WO2012006854A1 - 一种导光膜制作装置 - Google Patents

一种导光膜制作装置 Download PDF

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Publication number
WO2012006854A1
WO2012006854A1 PCT/CN2010/079736 CN2010079736W WO2012006854A1 WO 2012006854 A1 WO2012006854 A1 WO 2012006854A1 CN 2010079736 W CN2010079736 W CN 2010079736W WO 2012006854 A1 WO2012006854 A1 WO 2012006854A1
Authority
WO
WIPO (PCT)
Prior art keywords
roller
light guiding
guiding film
film
light guide
Prior art date
Application number
PCT/CN2010/079736
Other languages
English (en)
French (fr)
Inventor
吴智华
周小红
方宗豹
申溯
魏国军
浦东林
陈林森
Original Assignee
苏州苏大维格光电科技股份有限公司
苏州大学
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 苏州苏大维格光电科技股份有限公司, 苏州大学 filed Critical 苏州苏大维格光电科技股份有限公司
Priority to US13/583,290 priority Critical patent/US8961166B2/en
Publication of WO2012006854A1 publication Critical patent/WO2012006854A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/06—Embossing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/20—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of continuous webs only
    • B32B37/203—One or more of the layers being plastic
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/0001—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems
    • G02B6/0011—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems the light guides being planar or of plate-like form
    • G02B6/0065—Manufacturing aspects; Material aspects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2551/00—Optical elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2590/00—Signboards, advertising panels, road signs
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/0001—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems
    • G02B6/0011—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems the light guides being planar or of plate-like form
    • G02B6/0033—Means for improving the coupling-out of light from the light guide
    • G02B6/0035—Means for improving the coupling-out of light from the light guide provided on the surface of the light guide or in the bulk of it
    • G02B6/0036—2-D arrangement of prisms, protrusions, indentations or roughened surfaces

Definitions

  • the present invention relates to a device for fabricating a light guiding film, and more particularly to a light guiding method using a roll-to-roll hot stamping
  • the light guide plate is one of the key components.
  • the manufacturing method of the light guide plate can be divided into a printing method and a non-printing method.
  • the printing method is to appropriately distribute the printing materials of the high-scattering light source materials (such as SiO 2 and TiO 2 ) to the bottom surface of the light guide plate, and absorb the light source through the printing material.
  • the non-printing method is to first fabricate the light-guided mold with image, and then use the method of injection molding on the light guide plate.
  • the pattern is directly generated, and the pattern is used to derive the light, and the uniform bottom is dispersed in the light-emitting area.
  • the light guide plates in the display backlight module of the mainstream products are mostly made by non-printing injection molding, and are manufactured by means of plastic injection molding, and the structure is about 0.5-2.0 mm acrylic plate.
  • the display products are moving toward a thinner and lighter direction, which inevitably requires thin and light requirements for the backlight module.
  • the backlight source is gradually utilizing the LED.
  • the light guide plate When the volume of the backlight is reduced, and the display product has a chance to be thinner and lighter, the light guide plate must be thinned to achieve the purpose of thinness and lightness.
  • the thickness of the general light guide plate is about 1.0mm, but with the market trend and technical requirements, the thickness of the light guide plate has gradually become thinner, reaching 0.5mm. Due to the thinning of the thickness, some problems will occur in the molding of the light guide plate. If the thin light guide plate is completed by the conventional injection molding technology, the ultra-thin light guide film must be changed to a high-speed injection molding machine, but Thin light-guide films require high surface quality and therefore require higher requirements for temperature control and environment.
  • the ink method is formed by directly ejecting a resin material by using an ink jet head, and the thickness of the light guide plate is 50 ⁇ m.
  • the diameter of the dot produced by the ink jet method is limited to 20-120 um, and the dot is basically a microlens type, and the variability of the groove shape, depth, and shape of the dot is not strong. Therefore, how to obtain high-quality, high-yield, low-cost ultra-thin light-guiding film is an industry concern, and it is an urgent problem to be solved.
