US20090316270A1 - Diffuser-integrated prism sheet for backlight units and method of manufacturing the same - Google Patents

Diffuser-integrated prism sheet for backlight units and method of manufacturing the same Download PDF

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Publication number
US20090316270A1
US20090316270A1 US12/522,886 US52288608A US2009316270A1 US 20090316270 A1 US20090316270 A1 US 20090316270A1 US 52288608 A US52288608 A US 52288608A US 2009316270 A1 US2009316270 A1 US 2009316270A1
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Prior art keywords
layer
resin
prism
sheet
diffuser
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Gi Suk Sung
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ON-NURI ELECTRONICS Inc
ON NURI ELECTRONICS Inc
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ON NURI ELECTRONICS Inc
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M1/00—Suction or pumping devices for medical purposes; Devices for carrying-off, for treatment of, or for carrying-over, body-liquids; Drainage systems
    • A61M1/08—Cupping glasses, i.e. for enhancing blood circulation
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/02—Diffusing elements; Afocal elements
    • G02B5/0205—Diffusing elements; Afocal elements characterised by the diffusing properties
    • G02B5/021—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/005—Diaphragms
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/133504—Diffusing, scattering, diffracting elements
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/1336—Illuminating devices
    • G02F1/133602—Direct backlight
    • G02F1/133606—Direct backlight including a specially adapted diffusing, scattering or light controlling members
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M2205/00—General characteristics of the apparatus
    • A61M2205/02—General characteristics of the apparatus characterised by a particular materials
    • A61M2205/0216—Materials providing elastic properties, e.g. for facilitating deformation and avoid breaking
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M2205/00—General characteristics of the apparatus
    • A61M2205/07—General characteristics of the apparatus having air pumping means
    • A61M2205/071—General characteristics of the apparatus having air pumping means hand operated
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/04—Prisms
    • G02B5/045—Prism arrays
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/1336—Illuminating devices
    • G02F1/133602—Direct backlight
    • G02F1/133606—Direct backlight including a specially adapted diffusing, scattering or light controlling members
    • G02F1/133607—Direct backlight including a specially adapted diffusing, scattering or light controlling members the light controlling member including light directing or refracting elements, e.g. prisms or lenses
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1007—Running or continuous length work
    • Y10T156/1023—Surface deformation only [e.g., embossing]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1039—Surface deformation only of sandwich or lamina [e.g., embossed panels]

