WO2016004638A1 - 用于制造导光板的设备 - Google Patents

用于制造导光板的设备 Download PDF

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Publication number
WO2016004638A1
WO2016004638A1 PCT/CN2014/082334 CN2014082334W WO2016004638A1 WO 2016004638 A1 WO2016004638 A1 WO 2016004638A1 CN 2014082334 W CN2014082334 W CN 2014082334W WO 2016004638 A1 WO2016004638 A1 WO 2016004638A1
Authority
WO
WIPO (PCT)
Prior art keywords
roller
light guide
guide plate
pressing
raw material
Prior art date
Application number
PCT/CN2014/082334
Other languages
English (en)
French (fr)
Inventor
贺虎
Original Assignee
深圳市华星光电技术有限公司
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 深圳市华星光电技术有限公司 filed Critical 深圳市华星光电技术有限公司
Priority to US14/416,753 priority Critical patent/US20160009011A1/en
Publication of WO2016004638A1 publication Critical patent/WO2016004638A1/zh

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Classifications

    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • 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
    • G02B6/0013—Means for improving the coupling-in of light from the light source into the light guide
    • G02B6/0015—Means for improving the coupling-in of light from the light source into the light guide provided on the surface of the light guide or in the bulk of it
    • G02B6/002—Means for improving the coupling-in of light from the light source into the light guide provided on the surface of the light guide or in the bulk of it by shaping at least a portion of the light guide, e.g. with collimating, focussing or diverging surfaces
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/24—Calendering
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0011—Combinations of extrusion moulding with other shaping operations combined with compression moulding
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • B29L2011/0075—Light guides, optical cables

Definitions

  • the present invention relates to the field of liquid crystal display technology, and in particular, to an apparatus for manufacturing a light guide plate. Background technique
  • the thickness of the light guide plate is also gradually reduced, from the initial 4mm to 3mm, and further reduced to 2mm, or even thinner.
  • the thickness of the light guide plate is reduced, the cost of the light guide plate can be reduced, the weight of the module can be reduced, and even a better appearance can be achieved.
  • the thinning of the light guide plate also faces some problems.
  • the dimming efficiency of the thinned light guide plate is reduced due to the size limitation of the light emitting diode (LED).
  • Figure 1 shows a schematic view of the optical path of a thicker light guide plate in the prior art.
  • the propagation of light from the light-emitting element 1 is indicated by an arrow.
  • the light-emitting element 1 is an LED 7030 having a light-emitting surface width of 2,6 mm.
  • the thickness of the light guide plate 2 in Fig. 1 is 3 mm.
  • Fig. 2 is a view showing the optical path of a thinner light guide plate in the prior art.
  • the propagation of light from the light-emitting element 1 is indicated by an arrow.
  • the light-emitting element 1 is an LED 7030 having a light-emitting surface width of 2.6 mm.
  • the thickness of the light guide plate 2 is 2 mm.
  • the thickness of the light guide plate 2 becomes thinner, in particular, it becomes thinner than the light-emitting surface width of the light-emitting element 1, it is thinner as shown in FIG. In the case of the light guide plate, some of the light does not enter the light guide plate 2
  • FIG. 3 shows a typical light guide plate having a wedge-shaped projection on the light incident side, that is, the thickness 1 of the light guide plate 20 on the light incident side is larger than the thickness T 2 of other regions.
  • the light coupling efficiency of the large-sized light-emitting element (LE: D) 0 and the thin light guide plate 20 can be improved, and at the same time, the light guide plate 20 can have a thin thickness T 2 in most regions. .
  • the present invention proposes an apparatus for manufacturing a light guide plate which can be used to manufacture a wedge-shaped projection on the light-incident side.
  • the light guide plate (the typical structure thereof is as shown in Fig. 3), at the same time, the device according to the present invention can manufacture a larger-sized light guide plate than the prior art, without being limited by the design of the device itself.
  • the present invention provides an apparatus for manufacturing a light guide plate.
  • the apparatus includes : a feeding unit having a slit-shaped discharge port for supplying a raw material constituting the light guide plate; a unit, the pressing unit includes a conveying roller for conveying the raw material and a pressing roller for pressing the raw material; and a cutting unit for cutting a guide derived by the pressing unit A light plate, wherein an elongated recess that is recessed toward the inside of the pressing roller is disposed on a roller of the pressing roller to prepare a light guiding plate having a thickness variation.
  • Embodiment 2 modified according to Embodiment 1 the conveying roller is located on one side of the raw material, and the pressing roller is located on the other side of the raw material, and corresponds to the pressing roller
  • the position of the conveyor roller is matched with the position.
  • the squeezing roller and the corresponding conveying roller form a pair of rollers to collectively perform the pressing action on the raw material, and the remaining conveying rollers mainly perform the transportation function for the raw material.
  • the apparatus has only one squeeze roller, and in the extrusion unit, a rotation direction of the squeeze roller and the roller of the conveyance roller
  • the direction of advancement of raw materials is the same. This is to ensure that the parts of the instantaneous rolling contact in the entire system move in the same direction.
  • Embodiment 4 modified according to Embodiment 2, the recess completely surrounds the roller of the pressing roller in the circumferential direction, and the extending direction of the recess is perpendicular to the central rotating shaft of the pressing roller.
  • the wedge-shaped projection extending along a direction of advancement of the light guide plate (ie, a rotation direction of the roller) t> in Embodiment 5 modified according to Embodiment 4, the concave portion ⁇ the roller At the axial end.
  • the concave portion is at the axial center of the roller.
  • the number and position of the recesses can be adjusted depending on the relationship between the axial length of the roller and the size of the target light guide.
  • the recess extends from one end to the other end of the roller of the pressing roller in the axial direction, and the extending direction of the recess and the center of the pressing roller
  • the shafts are parallel.
  • the light guide plate manufactured in this manner has a wedge-shaped projection extending perpendicularly to the advancing direction of the light guide plate, i.e., extending in the axial direction of the roller.
  • Embodiment 8 modified according to Embodiment 7, on one of the pressing rolls, a plurality of said recesses are equally spaced apart in the circumferential direction of the rolls of said pressing rolls.
  • Embodiment 9 modified according to Embodiment 8 two recesses are provided on one squeeze roller.
  • the embodiment 10 modified according to the embodiment 7 only one recess is provided on one squeeze roller.
  • the number and position of the recesses can be adjusted depending on the relationship between the circumference of the roller and the size of the target light guide.
  • the recess has a sector shape in cross section, the side walls of the sector form the waist of the sector, and one side of the opening constitutes a long arc of the sector.
  • the convex portion (thickness region) on the light guide plate obtained by the pressing of the concave portion has a wedge shape.
  • the light guide plate derived from the pressing unit has a relatively thin area and a relatively thick area, and the cutting unit is in the relatively thick area.
  • the light guide plate is cut. In this way, a light guide plate having a specific size having a wedge-shaped projection (a thicker region) on the light incident side can be obtained. Subsequent molding and polishing can be applied to the display.
  • the apparatus according to the present invention can produce a light guide plate having a wedge-shaped projection on the incident light side, and can cut the resulting light guide plate to any desired size, especially larger than that of the prior art.