  • the object of the present invention is to provide a roll-to-roll light guiding film manufacturing device, which overcomes the defects of low efficiency and high cost of the existing flat pressing device; at the same time, it overcomes the existing injection device and cannot manufacture a large size, ultra-thin light guiding material. Defects.
  • a light guiding film manufacturing apparatus includes: a discharging roller and a receiving roller disposed at both ends of the manufacturing device; and a separating device disposed after the discharging roller to guide the guiding The substrate layer and the protective layer of the light film are separated to expose the surface to be processed of the substrate layer;
  • the hot stamping device has a pressure roller and a plate roller, and the plate roller is provided with a light guiding film mold core, the light guiding film
  • the surface of the mold core has a microstructure, and the pressing roller cooperates with the plate roller to imprint the microstructure of the light guiding film mold core onto the surface to be processed of the substrate layer to form a light guiding mesh point; and a composite roller disposed on the heat
  • the protective layer for separating the separating device is reapplied to the embossed substrate; wherein the light guiding film roll is discharged from the discharging roller, and the separating device, the embossing device, and the composite The roll is then
  • a light guiding film manufacturing apparatus wherein the microstructure of the light guiding film mold is a grating-like micro-nano structure or a cylindrical micro-lens structure.
  • a light guiding film manufacturing apparatus is provided, wherein the light guiding film mold core adopts a 360 degree inserting film, and both ends of the film are inserted into a slit and 360 degrees looped on the plate roller.
  • a light guiding film manufacturing apparatus is provided, wherein the light guiding film mold core adopts a 180 degree clamp upper film, and two ends are provided with a jig and a 180 degree half ring is clamped on the plate roller.
  • a light guiding film manufacturing apparatus wherein the pressing roller includes a first pressing roller and a second pressing roller, respectively located on both sides of the plate roller, wherein the first pressing roller cooperates with the plate roller
  • the embossed area on the light directing film is complementary to the second nip to match the embossed area of the platen on the light directing film to form a continuous light guiding dot.
  • the separating apparatus further includes an edge trimmer and a waste recycling roller, the trimmer cutting off excess margin of the protective layer, and the waste recycling roller recovers the The margin of the cut.
  • a light guiding film producing apparatus wherein the hot stamping apparatus further includes a pressure control system that controls a pressure between the press roll and the plate roll.
  • the hot stamping apparatus further includes a temperature control system that heats the plate roll or the press roll and controls the heating temperature.
  • a light guiding film manufacturing apparatus further includes a front and rear two rectifying system, wherein the rectifying system is provided with a material edge sensor and a conveying repairing device, and the material edge sensor is disposed on the discharging roller And on the take-up roll, the transfer repairing device is coupled to the shaft of the discharge roller and the take-up roller, and the transfer repair device controls the release when the material edge sensor senses that the material is offset inward during the conveyance process The feed roller or the take-up roller moves inwardly, and vice versa.
  • a light guiding film manufacturing apparatus further includes a force control system, wherein the tension control system is mainly composed of a tension sensing device and a magnetic powder clutch device, and the tension is greater when the tension sensing device detects material transmission.
  • the magnetic powder clutch device slightly reduces the winding speed.
  • the rotation speed control device slightly raises the winding speed.
  • FIG. 1 is a light guiding film manufacturing apparatus according to a first embodiment of the present invention
  • FIG. 2 is a schematic view showing the surface structure of a light guiding film mold core of the present invention
  • FIG. 3 is a schematic view showing the surface structure of another light guiding film mold core of the present invention.
  • FIG. 4 is a schematic view showing the installation of the light guiding film mold core in the first embodiment
  • Figure 5 is a schematic structural view of a correction system according to the present invention.
  • Figure 6 is a light guide film manufacturing apparatus according to a second embodiment of the present invention
  • 7 is a schematic structural view of a light guiding film mold core in a second embodiment
  • FIG. 8 is a schematic view showing the mounting of the center light guiding film mold core in the second embodiment.
  • BEST MODE FOR CARRYING OUT THE INVENTION The light guiding film producing apparatus of the present invention is a device for producing a light guiding dot by winding a cylindrical light guiding film material by a roll-to-roll nanoimprint method.