Definitions

  • the present invention relates to a diffuser-integrated prism sheet for backlight units and a method of manufacturing the same. More particularly, the present invention relates to a prism sheet for backlight units, in which diffuser layers are provided on upper and lower surfaces of the prism sheet and prism-shaped protrusions are formed in the prism sheet, and to a method of manufacturing the same.
  • FIG. 1 illustrates the construction of a conventional backlight unit.
  • a fluorescent lamp 1 which is a linear light source, and a lamp reflector plate 2 for reflecting the light of the fluorescent lamp 1 are disposed to one side of a light guide plate 3 for using the light from the fluorescent lamp 1 as a surface light source, and a reflector sheet 4 for preventing the leakage of light is disposed under the light guide plate 3 .
  • a diffuser sheet 5 for uniformly diffusing light is placed on the light guide plate 3 , and prism sheets 6 , 7 respectively having a plurality of triangular linear prisms 8 , 9 to collect scattered light are sequentially placed on the diffuser sheet 5 .
  • Two prism sheets 6 , 7 are disposed so that linear prisms 8 , 9 are perpendicular to each other, thus collecting light radiated in different directions.
  • a protector sheet 10 for protecting the prisms from being scratched and preventing the entry of impurities between the prisms is disposed. The individual constituents are assembled, thereby completing a backlight unit.
  • the conventional prism sheet has the prism-shaped protrusions on one surface thereof, defects caused by scratching of the prism-shaped protrusions and by the entry of small impurities into the valleys between the prism-shaped protrusions and shatter cracks caused by cutting of the prism-shaped protrusions, attributable to friction with the protective sheet, may be generated when the backlight unit is assembled. Hence, even if the backlight unit is carefully assembled, many assembly defects may occur, undesirably decreasing productivity, and furthermore, in the case where defects occur, the manufacturing process must be conducted again, resulting in high material cost loss.
  • the present invention has been made keeping in mind the above problems occurring in the related art, and provides a diffuser-integrated prism sheet, in which various optical sheets are integratedly layered, and thus diffuser layers are formed on the outer surfaces of the prism sheet, and prism-shaped protrusions are formed in the prism sheet, in order to prevent the prism-shaped protrusions from being scratched, prevent the entry of impurities into the valleys between the prism-shaped protrusions in the course of assembling a backlight unit, and realize a short assembly time and a simple assembly process, resulting in decreased costs, and also provides a method of manufacturing the same.
  • a diffuser-integrated prism sheet for backlight units may comprise a lower diffuser layer having a light diffusion structure, a lower layer formed on the upper surface of the lower diffuser layer, a first intermediate layer formed on the upper surface of the lower layer and having a plurality of prism-shaped protrusions formed parallel to each other, a second intermediate layer formed on the upper surface of the first intermediate layer, an upper layer formed on the upper surface of the second intermediate layer, and an upper diffuser layer formed on the upper surface of the upper layer and having a light diffusion structure, wherein an air layer is formed between the lower surface of the second intermediate layer and the valleys of the prism-shaped protrusions of the first intermediate layer.
  • FIG. 1 is an exploded perspective view illustrating a conventional backlight unit
  • FIG. 2 is a perspective view illustrating a diffuser-integrated prism sheet according to a first embodiment of the present invention
  • FIG. 3 is a bottom perspective view illustrating the diffuser-integrated prism sheet of FIG. 2 , in which the size and density of the protrusions of the lower diffuser layer are suppressed;
  • FIG. 4 is a perspective view illustrating a diffuser-integrated prism sheet according to a second embodiment of the present invention.
  • FIG. 5 is a perspective view illustrating a diffuser-integrated prism sheet according to a third embodiment of the present invention.
  • FIG. 6 is a perspective view illustrating a diffuser-integrated prism sheet according to a fourth embodiment of the present invention.
  • FIG. 7 is a perspective view illustrating a diffuser-integrated prism sheet according to a fifth embodiment of the present invention.
  • FIG. 8 is a perspective view illustrating a diffuser-integrated prism sheet according to a sixth embodiment of the present invention.
  • FIG. 9 is a perspective view illustrating a diffuser-integrated prism sheet according to a seventh embodiment of the present invention.
  • FIG. 10 is a perspective view illustrating a diffuser-integrated prism sheet according to an eighth embodiment of the present invention.
  • FIG. 11 is a perspective view illustrating a diffuser-integrated prism sheet according to a ninth embodiment of the present invention.
  • FIG. 12 is a perspective view illustrating a diffuser-integrated prism sheet according to a tenth embodiment of the present invention.
  • FIG. 13 is a perspective view illustrating a diffuser-integrated prism sheet according to an eleventh embodiment of the present invention.
  • FIG. 14 is a perspective view illustrating a diffuser-integrated prism sheet according to a twelfth embodiment of the present invention.
  • FIG. 15 is a flowchart illustrating a process of manufacturing the diffuser-integrated prism sheet according to the first embodiment of the present invention.
  • FIG. 16 is a flowchart illustrating a process of manufacturing the diffuser-integrated prism sheet according to the second embodiment of the present invention.