  • the entire manufacturing process is included in one equipment, and the process runs smoothly, the production efficiency is high, the maintenance is convenient, and the integration cost is low.
  • FIG. 1 shows a schematic diagram of an optical path of a thicker light guide plate in the prior art
  • FIG. 2 is a schematic view showing the optical path of a thinner light guide plate in the prior art
  • Figure 3 is a view showing the structure of a light guide plate to be manufactured by the apparatus according to the present invention.
  • FIG. 4 is a structural view showing a first embodiment of an apparatus for manufacturing a light guide plate according to the present invention.
  • FIG. 5 is a side view showing a first embodiment of an apparatus for manufacturing a light guide panel according to the present invention;
  • FIG. 7 shows a light guide plate of a first embodiment of an apparatus for manufacturing a light guide panel according to the present invention, and
  • FIG. 8 shows a side view of the light guide plate of Figure 7;
  • Figure 9 shows a squeeze roller of a second embodiment of an apparatus for manufacturing a light guide plate according to the present invention
  • Figure 10 is a view showing a light guide plate of a second embodiment of an apparatus for manufacturing a light guide panel according to the present invention.
  • 11 is a side view showing a third embodiment of an apparatus for manufacturing a light guide plate according to the present invention
  • FIG. 12 is a view showing a roller of a squeeze roll of a third embodiment of the apparatus for manufacturing a light guide plate according to the present invention.
  • Figure 13 is a side elevational view of the roller of the squeeze roll of Figure 12;
  • Figure 14 is a view showing the dimensional relationship of the roller of the pressing roller in Fig. 3 and the obtained light guiding plate;
  • Figure 15 is a view showing an alternative layout of the second embodiment of the apparatus for manufacturing a light guiding plate according to the present invention;
  • 16 shows a squeeze roller of a fourth embodiment of the apparatus for manufacturing a light guide plate according to the present invention.
  • the same components are labeled with the same W. The drawings are not in actual proportions. detailed description
  • Fig. 3 shows a light guide plate 20 having a wedge-shaped projection on the light incident side, which is a type of light guide plate to be manufactured by the apparatus according to the present invention.
  • the purpose of the apparatus of the present invention is to prepare a light guide plate having a thickness variation.
  • the specific form of the light guide plate is not limited to the state shown in FIG. 3.
  • the wedge-shaped protrusion may be located at other positions of the light guide plate, or
  • the projections have different cross sections such as a rectangle, an arc, and the like.
  • the thickness of the light guide plate 20 on the light incident side is larger than the thickness T 2 of the other regions.
  • the light coupling efficiency of the large-sized light-emitting element (LED) li) and the thin light guide plate 20 can be improved, and at the same time, the light guide plate 20 can have a thin thickness T 2 in most regions.
  • the large-sized planar light guide plate preparation process may include a step of passing a plurality of polymers (typically, for example, polymethacrylate ( ⁇ ) or styrene-methacrylic acid W ester copolymer (MS)) in a molten state through several The squeeze roller is pressed and cooled to form a large plate of the light guide plate.
  • a plurality of polymers typically, for example, polymethacrylate ( ⁇ ) or styrene-methacrylic acid W ester copolymer (MS)
  • the apparatus according to the present invention is developed and improved based on the above-described process principles.
  • Fig. 4 is a view showing the structure of an apparatus 50 for manufacturing a light guide plate according to the present invention in the first embodiment.
  • the apparatus 50 of the first embodiment is first comprised of a feed unit! 00.
  • the supply unit 00 may be a container having a slit-shaped discharge port for supplying the raw material 101 constituting the light guide plate. After flowing out of the supply unit 00, the raw material 101 has a substantially plate shape due to the restriction of the slit-shaped discharge port. Of course, at this time, the shape of the plate of the light guide plate raw material 101 is merely for the convenience of the subsequent process, and is not close to its final form.
  • the apparatus 50 further includes an squeezing unit including a conveying roller for conveying the raw material 10 and a squeezing roller for squeezing the raw material 101.
  • the apparatus 50 has a conveying roller 201, a conveying roller 203, and a conveying roller 204, and has a pressing roller 202.
  • the conveying roller 20, the conveying roller 203 and the conveying roller 204 are located on one side of the raw material 10], and the pressing roller 202 is located separately on the other side of the raw material 101.
  • a conveying roller 201 is provided which cooperates therewith, and the pressing roller 202 and the conveying roller 201 form a pair of rollers to collectively perform the pressing action on the raw material 101 (described later in detail). Thereafter, the squeezing roller 202 and the conveying roller 203 form a pair of rollers again, and the conveying roller 204 mainly performs a transportation function for the raw material 101.
  • Figure 5 shows a side view of the apparatus 50 of Figure 4.
  • the direction of rotation of the conveying roller 201, the conveying roller 203, the conveying roller 204, and the pressing roller 202 is indicated by arrows in Fig. 5.
  • the pressing unit which is constituted by the conveying roller 20, the conveying roller 203, the conveying roller 204, and the pressing roller 202 in the first embodiment
  • all the rollers of the squeezing roller and the conveying roller rotate in the same direction as the direction in which the raw material 101 is advanced.
  • the raw material 01 is advanced from left to right, and the conveying roller 201, the conveying roller 203, and the conveying roller 204 on the side of the raw material 101 are all rotated clockwise, and the pressing roller 202 on the other side of the raw material 101 is rotated counterclockwise. , so that the parts of the entire system that are in instantaneous rolling contact move in the same direction.
  • the apparatus 50 further includes a cutting unit 230 for cutting the light guide plate 300 that is led out of the extrusion unit. It is easy to understand that the raw material 101 has been subjected to the extrusion process of the extrusion unit, and has become the light guide plate 300 having the target shape, except that the size of the light guide plate 300 is large at this time. It is also necessary to cut it by the cutting unit 230 into a size that matches a particular type of liquid crystal display.
  • Fig. 6 shows a squeezing roller 210 (which is used as the squeezing roller 202 in Figs. 4 and 5) of the first embodiment of the apparatus for manufacturing a light guide plate according to the present invention.
  • a squeezing roller 210 which is used as the squeezing roller 202 in Figs. 4 and 5) of the first embodiment of the apparatus for manufacturing a light guide plate according to the present invention.
  • an elongated recess 213 is formed on the roller 212 of the squeezing roller 210 toward the inner recess of the squeezing roller 210.
  • the light guide plate raw material 101 is pressed by the squeeze roller 210, and a light guide plate having a thickness variation (for example, the light guide plate 20 shown in Fig. 3) can be prepared.
  • a light guide plate having a thickness variation for example, the light guide plate 20 shown in Fig. 3
  • the recess 213 completely surrounds the roller 212 of the pressing roller 210 in the circumferential direction, and the extending direction of the recess 213 is perpendicular to the central rotating shaft 2 of the pressing roller 210. In other words, the recess 2 3 extends one turn along the circumferential direction of the roller 212.
  • the elongated recess 213 is located at the axial end of the roller 2].
  • Recesses 213 may be provided at one axial end of the roller 212 or at 3 ⁇ 4 axial ends, depending on the particular production size and model requirements.