  • the light guiding film material comprises a substrate layer and a protective layer. When the film is formed, the protective layer is first peeled off to expose the surface to be processed of the substrate layer, and then embossed.
  • FIG. 1 is a light guide film manufacturing apparatus according to a first embodiment of the present invention.
  • the apparatus includes a discharge roller 1, a take-up roller 20, a separating device, an imprinting device, a composite device, and a plurality of sub-rollers 2, 4, 5, 7, 9, 11, 14, 15, 18.
  • the light guide film raw material roll is disposed on the discharge roller 1, and is recovered to the take-up roller 20 after passing through a separating device, an imprinting device, a composite device, and a plurality of sub-rollers.
  • a separating device is disposed behind the discharge roller, and the separating device includes a peeling roller 3, a trimming roller 6, a trimmer 8, and a waste recycling roller 12.
  • the protective layer and the substrate layer of the light guiding film raw material are separated at the peeling roller 3, wherein the protective layer is passed through the secondary roller 4 and the excess edge is cut by the edger 8 at the trimming roller 6, the excess edge being scrapped
  • the recovery roller 12 recovers, the trimmed protective layer continues to be transported through the secondary roller 15, and is reapplied to the substrate layer at the composite device; after the substrate layer is separated from the protective layer, the surface to be processed is exposed, and The light guide is embossed by the embossing device, and a light guiding dot is formed on the surface to be processed.
  • the imprint apparatus includes a press roll 10 and a plate roll 13, and the press roll 10 may be a roll or a plastic roll, and the plate roll 13 is a mirror roll.
  • a light guide film mold is disposed on the plate roller 13 , and the surface of the light guide film mold core has a microstructure, and the pressure roller 10 cooperates with the plate roller 13 to imprint the microstructure of the light guide film mold core to the substrate layer.
  • a light guiding mesh is formed on the surface to be processed. Please refer to FIG. 2 and FIG. 3 together.
  • FIG. 2 and FIG. 3 are schematic diagrams showing different surface microstructures of the light guiding film mold of the present invention.
  • the microstructure of the surface of the light guiding film mold can be arranged according to the distance of the light source, and the microstructure is a grating-like micro The nanostructure helps the uniformity of the illuminating surface.
  • the microstructure is designed in the regions where light is required to be emitted, and the microstructure at this time is designed as a columnar microlens structure to increase the light emission rate.
  • the above-mentioned light guiding film mold core may be made of nickel or aluminum. Please refer to FIG. 4 again. FIG.
  • the light guiding film mold core adopts a 360 degree inserting film, and a slit is arranged on the plate roller 13.
  • a slit is arranged on the plate roller 13.
  • the imprint apparatus further includes a pressure control system and a temperature control system.
  • the pressure control system may be pneumatic or hydraulic, connected to the pressure roller 10, drives the pressure roller 10, and controls the pressure between the pressure roller 10 and the plate roller 13.
  • the temperature control system is disposed on the platen roller 13 or the pressure roller 10, and may be a resistance heating device or an infrared heating device. At the same time as the imprinting, the temperature control system heats the plate roll 13 or the press roll 10, and controls the heating temperature to optimize the embossing effect. After the embossing is completed, the substrate layer is transferred to the composite device.
  • the composite device comprises two press rolls 16 and 17 which re-align the protective layer from the separating device and the substrate layer from the imprinting device to form a complete light directing film. Finally, the light guiding film is recovered on the take-up roll 20.
  • a front and rear two correcting system is disposed on the discharge roller 1 and the take-up roller 20.
  • the correction system includes a material edge sensor and a transfer repairing device.
  • the material edge sensor may be an infrared sensing device 25, and the transmission repairing device is provided with an axial displacement device 26 on the discharge roller 1 and the receiving roller 20, and the two are electrically connected.
  • the axial displacement device 26 controls the discharge roller 1 or the take-up roller 20 to move inwardly, and vice versa.
  • the two correcting system makes the displacement error of the light guiding film within 30 um during the transmission process, thereby eliminating the alignment step and ensuring the printing quality.