  • FIG. 17 is a flowchart illustrating a process of manufacturing the diffuser-integrated prism sheet according to the fifth embodiment of the present invention.
  • FIG. 18 is a flowchart illustrating a process of manufacturing the diffuser-integrated prism sheet according to the ninth embodiment of the present invention.
  • FIG. 19 is a flowchart illustrating a process of manufacturing the diffuser-integrated prism sheet according to the eleventh embodiment of the present invention.
  • FIG. 2 is a perspective view illustrating a diffuser-integrated prism sheet according to a first embodiment of the present invention.
  • the diffuser-integrated prism sheet according to the first embodiment of the present invention comprises a lower diffuser layer 110 , a lower layer 120 , a first intermediate layer 130 , a second intermediate layer 140 , an upper layer 150 , an upper diffuser layer 160 , and an air layer 170 .
  • the lower diffuser layer 110 and the upper diffuser layer 160 have structures for uniformly diffusing light.
  • the lower diffuser layer 110 has a plurality of hemispherical protrusions for diffusing light on the lower surface thereof
  • the upper diffuser layer 160 has a plurality of hemispherical protrusions for diffusing light on the upper surface thereof.
  • the height of the protrusions formed on the lower diffuser layer 110 and the upper diffuser layer 160 ranges from 1 ⁇ m to 150 ⁇ m.
  • the lower layer 120 and the upper layer 150 are formed of synthetic resin, such as PET (polyethyleneterephthalate).
  • the lower diffuser layer 110 , the first intermediate layer 130 , the second intermediate layer 140 , and the upper diffuser layer 160 are formed of a UV light-curable acrylic resin or a heat-curable acrylic resin.
  • a plurality of prism-shaped protrusions, cross-sections of which have a triangular shape or a polygonal shape having five or more sides, similar to the triangular shape, is formed parallel to each other, in order to collect light in a direction perpendicular to the upper and lower surfaces of the diffuser-integrated prism sheet.
  • the ridges 133 of the prism-shaped protrusions of the first intermediate layer 130 are integrated with the lower surface of the second intermediate layer 140 through fusion. Further, an air layer 170 is formed between the lower surface of the second intermediate layer 140 and the valleys 136 of the prism-shaped protrusions.
  • the reason why the air layer 170 is formed is as follows. That is, because the refractive index of air is 1 and the refractive index of material other than air is greater than 1, in the case where the above space is filled with material other than air, the effect of collecting light in the direction perpendicular to the upper and lower surfaces of the diffuser-integrated prism sheet is decreased, as per Snell's law. Thus, the intention is to maximize the light collection effect.
  • FIG. 4 is a perspective view illustrating a diffuser-integrated prism sheet according to a second embodiment of the present invention.
  • the diffuser-integrated prism sheet comprises a lower diffuser layer 210 , a lower layer 120 , a first intermediate layer 130 , a second intermediate layer 140 , an upper layer 150 , an upper diffuser layer 220 , and an air layer 170 .
  • the lower diffuser layer 210 and the upper diffuser layer 220 have structures for uniformly diffusing light. Specifically, the lower diffuser layer 210 has a plurality of hemispherical recesses for diffusing light in the lower surface thereof, and the upper diffuser layer 220 has a plurality of hemispherical recesses for diffusing light in the upper surface thereof.
  • the depth of the recesses formed in the lower diffuser layer 210 and the upper diffuser layer 220 ranges from 1 ⁇ m to 150 ⁇ m.
  • the lower layer 120 , the first intermediate layer 130 , the second intermediate layer 140 , the upper layer 150 , and the air layer 170 are formed as in the diffuser-integrated prism sheet according to the first embodiment of the present invention, and a detailed description thereof is thus omitted.
  • the diffuser-integrated prism sheet according to the present invention may be manufactured in a manner such that the lower diffuser layer 210 and the upper diffuser layer 160 are provided as illustrated in FIG. 5 (3 rd embodiment), or such that the lower diffuser layer 110 and the upper diffuser layer 220 are provided as illustrated in FIG. 6 (4 th embodiment).
  • FIG. 7 is a perspective view illustrating a diffuser-integrated prism sheet according to a fifth embodiment of the present invention.
  • the diffuser-integrated prism sheet according to the fifth embodiment of the present invention comprises a lower diffuser layer 110 , a lower layer 120 , an intermediate layer 300 , an upper layer 150 , an upper diffuser layer 160 , and an air layer 170 .
  • a small amount of adhesive 320 is applied on the ridges 310 of the prism-shaped protrusions of the intermediate layer 300 , and the ridges 310 of the prism-shaped protrusions are integrated with the lower surface of the upper layer 150 through adhesion using the adhesive.
  • Useful adhesives include, for example, highly transparent polymers, such as silicone-urethane (SU) hybrid polymers, acrylic polymers, and polyester-based polymers. In the case where too much adhesive is used, the functionality of the prism is weakened, and stain defects may occur. Preferably, the adhesive is used in as small an amount as possible while still maintaining adhesion.
  • the lower diffuser layer 110 , the lower layer 120 , the upper layer 150 , the upper diffuser layer 160 , and the air layer 170 are formed as in the diffuser-integrated prism sheet according to the first embodiment of the present invention, and thus a detailed description thereof is omitted.