  • the radial dimension of the roller 212 is clearly less than the remainder of the roller 212. That is, the diameter D 2 of the roller 212 at the recess 213 at its axial end portion is smaller than the diameter D t of the remaining portion of the roller 212.
  • the recess 213 further has a sidewall 214 having a certain width in the axial width L,
  • the side wall 214 of the recess 213 is defined by a broken line.
  • Fig. 7 shows the finished product of the light guide plate 300 of the first embodiment of the apparatus for manufacturing a light guide plate according to the present invention. It can be seen that the light guide plate 300 has a thinner region 30 and a thicker region 302, and a slope region 303 having a certain inclination between the thinner region 301 and the thicker region 302.
  • the arrow A indicated by hatching in the figure shows the direction of rotation of the roller of the squeezing roller acting on the light guide plate 300.
  • Figure 8 shows a side view of the light guide plate of Figure 7.
  • the slope region 303 is defined by two broken lines in FIG. It is easily understood that the roller 212 of the squeeze roller 210 and the corresponding surface of the light guide plate 300 are concave-convex. 6 and 8, the wide-diameter portion (the region of the non-recessed portion) of the roller 212 corresponds to the thinner region 301 of the light guide plate 300, and the concave portion 213 of the roller 212 corresponds to the thicker region 302 of the light guide plate 300.
  • the side wall 214 of the roller 212 corresponds to the slope region 303 of the light guide plate 300.
  • the size of the roller 2] 2 is also related to the size of the target wedge-shaped light guide plate 300.
  • Dimension I is the diameter of the wide-diameter portion of the roller 212, 1) 2 is The diameter of the roller 212 at the recess 213.
  • ⁇ is the thickness of the thicker region of the light guide plate 300, and T 2 is the thickness of the thinner region of the light guide plate 300.
  • the dimensional relationship equation is only a theoretical value, and those skilled in the art will readily understand that the product size will of course have a certain tolerance in actual process production.
  • the width L of the side wall 214 of the concave portion 213 of the roller 212 in the axial direction is the same as the width W of the slope region 303 of the light guide plate 300 in the axial direction.
  • the wedge-shaped projections (thickness regions 302) of the manufactured light guide plate 300 extend along the advancing direction of the light guide plate material 10, after the roll is formed to utilize the molding machine pair
  • the edge of the obtained light guide plate 300 in the machine advancement direction (MD) is subjected to cutting and polishing to further realize that the light incident side of the finished light guide plate 300 includes a wedge-shaped convex structure.
  • Fig. 9 shows a squeezing roller 40 of a second embodiment of an apparatus for manufacturing a light guide plate according to the present invention.
  • the second embodiment most of the structure of the apparatus is the same as that of the first embodiment shown in Figs. 4 and 5, and will not be described in detail herein. It is significantly different from the first embodiment in that, in the second embodiment, instead of the pressing roller 210 shown in Fig. 6, the pressing roller 410 shown in Fig. 9 is employed as the extrusion in Figs. 4 and 5. Pressure roller 202.
  • an elongated recess 413 and a recess 415 are formed on the roller 412 of the squeezing roller 410 toward the inner recess of the squeezing roller 410.
  • the recess 413 is located at the end of the shaft 314 of the drum 412, and the recess 415 is located at the axial center of the drum 412.
  • the light guide plate raw material 101 is extruded through the squeezing roller 410, and a light guide plate having a thickness variation can be prepared.
  • recess 4! 3 and the recess 415 completely surrounds the roller 412 of the pressing roller 410 in the circumferential direction, and the recess 413 and the recess 415 extend in a direction perpendicular to the central rotating shaft 411 of the pressing roller 410. In other words, the recess 413 and the recess 415 each extend one turn along the circumferential direction of the roller 412.
  • the radial dimension of the roller 412 is clearly smaller than the remainder of the roller 412. That is, the diameter of the roller at the recess 415 located in the axially middle portion thereof 1) 2 the diameter D at the non-recessed portion of the roller 4] 2
  • Figure 10 shows a light guide plate finished product 500 of a second embodiment of an apparatus for manufacturing a light guide plate according to the present invention.
  • the roller 412 of the squeeze roller 410 and the corresponding surface of the light guide plate 500 are concave-convex.
  • the wide-diameter portion (the region of the non-recessed portion) of the roller 412 corresponds to the thinner region 501 of the light guide plate 500
  • the concave portion 413 of the roller 412 at the axial end portion corresponds to the light guide plate.
  • the thicker region 502 at the edge of the 500, and the recess 415 at the axial center of the roller 412 corresponds to the thicker region 505 at the center of the light guide plate 500.
  • the second embodiment can be employed, that is, disposed perpendicular to the pressing roller 410 at the axial center of the roller 4]2.
  • the elongated recess 415 extends in the direction of the central rotating shaft 411, and the recess 415 surrounds the roller 412-week.
  • the number and position of the recesses in the first embodiment and the second embodiment are merely exemplary and are not limitative.
  • the number and position of the narrow recesses on the rollers of the squeeze roller can be adjusted, and a plurality of verticals can be arranged at equal intervals on the roller.
  • the elongated recess may be a slit having a trapezoidal cross section.
  • Figure 11 shows a side view of the third embodiment of the apparatus for manufacturing a light guide plate according to the present invention.
  • the apparatus 60 in the third embodiment first includes a supply unit 100. Further, the apparatus 60 further includes an squeezing unit including a conveying roller for conveying the light guide plate raw material 101 and a squeezing roller for squeezing the raw material.
  • the apparatus 60 has a conveying roller 601, a conveying roller 603 and a conveying roller 604 having a pressing roller 602. Conveyor roller for easy operation
  • the conveying roller 603 and the conveying roller 604 are located on one side of the raw material 101, and the pressing roller 602 is separately positioned on the other side of the raw material 101.
  • a conveying roller 601 is provided at a position corresponding to the pressing roller 602, and the pressing roller 602 and the conveying roller 601 form a pair of rollers to collectively complete the pressing of the raw material 101 (described later in detail). Thereafter, the squeezing roller 602 and the conveying roller 603 form a pair of rollers again, and the conveying roller 604 mainly performs a transportation function for the raw material 101.
  • the direction of rotation of the conveying roller 601, the conveying roller 603, the conveying roller 604, and the squeezing roller 602 is further indicated by arrows in Fig. 11.
  • the pressing unit which is constituted by the conveying roller 601, the conveying roller 603, the conveying roller 604, and the pressing roller 602 in the third embodiment
  • all of the pressing roller and the conveying roller coincides with the direction of advancement of the raw material 101.
  • the raw material 10 is pushed from left to right, and the conveying roller 601, the conveying roller 603, and the conveying roller 604 on the side of the raw material 01 are all rotated clockwise, and the pressing roller 602 located on the other side of the raw material 101 is reversed.
  • the hour hand rotates so that the parts of the entire system that are in instantaneous rolling contact move in the same direction.
  • the apparatus 60 further includes a cutting unit 630 for cutting the light guide plate 600 derived by the extrusion unit. It is easy to understand that the raw material 101 has become the light guide plate 600 having the target shape after being processed by the extrusion process of the extrusion unit, except that the size of the light guide plate 600 is large at this time. It is also necessary to cut it into a size matching a specific type of liquid crystal display by the cutting unit 630.