  • a unwinding tension sensor may be disposed on the secondary roller 2 adjacent to the discharge roller 1, and a winding tension sensor may be disposed on the secondary roller 19 adjacent to the take-up roller 20, while at the same time the discharge roller 1 and the take-up roller 20
  • the rotation speed control device is respectively arranged on the tension sensor, and when the tension sensor finds that the tension of the light guide film is greater than a preset value when the light guide film is transmitted, the rotation speed control device slightly reduces the winding speed, and when the tension is found to be smaller than At the preset value, the rotational speed control device slightly raises the winding speed.
  • the predetermined value may be a deformation rating of the light guiding film or other value that may affect the surface tension of the light guiding film.
  • FIG. 6 is a schematic structural view of a second embodiment of a light guiding film manufacturing apparatus according to the present invention.
  • the rest is the same as that in the first embodiment, and therefore will not be described again.
  • the light guiding film mold core on the platen roller 13 is fixed by means of a 180-degree jig upper die, that is, the platen roller 13 is coated with a light guiding film mold core only on the half ring.
  • the embossed light guiding dots may be intermittent every cycle, but in this embodiment, it is only necessary to pass the simple
  • the embossing area of the first pressure roller 10 on the light guiding film is matched with the second pressure roller 22, and the embossing area of the plate roller 13 on the light guiding film is complementary, so that the pressure can be pressed.
  • Print continuous light guide dots Referring to FIG. 8 in conjunction with FIG. 7, FIG. 7 is a schematic structural view of the light guiding film mold core in the embodiment, and FIG.