  • the diffuser-integrated prism sheet according to the fifth embodiment of the present invention may be modified in a manner such that the lower diffuser layer 110 and the upper diffuser layer 160 are replaced with the lower diffuser layer 210 and the upper diffuser layer 220 , as illustrated in FIG. 8 (6 th embodiment), such that the lower diffuser layer 210 and the upper diffuser layer 160 are provided as illustrated in FIG. 9 (7 th embodiment), or such that the lower diffuser layer 110 and the upper diffuser layer 220 are provided as illustrated in FIG. 10 (8 th embodiments).
  • FIG. 11 is a perspective view illustrating a diffuser-integrated prism sheet according to a ninth embodiment of the present invention.
  • the diffuser-integrated prism sheet according to the ninth embodiment of the present invention comprises a PC lower layer 400 , an upper layer 150 , an upper diffuser layer 160 , and an air layer 170 .
  • the PC lower layer 400 is formed of PC (polycarbonate).
  • the upper surface of the PC lower layer 400 includes a plurality of prism-shaped protrusions formed parallel to each other, cross-sections of which have a triangular shape or a polygonal shape having five or more sides, similar to the triangular shape, in order to collect light in a direction perpendicular to the upper and lower surfaces of the flat prism sheet.
  • the lower surface thereof includes a plurality of hemispherical protrusions for diffusing light.
  • the height of the protrusions formed on the PC lower layer 400 ranges from 1 ⁇ m to 150 ⁇ m.
  • a small amount of adhesive 420 is applied on the ridges 410 of the prism-shaped protrusions of the PC lower layer 400 , and the ridges of the prism-shaped protrusions are integrated with the lower surface of the upper layer 150 through adhesion using the adhesive.
  • Useful adhesives include, for example, highly transparent polymers, such as silicone-urethane (SU) hybrid polymers, acrylic polymers, and polyester-based polymers. In the case where too much adhesive is used, the functionality of the prism is weakened, and stain defects may occur.
  • the adhesive is used in as small an amount as possible while still maintaining adhesion.
  • the upper layer 150 , the upper diffuser layer 160 , and the air layer 170 are formed as in the diffuser-integrated prism sheet according to the first embodiment of the present invention, and thus a detailed description thereof is omitted.
  • the diffuser-integrated prism sheet according to the ninth embodiment of the present invention may be modified in such a manner that the upper diffuser layer 160 is replaced with the upper diffuser layer 220 , as illustrated in FIG. 12 (10 th embodiment).
  • FIG. 13 is a perspective view illustrating a diffuser-integrated prism sheet according to an eleventh embodiment of the present invention.
  • the diffuser-integrated prism sheet according to the eleventh embodiment of the present invention comprises a PC lower layer 500 , an upper layer 150 , an upper diffuser layer 160 , and an air layer 170 .
  • the PC lower layer 500 is formed of PC (polycarbonate).
  • the upper surface of the PC lower layer 500 includes a plurality of prism-shaped protrusions formed parallel to each other, cross-sections of which have a triangular shape or a polygonal shape having five or more sides, similar to the triangular shape, in order to collect light in a direction perpendicular to the upper and lower surfaces of the flat prism sheet.
  • the lower surface thereof includes a plurality of hemispherical recesses for diffusing light.
  • the depth of the recesses formed in the PC lower layer 500 ranges from 1 ⁇ m to 150 ⁇ m.
  • a small amount of adhesive 520 is applied on the ridges 510 of the prism-shaped protrusions of the PC lower layer 500 , and the ridges of the prism-shaped protrusions are integrated with the lower surface of the upper layer 150 through adhesion using the adhesive.
  • Useful adhesives include, for example, highly transparent polymers, such as silicone-urethane (SU) hybrid polymers, acrylic polymers, and polyester-based polymers. In the case where too much adhesive is used, the functionality of the prism is weakened, and stain defects may occur. Preferably, the adhesive is used in as small an amount as possible while still maintaining adhesion.
  • the upper layer 150 , the upper diffuser layer 160 , and the air layer 170 are formed as in the diffuser-integrated prism sheet according to the first embodiment of the present invention, and a detailed description thereof is thus omitted.
  • the diffuser-integrated prism sheet according to the eleventh embodiment of the present invention may be modified in such a manner that the upper diffuser layer 160 is replaced with the upper diffuser layer 220 , as illustrated in FIG. 14 (12 th embodiment).
  • FIG. 15 there is a flowchart illustrating the process of manufacturing the diffuser-integrated prism sheet according to the first embodiment of the present invention.
  • the method of manufacturing the diffuser-integrated prism sheet according to the first embodiment comprises applying a UV light-curable acrylic resin or a heat-curable acrylic resin in an uncured state to a predetermined thickness on the lower surface of the lower layer 120 (S 110 ); passing the lower layer 120 having the uncured acrylic resin applied on the lower surface thereof over a roll having a plurality of hemispherical recesses and in contact therewith to thus form an uncured acrylic resin layer having a plurality of hemispherical protrusions, and then radiating UV light or applying heat to thus completely cure the uncured acrylic resin layer having the plurality of hemispherical protrusions, thereby forming the lower diffuser layer 110 (S 120 ); applying a UV light-curable acrylic resin or a heat-curable acrylic resin in an uncured state to a predetermined thickness on the upper surface of the lower layer 120 (S 130 ); passing the lower layer 120 having the uncured acrylic resin applied on the upper surface thereof over a roll having prism-shaped recesses and