  • Figure 12 is a perspective view showing a roller of a squeezing roller of a first embodiment of an apparatus for manufacturing a light guide plate according to the present invention. In the first embodiment, the pressing roller 6] shown in Fig. 12 is employed as the pressing roller 602 of the apparatus 60 shown in Fig. 11.
  • an elongated recess 612 is provided on the roller 61 of the squeeze roller 610. Concave
  • the 612 extends from one axial end of the roller 611 to the other axial end in the axial direction of the roller 61 1 .
  • the elongated recess 612 extends in a direction parallel to the central rotational axis of the squeeze roller 610.
  • the center shaft is not shown in Figure 12, although those skilled in the art will appreciate that the center shaft is typically located on the center axis of the drum.
  • Fig. 13 is a side view of the roller 611 of the squeeze roller 610 of Fig. 12 as viewed in the axial direction thereof.
  • the roller 611 has an elongated recess 612 that is recessed toward the inside of the pressing roller 610 (i.e., toward the central rotating shaft 613).
  • the recess 612 has a fan-shaped cross section, the side wall of the recess 612 forms a fan-shaped waist, and one side of the opening constitutes a fan-shaped length.
  • the convex portion (thickness region) on the light guide plate obtained by the pressing of the concave portion 612 has a wedge shape.
  • Fig. 14 shows the dimensional relationship of the roller 6 ⁇ of the squeezing roller 610 of Fig. 13 with the obtained light guide plate.
  • the upper side thereof is a side view of the roll 611 of the squeeze roll 610 in Fig. 13 as viewed in the axial direction thereof, and the lower side shows a side view of the light guide plate obtained by the press roll 610.
  • the radius at the recess of the roll is less than the radius Rt of the remainder of the roll (not at the recess).
  • the roller of the squeezing roller and the corresponding surface of the light guide plate are concave-convex.
  • the remainder of the roll corresponds to the thinner area of the light guide plate, while the recess of the roll corresponds to the thicker area of the light guide plate. Therefore, the thickness T 3 of the thicker region of the light guide plate is larger than the thickness ⁇ 2 of the thinner region of the light guide plate.
  • the size of the roller is also associated with the size of the target wedge-shaped light guide plate - - 0 ⁇ 2 .
  • R 2 is the radius at the recess of the roll, the radius of the remainder of the roll (not at the recess);
  • ⁇ is the thickness of the thicker portion of the light guide, and
  • T 2 is the thickness of the thinner portion of the light guide.
  • the roller also has a side wall having a certain inclination between the concave portion and the non-recessed portion, and the corresponding light guide plate manufactured has a certain relationship between the thinner portion and the thicker portion.
  • the sloped area of the inclination it is easy to understand that the circumferential dimension of the side wall and the size of the slope area of the light guide plate in the corresponding direction are also equal.
  • the cutting unit 630 is along the wedge-shaped projection. 705 (thicker area) is cut to obtain a light guide plate having a specific size having a wedge-shaped projection (a thicker region) on the light incident side. Subsequent molding and polishing can be applied to the display.
  • Figure 15 shows an alternative layout of a second embodiment of an apparatus for fabricating a light guide according to the present invention.
  • Most of the devices 80 shown in FIG. 15 are similar to the device 60 shown in FIG. 11, and will not be described again.
  • the significant difference is the number and location of the conveyor rollers. It can be seen that, in Fig. 15, four conveying rollers, that is, a conveying roller 801, a conveying roller 803, a conveying roller 804, and a conveying roller 805 are provided, and a pressing roller 806 having a groove 714 is also provided.
  • All of the conveying rollers and the squeezing rollers are no longer on the same horizontal surface, and the conveying rollers 801 and the squeezing rollers 806 are located at the upper positions, which form a pair of rollers, which cooperate to press the light guide plate raw material 101. Thereafter, the squeezing roller 806 and the conveying roller 803 form a counter roller again.
  • the conveying roller 804 and the conveying roller 805 mainly serve as a transport.
  • the cutting unit 730 performs cutting.
  • Figure 16 shows a squeeze roll of a fourth embodiment of an apparatus for manufacturing a light guide plate according to the present invention.
  • the fourth embodiment most of the structure of the device is the same as that of the third embodiment shown in Fig. 11, and will not be described in detail herein.
  • a significant difference from the third embodiment is that, in the fourth embodiment, instead of the pressing roller 610 shown in Fig. 12, the pressing roller 910 shown in Fig. 16 is employed as the pressing roller 602 in Fig. 1. .
  • the squeezing roller 910 includes a center shaft 914 and a roller 911, and two elongated recesses 913 are provided on the drum 911.
  • the recess 913 extends from one axial end of the roller 911 to the other axial end in the axial direction of the roller 911.
  • the roller of the squeezing roller may have a plurality of elongated recesses extending along the axis
  • the number of recesses is determined by considering the circumference of the roller and the corresponding size of the light guide plate to be produced -
  • the length of the long side is about 1240 mm; correspondingly, the diameter of the forming roll is 400 mm (circumference of about 1260 mm), and only on the roll An elongated recess extending in the axial direction is provided, that is, a light guide plate having a wedge-shaped convex structure on the light-incident side of the short side can be realized.
  • the corresponding forming roll has a diameter of 500 mm (a circumference of about 1570 mm).
  • a wedge-shaped light guide plate needs to be produced, it can be placed on the forming roll.
  • the slits extending in the axial direction (80° apart) ensure that the roller is pressed one turn to produce two rows of light guide plates having a wedge-shaped protruding structure on the light-incident side.
  • the arrangement of the elongated recesses in the first and second embodiments and the third and fourth embodiments may be combined to obtain a desired light guide plate having projections on the surface.