  • FIG. 8 is a schematic view showing the mounting of the light guiding film mold core in the embodiment.
  • the light guide film mold core 43 is provided with clamps 27 on both sides thereof, and the clamp 27 is provided with a plurality of screw holes 28, and correspondingly at the edge of the plate roller 13 The recess of the clamp 27 and the screw hole corresponding to the screw hole 28.
  • the present invention provides a light guiding film manufacturing apparatus using a roll-to-roll nanoimprinting technology, which has the characteristics of high production speed, large manufacturing size, and low cost.
  • the use of two correction systems and tension control system improves production yield and improves the quality of the light guide film.

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)

Abstract

一种导光膜制作装置，包括放料辊（1）、收料辊（20）、分离装置、压印装置和复合装置。首先，分离装置将导光膜的保护层和基材层分离；其次，压印装置在基材层的待加工面上压印出导光网点；复合装置将剥离的保护层复合到基材层上；最后，收料辊回收制得的导光膜。该导光膜制作装置具有产量高、产品尺寸大以及制作成本低的特点。

Description

一种导光膜制作装置 技术领域 本发明涉及一种导光膜的制作装置， 尤其是一种采用卷对卷热压印的导光 说
膜制作装置。 背景技术 在 LCD 显示器、 手机、 数码相机、 照明书等显示的背光模组中， 导光板是 关键部件之一。 目前， 导光板的制造方法可分为印刷方式和非印刷方式， 印刷 方式是将高散光源物质 (如 Si02和 Ti02)的印刷材料， 适当地分布与导光板底 面，通过印刷材料对光源吸收再扩散的性质，破坏全反射效应造成的内部传播， 是光线由正面射出并均匀分布与发光区； 非印刷方式则是先制作具有图像的导 光模仁， 再以射出成型的方法在导光板上直接产生图案， 并利用该图案将光导 出， 均匀底散布在发光区。 而目前主流产品的显示用背光模组中导光板大都采 用无印刷式的射出成形制成， 利用塑胶射出成型的方式来制作， 结构上大概是 0.5— 2.0mm的压克力板。 目前显示产品正朝着更轻薄的方向发展， 必然对背光模组提出轻薄的要 求。 其中， 背光光源正逐渐利用 LED, 当背光源的体积缩小， 显示产品有机会 更轻薄的机会下， 导光板必然要求变薄， 才能达到轻薄的目的。 现在一般的导 光板厚度为 1.0mm左右，但随着市场趋势和技术的要求下， 导光板的厚度已逐 渐薄化，达到 0.5mm。 由于厚度变薄，在导光板的成型方面将会出现一些问题， 如果采用传统的射出成形技术完成薄型导光板， 那么制作超薄型导光膜必须改 用高射速的射出成型机， 但是， 超薄型导光膜对表面质量要求较高， 因此， 对 温度控制、 环境提出更高的要求。 对于采用传统射出成型方式， 要求生产出高 质量的导光膜产品， 将面临良率和产能的问题， 可能会导致成本提高。 目前， 已有少数国家正在致力研究超薄导光膜的制造方法与工艺， 如日本提出采用喷 墨方法， 是利用喷墨头射出树脂材料， 直接在镜片上描绘而成， 制造的导光板 厚度最薄为 50um。 但是， 喷墨方式制作的网点直径限制在 20-120um， 网点基 本呈微透镜型， 网点的槽型、 深度、 形状的可变性不强。 因此， 如何获得高质量， 高良率， 低成本的超薄导光膜是行业关注的问题， 也是是目前急需解决的问题。
