122 of the light source 160 is a relatively flat surface on the connection surface 120 such that the light source 160 can be flat on the light guide plate 200.

Referring to FIG. 9B again, FIG. 9B is a perspective view of another embodiment of the light guide plate of the present invention in an assembly process. In the embodiment, the light guide plate 200 has been separated from the material (see FIG. 8) by the cutting mode of FIG. 8, and the light guiding pattern 130 has been transferred to the light guide plate 200. In addition, in FIG. 9B, the light guide plate 200 is cut in the manner of FIG. 8, and then vertically inverted.

Similarly, when the light guide plate 200 is separated from the material, the connecting surface 120 can be roughly divided into a predetermined position 122 and a pressing surface 124. The predetermined position 122 is a specific installation position of the light source 160, and the pressing surface 124 has a squeeze material generated by the die pressing (see Fig. 2). As mentioned above, the extrusion surface The extrudate on 124 will cause light from source 160 to be less easily transmitted into light guide 200. Conversely, the predetermined position 122 of the light source 160 is a relatively flat surface on the connection surface 120 such that the light source 160 can be flat on the light guide plate 200.

When integrated, the light source 160 is disposed at a relatively flat surface at the position of the light guide plate 200. Therefore, the light source 160 is flatly attached to the light guide plate 200, so that the light guide plate 200 does not leak light. In addition, the light source 160 also has a good fixing effect on the light guide plate 200.

The manufacturing method of the present invention promotes communication between different workstations after integrated processing, and in addition to the fact that there is no erroneous processing during the manufacturing process, the manufacturing yield of the light guide plate is also improved. More specifically, the light source setting position, the light guiding pattern forming position, and the die inserting position are independent of each other, and the mirror patterning mark can generate a correct die layout to improve the erroneous processing. In addition, through integration, the light source is applied to a flat surface, which increases the fixed bonding effect and reduces the light leakage problem of the light guide plate.

Although the present invention has been disclosed in the above embodiments, it is not intended to limit the present invention, and the present invention can be modified and modified without departing from the spirit and scope of the present invention. The scope is subject to the definition of the scope of the patent application attached.

110‧‧‧Materials

112‧‧‧ positive

116‧‧‧ border

120‧‧‧ Connection surface

122‧‧‧Predetermined location

130‧‧‧Light guide pattern

152‧‧‧Knife template

154‧‧‧Model

200‧‧‧Light guide plate

Claims (4)

A method for manufacturing a side-lit light guide plate for manufacturing a light guide plate having a light guide pattern on a front or a back surface, the light guide pattern for providing light provided by a light source assembled on a side of the light guide plate The method for manufacturing the side-lit light guide plate comprises the following steps: in the design stage of the light guide pattern: providing a light guide plate layout, the light guide plate layout includes an outer size data of the light guide plate and the guide a light pattern; and defining that the light source is assembled on a side of the light guide plate, where the light source is located immediately adjacent to the front or back surface of the light guide plate, and if the light source is located adjacent to the front surface of the light guide plate, marking a mirror processing mark In the mold making stage: according to the size information and the size of a material, define a die layout, if the mirror processing mark exists, the knife template mirror is turned over, and a knife template is prepared according to If the mirror processing mark does not exist, the knife template is directly formed according to the die pattern; in the light guiding pattern processing stage: a pattern mold is formed according to the light guiding pattern, and The pattern of the mold the light guide pattern transcribed on the multiple materials; and Die cutting stage: the tool material, along with the template pattern of the light guide, the light guide plate forming the cut. The side-by-side light guide plate manufacturing method according to claim 1, wherein the knife template has a plurality of die cutters, and a plurality of light guide plates are formed by one punching. The method of manufacturing a side-entry light guide plate according to claim 1, wherein the material is an optical grade plastic coil. The method of manufacturing a side-entry light guide plate according to claim 1, wherein the pattern mold is a roller.