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Abstract

一种用于制造导光板的设备。所述设备包括：供料单元（100），其具有狭缝形的出料口；挤压单元，所述挤压单元包括用于输送所述原材料（101）的输送辊（201，203，204）和用于挤压所述原材料的挤压辊（202）；以及切割单元，所述切割单元用于切割所述挤压单元所导出的导光板，其中，在所述挤压辊的辊筒上设置有朝向所述挤压辊内部凹陷的狭长凹部，以制备具有厚度变化的导光板。该设备生产效率高。

Description

用于制造导光板的设备 相关申请的交叉引用
本申请要求享有亍 2014年 7月 10日提交的名称为"用于制造导光板的设备" 的中国专利申请 CN201410326527.3 的优先权， 该申请的全部内容通过引用并入 本文中。 技术领域
本发明涉及液晶显示技术领域， 尤其涉及一种用亍制造导光板的设备。 背景技术
随着大尺^发光二极管 (LED)侧边式背光源的发展， 薄型化成为趋势。 导光 板的厚度也在逐渐减薄， 从最初的 4mm降低到 3mm, 又进一步降低至 2mm, 甚 至可以更薄。 导光板的厚度减薄， 可以实现导光板成本的降低， 模组的轻量化， 甚至实现较佳的外观。
然而， 另一方面， 导光板的薄形化也面临着一些问题。 典型地， 由于发光二 极管 (LED)的尺寸限制， 薄型化后的导光板的耩光效率有所降低。
图 1显示了现有技术中较厚的导光板的光路示意图。 其中通过箭头标示了来 自发光元件 1的光线的传播。 发光元件 1为 LED7030, 其发光面宽度为 2,6mm。 而图 1中导光板 2的厚度为 3mm。
图 2显示了现有技术中较薄的导光板的光路示意图。 其中通过箭头标示了来 自发光元件 1的光线的传播。 发光元件 1为 LED7030, 其发光面宽度为 2.6mm。 而图 2中导光板 2的厚度为 2mm。
通过对比图 1和图 2可容易理解， 在图 2中， 由于导光板 2的厚度变薄， 尤 其是变得比发光元件 1的发光面宽度还要薄， 因此在图 2所示的较薄的导光板的 情况中， 有部分光线没有进入导光板 2„
因此， 容易理解， LED7030 (发光面宽度 2.6mm ) 与图 2所示的 2nim厚度 的导光板的耦光效率远小于其与图 1所示的 3mm厚度的导光板的耦光效率， 也 以这种形式造成了光能量损失。 由此衍生出了使用楔形导光板的想法。 图 3所示为一种典型的入光侧具有楔 形凸出部的导光板， 即导光板 20在入光侧的厚度1 大于其它区域的厚度 T2。 使 用这种导光板，既可以提升大尺寸的发光元件 (LE:D)】0与薄型导光板 20的耦光效 率， 同时又可以保证导光板 20在大部分区域中具有较薄的厚度 T2。
传统的禊形导光板使用注塑成型或射出成型等工艺实现， 这些制程存在尺寸 限制。 以射出成型工艺为例， 射出成型工艺目前只可以傲到 32 英寸， 这主要是 由于受到机台吨数的限制。 因此， 现有技术中尚没有用亍更大尺寸的楔形导光板 的成型工艺及相关设备。 发明内容
针对现有技术中无法制作 （较大的） 所需尺寸的楔形导光板的问题， 本发明 提出了一种用于制造导光板的设备， 其可用来制造在入光侧具有楔形凸出部的导 光板 （其典型结构如附图 3所示） ， 同时， 相比现有技术， 根据本发明的设备可 制造尺寸更大的导光板， 而不受设备自身设计的限制。
本发明提出了一种用于制造导光板的设备，在实施方案 1中，所述设备包括 : 供料单元， 其具有狭缝形的出料口， 用于供给构成导光板的原材料； 挤压单元， 所述挤压单元包括用于输送所述原材料的输送辊和用于挤压所述原材料的挤压 辊； 以及切割单元， 所述切割单元用于切割所述挤压单元所导出的导光板， 其中， 在所述挤压辊的辊筒上设置有朝向所述挤压辊内部凹陷的狭长凹部， 以制备具有 厚度变化的导光板。
在根据实施方案 1所改进的实施方案 2中， 所述输送辊位于所述原材料的一 侧， 而所述挤压辊位于所述原材料的另一侧， 且在与所述挤压辊相对应的位置处 设置有与其配合的输送辊。 挤压辊和相应的输送辊形成对辊， 以共同完成对原材 料的挤压作用， 而其余的输送辊则主要执行对原材料的运输功能。
在根据实施方案 2所改进的实施方案 3中， 所述设备仅具有一个挤压辊， 且 在所述挤压单元中， 所述挤压辊和所述输送辊的辊筒的旋转方向与所述原材料的 推进方向一致。 这是为了保证整个系统中瞬时滚动接触的部位均朝向相同的方向 运动。
在根据实施方案 2所改进的实施方案 4中， 所述凹部沿周向完全环绕所述挤 压辊的辊筒， 旦所述凹部的延伸方向与所述挤压辊的中心转轴垂直。 以此方式所 制造的导光板， 其楔形凸出部沿着导光板的推进方向（即辊筒的旋转方向）延伸 t> 在根据实施方案 4所改进的实施方案 5中， 所述凹部位亍所述辊筒的轴向端 部处。
在根据实施方案 4所改进的实施方案 6中， 所述凹部位亍所述辊筒的轴向中 央处。
当然， 根据辊筒轴向长度和目标导光板尺寸之间的关系， 凹部的数量和位置 可以进行调整。
在根据实施方案 2所改进的实施方案 7中， 所述凹部沿轴向从所述挤压辊的 辊筒的一端延伸至另一端， 且所述凹部的延伸方向与所述挤压辊的中心转轴平 行。 以此方式所制造的导光板， 其楔形凸出部垂直于导光板的推进方向延伸， 即 沿着辊筒的轴向方向延伸。
在根据实施方案 7所改进的实施方案 8中， 在一个挤压辊上， 多个所述凹部 在所述挤压辊的辊筒的周向上等距离间隔分布。
在根据实施方案 8所改进的实施方案 9中，在一个挤压辊上设置有两条凹部。 在根据实施方案 7所改进的实施方案 10中， 在一个挤压辊上仅设置有一条 凹部。
当然， 根据辊筒周长和目标导光板尺寸之间的关系， 凹部的数量和位置可以 进行调整。
在根据实施方案 7到 10中任一个所改进的实施方案 11中， 所述凹部的横截 面为扇形， 其侧壁构成所述扇形的腰， 且开口的一边构成所述扇形的长弧。 如此 地， 通过凹部挤压而得到的位于导光板上的凸出部 （较厚区域） 的形状为楔形。
在根据实施方案 Ί到 10中径一个所改进的实施方案 2中， 所述挤压单元所 导出的导光板具有相对薄的区域和相对厚的区域， 所述切割单元在所述相对厚的 区域处对所述导光板进行切割。 以此方式， 可得到在入光侧具有楔形凸出部 （较 厚区域）的具有特定尺寸的导光板大板。后续再经过成型抛光即可应用于显示器。
根据本发明的设备可制作入射光侧具有楔形凸出部的导光板， 且能够将所得 到的导光板裁切为任意所需的尺寸， 尤其是大于现有技术能力所及的尺寸。 另一 方面， 将整个制作工艺包含在一个设备内， 工艺运行流畅、 生产效率高、 维修方 便、 整合成本低。