本发明的目的是提供一种卷对卷导光膜制作装置， 以克服现有平压设备低 效率高成本的缺陷； 同时也克服了现有射出设备， 不能制大尺寸,超薄导光材料 的缺陷。 根据本发明的目的提供的一种导光膜制作装置， 包括： 放料辊和收料辊， 设置于该制作装置的两端； 分离装置， 设置与该放料辊之后， 用以将该导光膜 的基材层和保护层分离， 以露出该基材层的待加工面； 热压印装置， 具有压辊 和版辊， 该版辊上设有导光膜模仁， 该导光膜模仁表面具有微结构， 该压辊配 合该版辊将该导光膜模仁的微结构压印至所述基材层的待加工面上形成导光 网点； 以及复合辊， 设置于该热压印装置后， 用以将该分离装置分离的保护层 重新贴敷到完成压印的基材上； 其中该导光膜卷从放料辊放出后,经该分离装 置、 压印装置、 复合辊后重新回收于该收料辊。 根据本发明的目的提供的一种导光膜制作装置， 其中所述导光膜模仁的微 结构为光栅状微纳米结构或圆柱状微透镜结构。 根据本发明的目的提供的一种导光膜制作装置， 其中所述导光膜模仁采用 360度插版上膜， 其两端插在一缝隙中并 360度环贴在版辊上。 根据本发明的目的提供的一种导光膜制作装置， 其中所述导光膜模仁采用 180度夹具上膜， 其两端设有夹具并 180度半环夹固于版辊上。 根据本发明的目的提供的一种导光膜制作装置， 其中所述压辊包括第一压 辊和第二压辊， 分别位于版辊的两侧， 其中该第一压辊配合该版辊在该导光膜 上的压印区域与该第二压辊配合该版辊在该导光膜上的压印区域互补， 以形成 连续的导光网点。 根据本发明的目的提供的一种导光膜制作装置， 其中所述分离装置还包括 修边器和废料回收辊， 该修边器裁除该保护层多余的边幅， 该废料回收辊回收 该被裁除的边幅。 根据本发明的目的提供的一种导光膜制作装置， 其中所述热压印装置还包 括压力控制系统， 该压力控制系统控制该压辊和该版辊之间的压力。 根据本发明的目的提供的一种导光膜制作装置， 其中所述热压印装置还包 括温度控制系统， 该温度控制系统对该版辊或压辊加热， 并控制该加热温度。 根据本发明的目的提供的一种导光膜制作装置， 其中还包括前后二纠偏系 统， 所述的纠偏系统设有材料边缘感应器和传送修复装置， 所述材料边缘感应 器设置在放料辊和收料辊上， 所述传送修复装置连接在放料辊和收料辊的轴 上， 当该材料边缘感应器感应到材料在输送过程中向内偏移时， 该传送修复装 置控制该放料辊或该收料辊向内移动， 反之向外发生位移。 根据本发明的目的提供的一种导光膜制作装置， 其中还包括一张力控制系 统， 所述的张力控制系统主要由张力感应装置和磁粉离合装置组成， 当张力感 应装置发现材料传输时张力大于一预设值时， 磁粉离合装置微动减小收卷转 速， 当发现张力小于该预设值时， 转速控制装置微动提升收卷转速。 本发明方法与现有方法相比， 具有如下优点： 采用卷对卷纳米压印技术， 与射出相比， 制作尺寸更大， 厚度更薄。 采用卷对卷纳米压印技术， 与平压方 式相比， 生产效率显著提高， 压印过程稳定， 整卷的一致性高， 良率 >95%。 对 温度、 环境的要求比射出成型， 喷墨工艺低， 更易控制。 下面结合附图以具体实施例对本发明做详细说明。 國翻
图 1是本发明的第一实施方式的导光膜制作装置；
图 2是本发明的一种导光膜模仁的表面结构示意图；
图 3是本发明的另一种导光膜模仁的表面结构示意图；
图 4是第一实施例中的导光膜模仁安装示意图；
图 5是本发明的纠偏系统的结构示意图；
图 6是本发明的第二实施方式的导光膜制作装置； 图 7是第二实施方式中的导光膜模仁结构示意图；
图 8是第二实施方式中中导光膜模仁的安装示意图。 具体实施方式 本发明的导光膜制作装置， 是一种利用卷对卷纳米压印的方式， 对卷积成 筒状的导光膜原料进行导光网点制作的装置。 该导光膜原料包括基材层和保护 层， 制作时， 先要剥离保护层露出该基材层的待加工面， 然后再对其进行压印 制作。 下面将以具体的实施例介绍本发明的导光膜制作装置。 实施例一： 请参见图 1， 图 1是本发明的第一实施方式的导光膜制作装置。如图所示， 该装置包括放料辊 1、 收料辊 20、 分离装置、 压印装置、 复合装置以及多个副 辊 2、 4、 5、 7、 9、 11、 14、 15、 18。 导光膜原料卷设置于放料辊 1上， 并且 经过分离装置、 压印装置、 复合装置以及多个副辊后回收至该收料辊 20上。 需要注意的是， 该多个副辊的数量和编排位置可以根据实际需要进行设计， 且 不是必须的。 