  • FIG. 16 is a flowchart illustrating a process of manufacturing the diffuser-integrated prism sheet according to the second embodiment of the present invention.
  • the method of manufacturing the diffuser-integrated prism sheet according to the second embodiment comprises applying a UV light-curable acrylic resin or a heat-curable acrylic resin in an uncured state to a predetermined thickness on the lower surface of the lower layer 120 (S 210 ); passing the lower layer 120 having the uncured acrylic resin applied on the lower surface thereof over a roll having a plurality of hemispherical protrusions and in contact therewith to thus form an uncured acrylic resin layer having a plurality of hemispherical recesses, and then radiating UV light or applying heat to thus completely cure the uncured acrylic resin layer having the plurality of hemispherical recesses, thereby forming the lower diffuser layer 210 (S 220 ); applying a UV light-curable acrylic resin or a heat-curable acrylic resin in an uncured state to a predetermined thickness on the upper surface of the lower layer 120 (S 230 ), passing the lower layer 120 having the uncured acrylic resin applied on the upper surface thereof over a roll having prism-shaped rece
  • FIG. 17 is a flowchart illustrating a process of manufacturing the diffuser-integrated prism sheet according to the fifth embodiment of the present invention.
  • the method of manufacturing the diffuser-integrated prism sheet according to the fifth embodiment comprises applying a UV light-curable acrylic resin or a heat-curable acrylic resin in an uncured state to a predetermined thickness on the lower surface of the lower layer 120 (S 310 ); passing the lower layer 120 having the uncured acrylic resin applied on the lower surface thereof over a roll having a plurality of hemispherical recesses and in contact therewith to thus form an uncured acrylic resin layer having a plurality of hemispherical protrusions, and then radiating UV light or applying heat to thus completely cure the uncured acrylic resin layer having the plurality of hemispherical protrusions, thereby forming the lower diffuser layer 110 (S 320 ); applying a UV light-curable acrylic resin or a heat-curable acrylic resin in an uncured state to a predetermined thickness on the upper surface of the lower layer 120 (S 330 ); passing the lower layer 120 having the uncured acrylic resin applied on the upper surface thereof over a roll having prism-shaped rece
  • FIG. 18 is a flowchart illustrating a process of manufacturing the diffuser-integrated prism sheet according to the ninth embodiment of the present invention.
  • the method of manufacturing the diffuser-integrated prism sheet according to the ninth embodiment comprises passing a PC lower layer 400 formed of PC between an upper roll having prism-shaped recesses and a lower roll having a plurality of hemispherical recesses to thus form the PC lower layer 400 having prism-shaped protrusions on the upper surface thereof and a plurality of hemispherical protrusions on the lower surface thereof, and then radiating UV light or applying heat to thus cure the PC lower layer 400 (S 410 ); applying a UV light-curable acrylic resin or a heat-curable acrylic resin in an uncured state to a predetermined thickness on the upper surface of the upper layer 150 (S 420 ); passing the upper layer 150 having the uncured acrylic resin applied on the upper surface thereof over a roll having a plurality of hemispherical recesses and in contact therewith to thus form an uncured acrylic resin layer having a plurality of hemispherical protrusions, and then radiating UV light or applying heat to thus completely cure the
  • FIG. 19 is a flowchart illustrating a process of manufacturing the diffuser-integrated prism sheet according to the eleventh embodiment of the present invention.
  • the method of manufacturing the diffuser-integrated prism sheet according to the eleventh embodiment comprises passing a PC lower layer 500 formed of PC between an upper roll having prism-shaped recesses and a lower roll having a plurality of hemispherical protrusions to thus form the PC lower layer 500 having prism-shaped protrusions on the upper surface thereof and a plurality of hemispherical recesses in the lower surface thereof, and then radiating UV light or applying heat to thus cure the PC lower layer 500 (S 510 ); applying a UV light-curable acrylic resin or a heat-curable acrylic resin in an uncured state to a predetermined thickness on the upper surface of the upper layer 150 (S 520 ); passing the upper layer 150 having the uncured acrylic resin applied on the upper surface thereof over a roll having a plurality of hemispherical recesses and in contact therewith to thus form an uncured acrylic resin layer having a plurality of hemispherical protrusions, and then radiating UV light or applying heat to thus completely cure
  • the present invention provides a diffuser-integrated prism sheet for backlight units and a method of manufacturing the same.
  • the prism sheet includes prism-shaped protrusions formed therein and diffuser layers integrated therewith, the defect rates attributable to scratching and the entry of impurities in the course of assembling a backlight unit can be drastically decreased. Further, the generation of shatter cracks by friction with other sheets can be decreased, thus improving workability, and accordingly, defect rates can be greatly decreased, resulting in improved productivity.
  • various optical sheets are integratedly layered, thus realizing a short assembly time and a simple assembly process, resulting in decreased costs.