上述技术特征可以各种适合的方式组合或由等效的技术特征来替代， 只要能 够达到本发明的目的。 附图说明
在下文中将基于实施例并参考附图来对本发明进行更详细的描述。 其中： 图 1显示了现有技术中较厚的导光板的光路示意图；
图 2显示了现有技术中较薄的导光板的光路示意图；
图 3显示了根据本发明的设备所要制造的导光板的结构示意图；
图 4 显示了根据本发明的用于制造导光板的设备的第一实施例的结构示意 图 5显示了根据本发明的用于制造导光板的设备的第一实施 ί到的侧视图； 图 6显示了根据本发明的用于制造导光板的设备的第一实施例的挤压辊； 图 7 显示了根据本发明的用于制造导光板的设备的第一实施例的导光板成 图 8显示了图 7中的导光板的侧视图；
图 9显示了根据本发明的用于制造导光板的设备的第二实施例的挤压辊； 图 10 显示了根据本发明的用于制造导光板的设备的第二实施例的导光板成 图 11显示了根据本发明的 ^于制造导光板的设备的第三实施例的侧视图； 图 12 显示了根据本发明的用于制造导光板的设备的第三实施例的挤压辊的 辊筒的立体图；
图 13显示了图 12中的挤压辊的辊筒的沿轴向观测的侧视图；
图 14显示了图】3中的挤压辊的辊筒与所获得的导光板的尺寸关系； 图 15显示了根据本发明的用于制造导光板的设备的第≡实施例的替换布局； 图 16显示了根据本发明的用于制造导光板的设备的第四实施例的挤压辊。 在附图中， 相同的部件使用相同的 W图标记。 附图并未按照实际的比例。 具体实施方式
下面将结合 ΡΙΪ图对本发明作进一歩说明。
上面已经介绍过， 图 3所示为入光侧具有楔形凸出部的导光板 20, 楔形导光 板 20 即是根据本发明的设备所要制造的导光板的类型。 当然， 总地来说， 根据 本发明的设备的目的是制备具有厚度变化的导光板， 这种导光板的具体形态并不 拘泥于图 3中所示的样态， 例如楔形凸出部也可位于导光板的其它位置， 或者凸 出部具有例如矩形、 弧形等不同的横截面。
从图 3可明显看出， 导光板 20在入光侧的厚度 大于其它区域的厚度 T2。 使用这种导光板，既可以提升大尺寸的发光元件 (LED)li)与薄型导光板 20的耦光 效率， 同时又可以保证导光板 20在大部分区域中具有较薄的厚度 T2。
大尺寸平面导光板制备工艺可包括如下步骤， 即将熔融状态下的高分子 （典 型地， 例如聚甲基丙烯酸 酯 (ΡΜΜΑ)或苯乙烯-甲基丙烯酸 W酯共聚物 (MS))经 过数个挤压辊的挤压， 冷却后形成导光板大板。 根据本发明的设备即为基于上述 工艺原理进行开发和改进。
图 4显示了第一实施例中的根据本发明的用于制造导光板的设备 50的结构 示意图。
从图 4可看出， 第一实施 ί到中的设备 50首先包括供料单元！ 00。 供料单元 00可为具有狭缝形的出料口的容器， 用于供给构成导光板的原材料 101。 原材 料 101从供料单元 00流出后， 由于狭缝形的出料口的限制而具有大致的板体形 状。 当然， 此时导光板原材料 101的板体形状仅仅是为了方便后续工艺， 并非十 分接近其最终形态。
进一步地， 设备 50还包括挤压单元， 该挤压单元包括用于输送原材料 10 的输送辊和用于挤 ίΐ原材料 101的挤 ίΐ辊。在图 4所示的第一实施例中， 设备 50 具有输送辊 201、输送辊 203和输送辊 204， 同时具有挤压辊 202。为了方便作业， 输送辊 20 、 输送辊 203和输送辊 204位于原材料 10】的一侧， 而挤压辊 202单 独地位于原材料 101的另一侧。 在与挤压辊 202相对应的位置处设置有与其配合 的输送辊 201 , 挤压辊 202和输送辊 201形成对辊， 以共同完成对原材料 101的 挤压作用 （稍后将详细介绍） ， 之后挤压辊 202和输送辊 203再次形成对辊， 而 输送辊 204则主要执行对原材料 101的运输功能。
图 5显示了图 4中的设备 50的侧视图。 图 5中用箭头标示了输送辊 201、 输送辊 203、 输送辊 204和挤压辊 202的转动方向。 由图 5可看出， 在挤压单元 (在第一实施例中其由输送辊 20 、 输送辊 203、 输送辊 204和挤压辊 202构成） 中， 所有的挤 ίΐ辊和输送辊的辊筒的旋转方向都与原材料 101的推进方向一致。 在图 5中， 原材料 01由左至右推进， 位于原材料 101—侧的输送辊 201、 输送 辊 203和输送辊 204均为顺时针转动， 位于原材料 101另一侧的挤压辊 202逆时 针转动， 使得整个系统中瞬时滚动接触的部位均朝向相同的方向运动。
由图 5可看到， 设备 50还包括切割单元 230， 切割単元 230用于切割由挤 压单元所导出的导光板 300。 容易理解， 原材料 101在经过挤压单元的挤压工艺 处理后， 己经成为具有目标形状的导光板 300, 只是此刻导光板 300的尺寸较大。 还需要通过切割单元 230将其切割成与特定型号的液晶显示器相匹配的尺寸。
图 6显示了根据本发明的用于制造导光板的设备的第一实施例的挤压辊 210 (其 ^来作为图 4和图 5中的挤压辊 202 ) 。 从图 6可看出， 在挤压辊 210的辊 筒 212上设置有朝向挤] ΐ辊 210的内部凹陷的狭长形的凹部 213。通过挤压辊 210 来挤压导光板原材料 101， 可以制备具有厚度变化的导光板 （例如图 3所示的导 光板 20) 。 参照图 6, 凹部 213沿周向完全环绕挤压辊 210的辊筒 212, 旦凹部 213的延伸方向与挤压辊 210的中心转轴 2 〗垂直。 换句话说， 凹部 2 3沿着辊 筒 212的周向延伸一圈。
从图 6可清楚地看出， 狭长的凹部 213位于辊筒 2】2的轴向端部处。 根据具 体的生产尺寸和型号需求， 可以在辊筒 212的一个轴向端部处或 ¾个轴向端部处 设置凹部 213。 在凹部 213处， 辊筒 212的径向尺寸显然小于辊筒 212的其余部 分。 即辊筒 212在位于其轴向端部的凹部 213处的直径 D2小亍辊筒 212其余部 分的直径 Dt。 凹部 213还具有轴向宽度为 L的具有一定斜度的侧壁 214， 在图
6中， 通过虚线划定了凹部 213的侧壁 214。
图 7显示了根据本发明的 ^于制造导光板的设备的第一实施例的导光板 300 的成品。 可以看出， 导光板 300具有较薄区域 30 和较厚区域 302, 在较薄区域 301 和较厚区域 302之间还具有有一定倾斜度的斜坡区域 303。 图中用阴影线表 示的箭头 A显示了作用于导光板 300的挤压辊的辊筒的转动方向。
图 8显示了图 7中的导光板的侧视图。 图 8中通过两条虚线划定了斜坡区域 303。 容易理解， 挤压辊 210的辊筒 212与导光板 300的相应表面之间是凹凸配 合的。 可以对应参照图 6和图 8, 辊筒 212的宽径部分 （非凹部的区域） 对应导 光板 300的较薄区域 301 , 辊筒 212的凹部 213对应导光板 300的较厚区域 302, 辊筒 212的侧壁 214对应导光板 300的斜坡区域 303。