分离装置设置于该放料辊后， 该分离装置包括剥离辊 3、 修边辊 6、 修边 器 8和废料回收辊 12。导光膜原料的保护层和基材层在剥离辊 3处分离， 其中 该保护层经副辊 4后在修边辊 6处被修边器 8裁除多余的边幅， 该多余的边幅 经废料回收辊 12回收， 经修边后的保护层继续经副辊 15传输， 并且在复合装 置处重新贴敷到基材层上； 该基材层与保护层分离后， 露出其待加工面， 并经 压印装置压印， 在该待加工面上制作出导光网点。 该压印装置包括压辊 10和版辊 13， 该压辊 10可以为纲辊或者塑料辊， 该 版辊 13为镜面辊。 在版辊 13上设有导光膜模仁， 该导光膜模仁表面具有微结 构， 该压辊 10配合该版辊 13将该导光膜模仁的微结构压印至该基材层的待加 工面上形成导光网点。 请一并参见图 2和图 3， 图 2和图 3所示是本发明的导光膜模仁的不同表 面微结构的示意图。 如图所示， 根据导光膜的不同应用领域， 当导光膜需要做 整体均匀出光时， 可将导光膜模仁表面的微结构按光源的远近布置， 并且该微 结构为光栅状微纳米结构， 有助于出光面的均匀性。 当导光膜只需要在某些局 部区域出光时， 则将微结构设计在该些需要出光的区域， 并且将此时的微结构 设计成柱状的微透镜结构， 以增加光的出射率。 上述的导光膜模仁可以是镍、 铝等材质。 请再参见图 4， 图 4是本实施例中的导光膜模仁安装示意图。 该导光膜模 仁采用 360度插版上膜， 在版辊 13上设有缝隙， 安装时先将导光膜模仁的一 端插入该缝隙中 （要插到缝隙的底部）， 用左手按住模仁使模仁不离开缝隙底 部， 右手轻折模仁， 左手轻拉模仁顶端， 右手点动控制压辊 10转动 360° ， 将 模仁另一端塞到版辊 13的缝隙中， 转动压辊 10将模具顶部挤入缝隙中， 持续 转动两三圈使模仁紧贴到版辊 13上。 优选地， 该压印装置还包括压力控制系统和温度控制系统。 该压力控制系 统可以是气压或者液压， 连接在压辊 10上， 驱动该压辊 10， 并控制压辊 10和 版辊 13之间的压力。 该温度控制系统设置在版辊 13或者压辊 10上， 可以是 电阻加热装置或者是红外加热装置。在压印的同时， 该温度控制系统对版辊 13 或者压辊 10进行加热， 并控制该加热温度， 使压印的效果达到最佳。 压印完成后， 该基材层被传输至复合装置。 复合装置包括两个压合辊 16 和 17，该压合辊 16和 17将来自分离装置的保护层和来自压印装置的基材层重 新对位压合， 形成完整的导光膜。 最后将该导光膜回收于收料辊 20上。 优选地， 在放料辊 1和收料辊 20上设置前后二纠偏系统， 如图 5所示， 该纠偏系统包括材料边缘感应器和传送修复装置。 所述的材料边缘感应器可以 是红外感应装置 25， 所述的传送修复装置在放料辊 1和收料辊 20上设有轴向 位移器 26， 两者电性相连。 当该红外感应装置 25感应到材料在输送过程中向 内偏移时， 该轴向位移器 26控制该放料辊 1或该收料辊 20向内移动， 反之向 外发生位移。 该二纠偏系统使得导光膜在传输过程中， 前后位移误差在 30um 以内， 从而省去了对位的歩骤， 保证了压印品质。 优选地， 在靠近放料辊 1的副辊 2上可以设置放卷张力传感器， 在靠近收 料辊 20的副辊 19上可以设置收卷张力传感器， 同时在放料辊 1和收料辊 20 上设置转速控制装置， 该转速控制装置分别于上述的张力传感器连接， 当张力 传感器发现导光膜传输时张力大于一预设值时， 转速控制装置微动减小收卷转 速， 当发现张力小于该预设值时， 转速控制装置微动提升收卷转速。 该预定值 可以是导光膜的变形额定值或者其他可以影响导光膜表面张力的数值。 通过控 制导光膜在传输时的张力， 保证了导光膜在压印过程中始终处于张紧的状态， 避免了因皱褶而导致废品的产生， 提高了生产良率。 实施例二： 请参见图 6，图 6是本发明的导光膜制作装置第二实施方式的结构示意图。 在该实施例中， 除压印装置以外， 其余跟实施例一中的设置相同， 故不再赘述。 在该压印装置中， 版辊 13上的导光膜模仁采用 180度夹具上模的方式固 定， 即版辊 13 只有半环上贴敷有导光膜模仁。 所以在压印时， 需要使用两个 压辊， 进行前后两次压印。 与实施例一中的压印效果相比， 由于在实施例一中 版辊上有缝隙的存在， 压印出的导光网点每一个周期会出现间断， 而本实施例 中只需通过简单的设计， 将第一压辊 10配合该版辊 13在该导光膜上的压印区 域与该第二压辊 22配合该版辊 13在该导光膜上的压印区域互补， 从而可以压 印出连续的导光网点。 