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US12/522,886 2007-02-01 2008-01-31 Diffuser-integrated prism sheet for backlight units and method of manufacturing the same Abandoned US20090316270A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
KR1020070010774A KR100854752B1 (ko) 2007-02-01 2007-02-01 확산 수단이 일체화된 백라이트 유닛용 프리즘 시트 및 그제조방법
KR10-2007-0010774 2007-02-01
PCT/KR2008/000604 WO2008094006A1 (en) 2007-02-01 2008-01-31 Diffuser-integrated prism sheet for backlight units and method of manufacturing the same

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US20090316270A1 true US20090316270A1 (en) 2009-12-24

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US12/522,886 Abandoned US20090316270A1 (en) 2007-02-01 2008-01-31 Diffuser-integrated prism sheet for backlight units and method of manufacturing the same
US13/551,717 Expired - Fee Related US8852470B2 (en) 2007-02-01 2012-07-18 Diffuser-integrated prism sheet for backlight units and method of manufacturing the same
US13/551,743 Expired - Fee Related US8734608B2 (en) 2007-02-01 2012-07-18 Diffuser-integrated prism sheet for backlight units and method of manufacturing the same
US13/614,539 Abandoned US20130063956A1 (en) 2007-02-01 2012-09-13 Diffuser-integrated prism sheet for backlight units and method of manufacturing the same
US13/870,496 Abandoned US20130235461A1 (en) 2007-02-01 2013-04-25 Diffuser-integrated prism sheet for backlight units and method of manufacturing the same
US13/899,647 Abandoned US20130308194A1 (en) 2007-02-01 2013-05-22 Diffuser-integrated prism sheet for backlight units and method of manufacturing the same

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US13/551,717 Expired - Fee Related US8852470B2 (en) 2007-02-01 2012-07-18 Diffuser-integrated prism sheet for backlight units and method of manufacturing the same
US13/551,743 Expired - Fee Related US8734608B2 (en) 2007-02-01 2012-07-18 Diffuser-integrated prism sheet for backlight units and method of manufacturing the same
US13/614,539 Abandoned US20130063956A1 (en) 2007-02-01 2012-09-13 Diffuser-integrated prism sheet for backlight units and method of manufacturing the same
US13/870,496 Abandoned US20130235461A1 (en) 2007-02-01 2013-04-25 Diffuser-integrated prism sheet for backlight units and method of manufacturing the same
US13/899,647 Abandoned US20130308194A1 (en) 2007-02-01 2013-05-22 Diffuser-integrated prism sheet for backlight units and method of manufacturing the same

Country Status (7)

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US (6) US20090316270A1 (de)
EP (1) EP2102702B1 (de)
JP (2) JP5307031B2 (de)
KR (1) KR100854752B1 (de)
CN (1) CN101589332B (de)
TW (1) TWI350925B (de)
WO (1) WO2008094006A1 (de)

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KR100854752B1 (ko) 2008-08-27
WO2008094006A1 (en) 2008-08-07
US8734608B2 (en) 2014-05-27
EP2102702A1 (de) 2009-09-23
JP5307031B2 (ja) 2013-10-02
KR20080072270A (ko) 2008-08-06
EP2102702A4 (de) 2010-11-03
JP2010518424A (ja) 2010-05-27
US20130235461A1 (en) 2013-09-12
CN101589332B (zh) 2011-11-30
JP2013137569A (ja) 2013-07-11
CN101589332A (zh) 2009-11-25
US20120281291A1 (en) 2012-11-08
EP2102702B1 (de) 2016-05-25
US8852470B2 (en) 2014-10-07
US20120281290A1 (en) 2012-11-08
TW200834128A (en) 2008-08-16
US20130308194A1 (en) 2013-11-21
JP5961573B2 (ja) 2016-08-02
US20130063956A1 (en) 2013-03-14
TWI350925B (en) 2011-10-21

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