在尺寸方面， 辊筒 2】2 的尺寸与目标楔形导光板 300 的尺寸也是相关联的 Di-Ds^xs Ti-Ta). 其中 I 为辊筒 212的宽径部分的直径， 1)2为辊筒 212在凹部 213处的直径。 ^为导光板 300的较厚区域的厚度， T2为导光板 300的较薄区域 的厚度。 当然， 该尺寸关系等式仅仅为理论值， 本领域技术人员容易理解， 在实 际工艺生产中产品尺寸当然会具有一定公差。 另一方面， 辊筒 212的凹部 213的 侧壁 214在轴向方向上的宽度 L与导光板 300的斜坡区域 303在轴向方向上的宽 度 W相同。
再次参照图 5 , 在第一实施例中， 所制造的导光板 300的楔形凸出部 （较厚 区域 302 ) 沿着导光板材料 10 的推进方向延伸， 辊 ϊΐ成型之后 以利用成型机 台对所得到的导光板 300的沿机器推进方向 (MD)的边缘进行裁切抛光， 以进一步 实现使成品导光板 300的入光侧包含有楔形凸出结构。
图 9显示了根据本发明的用于制造导光板的设备的第二实施例的挤压辊 4 0。 在第二实施例中， 设备的大部分结构与图 4和图 5所示的第一实施例相同， 此处 不再详细介绍。 其与第一实施例的显著区别在于， 在第二实施例中， 替代于图 6 所示的挤压辊 210,采用图 9所示的挤压辊 410来作为图 4和图 5中的挤压辊 202。
从图 9可看出， 在挤压辊 410的辊筒 412上设置有朝向挤压辊 410的内部凹 陷的狭长形的凹部 413和凹部 415。 其中凹部 413位于辊筒 412的轴 | 端部处， 而凹部 415位于辊筒 412的轴向中央处。
通 ϋ挤压辊 410来挤压导光板原材料 101， 可以制备具有厚度变化的导光板
(：例如图 3所示的导光板 20 ) 。 参照图 9 , 凹部 4！ 3和凹部 415沿周向完全环绕 挤压辊 410的辊筒 412， 凹部 413、 凹部 415的延伸方向与挤压辊 410的中心 转轴 411垂直。 换句话说， 凹部 413、 凹部 415均沿着辊筒 412的周向延伸一圈。
在凹部 413和凹部 4】5处， 辊筒 412的径向尺寸显然小亍辊筒 412的其余部 分。 即辊筒在位亍其轴向中部的凹部 415处的直径 1)2小亍辊筒 4】2的非凹部处 的直径 D
图 10 显示了根据本发明的用于制造导光板的设备的第二实施例的导光板成 品 500。 容易理解， 挤压辊 410的辊筒 412与导光板 500的相应表面之间是凹凸 配合的。 可以对应参照图 9和图 10, 辊筒 412的宽径部分 （非凹部的区域）对应 导光板 500的较薄区域 501， 辊筒 412的位于轴向端部处的凹部 413对应导光板 500的位于边缘处的较厚区域 502, 而辊筒 412的位于轴向中央处的凹部 415对 应导光板 500的位于中央处的较厚区域 505。
当辊筒 412的轴向长度大亍导光板的相应需求长度的 2倍以上^ , 即可采用 第二实施例，即在辊筒 4】2的轴向中央处设置沿垂直于挤压辊 410的中心转轴 411 的方向而延伸的狭长凹部 415 , 凹部 415环绕辊筒 412—周。
当然, 第一实施例和第二实施例中的凹部的数量和位置仅仅是示例性的， 并 非是限定性的。 根据辊筒的轴向长度和所需求的导光板的相应尺 t 可以对挤压 辊的辊筒上的狭长凹部的数量和位置进行调试， 在辊筒上也可等距离间隔地设置 多个垂直于中心转轴且环绕辊筒一周的狭长凹部。 具体地， 该狭长凹部可以是横 截面为梯形的狭槽。
图 11 显示了根据本发明的用于制造导光板的设备的第：三实施 ί到的侧视图。 从图 11可看出， 第三.实施例中的设备 60首先包括供料单元 100。 进一步地， 设 备 60还包括挤压单元， 该挤压单元包括用于输送导光板原材料 101 的输送辊和 用于挤压原材料 10〗的挤压辊。 在图 I I所示的第:三实施例中， 设备 60具有输送 辊 601、 输送辊 603和输送辊 604， 同 Β寸具有挤压辊 602。 为了方便作业， 输送辊
601、 输送辊 603和输送辊 604位于原材料 101的一侧， 而挤压辊 602单独地位 于原材料 101的另一侧。 在与挤压辊 602相对应的位置处设置有与其配合的输送 辊 601 , 挤压辊 602和输送辊 601形成对辊， 以共同完成对原材料 101的挤压作 (稍后将详细介绍） ， 之后挤压辊 602和输送辊 603再次形成对辊， 而输送辊 604则主要执行对原材料 101的运输功能。
图 11中进一步用箭头标示了输送辊 601、 输送辊 603、 输送辊 604和挤] ΐ辊 602的转动方向。 由图 11可看 m， 在挤压单元（在第：三实施例中其由输送辊 601、 输送辊 603、 输送辊 604和挤压辊 602构成） 中， 所有的挤压辊和输送辊的辊筒 的旋转方向都与原材料 101 的推进方向一致。 在图 11中， 原材料 10〗 由左至右 推进， 位于原材料〗01—侧的输送辊 601、 输送辊 603和输送辊 604均为顺时针 转动， 位于原材料 101另一侧的挤压辊 602逆时针转动， 使得整个系统中瞬时滚 动接触的部位均朝向相同的方向运动。
由图 11可看到， 设备 60还包括切割单元 630, 切割单元 630用于切割由挤 压单元所导出的导光板 600。 容易理解， 原材料 101在经过挤压单元的挤压工艺 处理后， 已经成为具有目标形状的导光板 600， 只是此刻导光板 600的尺寸较大。 还需要通过切割单元 630将其切割成与特定型号的液晶显示器相匹配的尺寸。 图 12 显示了根据本发明的用于制造导光板的设备的第 实施例的挤压辊的 辊筒的立体图。 在第 实施例中， 采用图 12所示的挤压辊 6】0来作为图 11所示 的设备 60的挤压辊 602。
从图 12可看出， 在挤压辊 610的辊筒 61 上设置有狭长的凹部 612。 凹部
612沿辊筒 61 1的轴向方向从辊筒 611的一个轴向端部延伸至另一个轴向端部。 狭长的凹部 612的延伸方向与挤压辊 610的中心转轴平行。 图 12中未示出中心 转轴， 当然本领域技术人员了解中心转轴通常位于辊筒的中心轴线上。
图 13显示了图 12中的挤压辊 610的辊筒 611的沿其轴向观测的侧视图。 从 图 13可进一步看出，辊筒 611具有朝向挤压辊 610的内部（即朝向中心转轴 613 ) 凹陷的狭长形的凹部 612。 优选地， 凹部 612的横截面为扇形， 凹部 612的侧壁 构成扇形的腰， 且开口的一边构成扇形的长 。 如此地， 通过凹部 612挤压而得 到的位于导光板上的凸出部 （较厚区域） 的形状为楔形。