请结合图 7参见图 8， 图 7是本实施例中的导光膜模仁结构示意图， 图 8 是本实施例中导光膜模仁的安装示意图。 如图所示， 该导光膜模仁 43 的两侧 设有夹具 27， 该夹具 27上设有多个螺孔 28， 同时在版辊 13的边缘设有对应 该夹具 27的凹槽和对应该螺孔 28的螺孔。 安装时， 先用夹具 27把导光膜模 仁固定如图 7， 然后把夹具一边固定于版棍边缘的凹槽内， 只用一颗固定螺杆 锁住夹具 27中间的一个螺孔， 不要锁紧， 接着拉住导光膜模仁另一边的夹具， 转动版 13， 至版棍 13另一个凹槽的平面向上时停下， 用螺杆锁住夹具中间的 另一个螺孔， 此时螺杆不要锁紧。 将余下的螺杆放入余下的螺孔内， 均匀的拉 紧夹具 27， 使导光膜模仁紧贴在版棍 13的面上并且不能有发皱， 最后锁紧所 有的螺杆进行固定， 完成导光膜模仁的安装。 综上所述， 本发明提供了一种采用卷对卷纳米压印技术的导光膜制作装 置， 具有生产速度快， 制作尺寸大， 并且成本低廉的特点。 另外使用二纠偏系 统和张力控制系统， 提高了生产良率， 提升了导光膜的品质。 由以上较佳具体实施例的详述， 希望能更加清楚描述本发明的特征与精 神， 而并非以上述所揭露的较佳具体实施例来对本发明的权利要求范围加以限 制。 相反地， 其目的是希望能涵盖各种改变及具相等性的安排于本发明所欲申 请的权利要求的范围内。

Claims

权 利 要 求 书
1 . 一种导光膜制作装置， 该导光膜原料卷积成筒状， 包括基材层和保护 层， 其特征在于： 该制作装置包括： 放料辊和收料辊， 设置于该制作装置的两端； 分离装置，设置与该放料辊之后，用以将该导光膜的基材层和保护层分离， 以露出该基材层的待加工面； 热压印装置， 具有压辊和版辊， 该版辊上设有导光膜模仁， 该导光膜模仁 表面具有微结构， 该压辊配合该版辊将该导光膜模仁的微结构压印至所述基材 层的待加工面上形成导光网点； 以及 复合装置， 设置于该热压印装置后， 用以将该分离装置分离的保护层重新 贴敷到完成压印的基材上； 其中该导光膜原料卷从放料辊放出后,经该分离装置、压印装置、 复合装置 后重新回收于该收料辊， 形成完整的导光膜。
2. 如权利要求 1所述的导光膜制作装置， 其特征在于： 所述导光膜模仁的 微结构为光栅状微纳米结构或圆柱状微透镜结构。
3. 如权利要求 1所述的导光膜制作装置， 其特征在于： 所述导光膜模仁采 用 360度插版上膜， 其两端插在一缝隙中并 360度环贴在版辊上。
4. 如权利要求 1所述的导光膜制作装置， 其特征在于： 所述导光膜模仁采 用 180度夹具上膜， 其两端设有夹具并 180度半环夹固于版辊上。
5. 如权利要求 4所述的导光膜制作装置， 其特征在于： 所述压辊包括第一 压辊和第二压辊， 分别位于版辊的两侧， 其中该第一压辊配合该版辊在该导光 膜上的压印区域与该第二压辊配合该版辊在该导光膜上的压印区域互补， 以形 成连续的导光网点。
1
6. 如权利要求 1所述导光膜制作装置， 其特征在于： 所述分离装置还包括 修边器和废料回收辊， 该修边器裁除该保护层多余的边幅， 该废料回收辊回收 该被裁除的边幅。
7. 如权利要求 1所述的导光膜制作装置， 其特征在于： 所述热压印装置还 包括压力控制系统， 该压力控制系统控制该压辊和该版辊之间的压力。
8. 如权利要求 1所述的导光膜制作装置， 其特征在于： 所述热压印装置还 包括温度控制系统，该温度控制系统对该版辊或压辊加热，并控制该加热温度。
9. 如权利要求 1所述的导光膜制作装置， 其特征在于： 还包括前后二纠偏 系统， 所述的纠偏系统设有材料边缘感应器和传送修复装置， 所述材料边缘感 应器设置在放料辊和收料辊上， 所述传送修复装置连接在放料辊和收料辊的轴 上， 当该材料边缘感应器感应到材料在输送过程中向内偏移时， 该传送修复装 置控制该放料辊或该收料辊向内移动， 反之向外发生位移。
10. 如权利要求 1或 9所述的导光膜制作装置， 其特征在于： 还包括一张 力控制系统， 所述的张力控制系统主要由张力感应装置和磁粉离合装置组成， 当张力感应装置发现材料传输时张力大于一预设值时， 磁粉离合装置微动减小 收卷转速， 当发现张力小于该预设值时， 转速控制装置微动提升收卷转速。
2
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