图 14显示了图 13中的挤压辊 610的辊筒 6Π与所获得的导光板的尺寸关系。 其中上方为图 13中的挤压辊 610的辊筒 611的沿其轴向观测的侧视图， 而下方 显示了通过挤压辊 610所获得的导光板的侧视图。
首先参照图 14中的挤压辊,辊筒的凹部处的半径 小于辊筒的其余部分（非 凹部处） 的半径 Rt。 而另一方面， 容易理解， 挤压辊的辊筒与导光板的相应表面 之间是凹凸配合的。 辊筒的其余部分 （非凹部的区域） 对应导光板的较薄区域， 而辊筒的凹部对应导光板的较厚区域。因此导光板的较厚区域的厚度 T3大于导光 板的较薄区域的厚度 Τ2。
在尺寸方面， 辊筒的尺寸与目标楔形导光板的尺寸也是相关联的- - 0 Τ2。 其中 R2为辊筒的凹部处的半径， 为辊筒的其余部分（非凹部处） 的半径； ^为导光板的较厚区域的厚度， T2为导光板的较薄区域的厚度。 当然, 该尺寸关系等式仅仅为理论值， 本领域技术人员容易理解， 在实际工艺生产中产 品尺寸当然会具有一定公差。 在如图所示的情况中， 辊筒在凹部和非凹部之间还 具有有一定斜度的侧壁， 而所制造的相应的导光板在较薄区域和较厚区域之间也 具有有一定倾斜度的斜坡区域， 容易理解侧壁的周向尺寸与导光板的斜面区域的 在相应方向上的尺寸也是相等的。
再次参照图 11 , 当导光板大板 600冷却后， 切割单元 630沿着楔形凸出部 705 (较厚区域） 进行裁切， 以得到在入光侧具有楔形凸出部 （较厚区域） 的具 有特定尺寸的导光板大板。 后续再经过成型抛光即可应用于显示器。
图 15显示了根据本发明的用于制造导光板的设备的第≡实施例的替换布局。 在图 15所示的设备 80中， 大部分都与图 11所示的设备 60类似， 不再赘述。 其 显著区别是输送辊的数量和位置。 可以看到， 在图 15 中， 设置有四个输送辊， 即输送辊 801、 输送辊 803、 输送辊 804和输送辊 805， 同时还设置有具有凹槽 714 的挤压辊 806。 其中所有的输送辊和挤压辊不再位亍同一水平面上， 输送辊 801与挤压辊 806位于相对靠上的位置，它们形成对辊，协同对导光板原村料 101 进行挤压作用。 之后挤压辊 806与输送辊 803再次形成对辊。 而输送辊 804和输 送辊 805主要发挥运输作用。 切割单元 730进行切割。
图 16 显示了根据本发明的用于制造导光板的设备的第四实施例的挤压辊。 在第四实施例中， 设备的大部分结构与图 11 所示的第:三实施例相同， 此处不再 详细介绍。 其与第三实施例的显著区别在于， 在第四实施例中， 替代于图 12 所 示的挤压辊 610， 采用图 16所示的挤压辊 910来作为图 1中的挤压辊 602。
挤压辊 910包括中心转轴 914和辊筒 911， 在辊筒 911上设置有两个狭长形 的凹部 913。 凹部 913沿辊筒 911的轴向方向从辊筒 911的一个轴向端部延伸至 另一个轴向端部。
当然， 作为第四实施例的延伸， 挤压辊的辊筒可以具有多个沿轴 | 延伸的狭 长凹部， 且这多个凹部在挤压辊的辊筒的周 | 上等距离间隔分布。
凹部的数量 以考虑辊筒的周长和要生产的导光板的相应尺寸来决定-
( 1 ) 以 55英寸的短边入光的导光板为例， 其长边的长度约为 1240mm; 相 应地， 成型辊筒的直径为 400mm (周长约 1260mm) ， 则只需在辊筒上设置一条 沿轴向延伸的狭长凹部， 即可以实现短边入光侧具有楔形凸出结构的导光板。
(2 )以 32英寸的短边入光的导光板为例， 相应的成型辊筒的直径为 500mm (周长约 1570mm ) ， 需要生产楔形导光板时， 则可以在该成型辊筒上设置 2条 沿轴向延伸的狭长凹部 （间隔 80° 相对设置） ， 如此可以保证辊压一圈生产出 两排短边入光侧具有楔形凸出结构的导光板。
当然， 必要的情况下， 第一、 二实施例和第三、 四实施例中的狭长凹部的布 置可以结合起来， 以得到所需要的在表面具有凸出部的导光板。
虽然已经参考优选实施例对本发明进行了描述， 但在不脱离本发明的范围的 情况下， 可以对其进行各种改进并且可以用等效物替换其中的部件。 尤其是， 只 要不存在结构冲突， 各个实施例中所提到的各项技术特征均可以任意方式组合起 来。 本发明并不局限于文中公开的特定实施例， 而是包括落入权利要求的范围内 的所有技术方案。

Claims

权利要求书
1. 用于制造导光板的设备， 其中， 包括：
供料单元， 其具有狭缝形的出料口， 用于供给构成导光板的原材料； 挤压单元， 所述挤压单元包括用于输送所述原材料的输送辊和用于挤压所述 原材料的挤压辊； 以及
切割单元， 所述切割单元用于切割所述挤压单元所导出的导光板， 其中， 在所述挤压辊的辊筒上设置有朝向所述挤压辊内部凹陷的狭长凹部， 以制备具有厚度变化的导光板。
2. 根据权利要求 1所述的设备， 其中， 所述输送辊位于所述原材料的一侧， 而所述挤压辊位于所述原材料的另一侧， 且在与所述挤压辊相对应的位置处设置 有与其配合的输送辊。
3. 根据权利要求 2所述的设备， 其中， 所述设备仅具有一个挤压辊， 且在所 述挤压单元中， 所述挤压辊和所述输送辊的辊筒的旋转方向与所述原材料的推进 方向一致。
4. 根据权利要求 2所述的设备， 其中， 所述凹部沿周向完全环绕所述挤压辊 的辊筒， 且所述凹部的延伸方向与所述挤压辊的中心转轴垂直。
5. 根据权利要求 4所述的设备，其中，所述凹部位于所述辊筒的轴向端部处。
6. 根据权利要求 4所述的设备，其中，所述凹部位于所述辊筒的轴向中央处。
7. 根据权利要求 2所述的设备， 其中， 所述凹部沿轴向从所述挤压辊的辊筒 的一端延伸至另一端， 且所述凹部的延伸方 1 与所述挤压辊的中心转轴平行。
8. 根据权利要求 7所述的设备， 其中， 在一个挤压辊上， 多个所述凹部在所 述挤压辊的辊筒的周向上等距离间隔分布。
9, 根据权利要求 7所述的设备， 其中， 所述凹部的横截面为扇形， 其侧壁构 成所述扇形的腰， 且开口的一边构成所述扇形的长弧。
10 根据权利要求 8 所述的设备， 其中， 所述凹部的横截面为扇形， 其侧壁 构成所述扇形的腰， 且开口的一边构成所述扇形的长弧。
11. 根据权利要求 7所述的设备， 其中， 所述挤压单元所导出的导光板具有 相对薄的区域和相对厚的区域， 所述切割单元在所述相对厚的区域处对所述导光 板进行切割。 2, 根据权利要求 8所述的设备， 其中， 所述挤压单元所导出的导光板具有 相对薄的区域和相对厚的区域， 所述切割单元在所述相对厚的区域处对所述导光 板进行切割。
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