WO2016106833A1 - 一种制造导光板的方法 - Google Patents

一种制造导光板的方法 Download PDF

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Publication number
WO2016106833A1
WO2016106833A1 PCT/CN2015/070548 CN2015070548W WO2016106833A1 WO 2016106833 A1 WO2016106833 A1 WO 2016106833A1 CN 2015070548 W CN2015070548 W CN 2015070548W WO 2016106833 A1 WO2016106833 A1 WO 2016106833A1
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WIPO (PCT)
Prior art keywords
light guide
mold
guide plate
smooth surface
light
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Ceased
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PCT/CN2015/070548
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English (en)
French (fr)
Inventor
郑颖博
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TCL China Star Optoelectronics Technology Co Ltd
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Shenzhen China Star Optoelectronics Technology Co Ltd
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Application filed by Shenzhen China Star Optoelectronics Technology Co Ltd filed Critical Shenzhen China Star Optoelectronics Technology Co Ltd
Priority to US14/417,829 priority Critical patent/US20160245985A1/en
Publication of WO2016106833A1 publication Critical patent/WO2016106833A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • 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
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00663—Production of light guides
    • 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
    • G02B6/004—Scattering dots or dot-like elements, e.g. microbeads, scattering particles, nanoparticles
    • G02B6/0043—Scattering dots or dot-like elements, e.g. microbeads, scattering particles, nanoparticles provided on the surface of the light guide
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
    • G03F7/004—Photosensitive materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2033/00—Use of polymers of unsaturated acids or derivatives thereof as moulding material
    • B29K2033/04—Polymers of esters
    • B29K2033/12—Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2905/00—Use of metals, their alloys or their compounds, as mould material
    • B29K2905/08—Transition metals
    • B29K2905/12—Iron
    • 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
    • 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
    • G02F1/133611—Direct backlight including means for improving the brightness uniformity
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
    • G03F7/26—Processing photosensitive materials; Apparatus therefor
    • G03F7/42—Stripping or agents therefor
    • G03F7/422—Stripping or agents therefor using liquids only

Definitions

  • the invention belongs to the technical field of liquid crystal screens, and in particular to a method for manufacturing a light guide plate of a liquid crystal panel.
  • the light guide plate is mainly used to convert the line light source emitted by the light source into a surface light source, so that the brightness of the display screen of the liquid crystal screen is uniform.
  • the existing light guide plate is generally made of polymethyl methacrylate (abbreviated as PMMA) or polycarbonate (abbreviated as PC), and the polymethyl methacrylate or polycarbonate is shot by injection molding.
  • PMMA polymethyl methacrylate
  • PC polycarbonate
  • the light guide plate is inserted into the light guide plate mold and then cured under high pressure to form a light guide plate.
  • a light-weight light guide plate is manufactured by an injection molding method, in particular, a light guide plate having a thickness of less than 0.3 mm is produced, it is necessary to inject polymethyl methacrylate or polycarbonate into the light guide plate mold using an ultrahigh pressure. Under normal circumstances, the existing injection molding apparatus is difficult to achieve such an ultra-high pressure, resulting in a thicker thickness of the existing light guide plate.
  • an object of the present invention is to provide a method of manufacturing a light guide plate which can manufacture a light and thin light guide plate, improve the toughness of the light guide plate, and enhance the bending performance of the light guide plate, thereby promoting the development of the flexible liquid crystal panel.
  • the present invention provides a method of manufacturing a light guide plate comprising: constructing a mold core for forming an optical dot of a light guide plate on a smooth surface of the mold; and coating a photosensitive adhesive on a smooth surface having a mold core to form a photosensitive adhesive layer; exposing the photosensitive adhesive layer to form a light guiding plate; and detaching the light guiding plate from the mold.
  • the ultra-thin photosensitive layer can be easily formed by the coating method, and the ultra-thin photosensitive layer can be cured to form a light and thin light guide plate, thereby improving the toughness of the light guide plate and strengthening the bending property of the light guide plate, thereby Promote the development of flexible LCD screens.
  • the photoresist comprises an acrylic resin and a photosensitizer, wherein the acrylic resin has a solid content of more than 95%. It is verified by experiments that when the solid content of the acrylic resin is more than 95%, the shrinkage amount of the photosensitive adhesive layer during the conversion into the light guide plate is relatively small, and the thickness of the manufactured light guide plate is not uneven.
  • the photoresist layer is exposed using parallel light that vertically illuminates the smooth surface. Thereby, it is possible to ensure uniform density of the manufactured light guide plate.
  • the parallel light is ultraviolet parallel light. Since ultraviolet light has a better excitation effect, it can accelerate the polymerization reaction, shorten the curing time, and improve the production efficiency.
  • the acrylic resin is methyl methacrylate.
  • the photosensitizer can promote the polymerization reaction of the photosensitive adhesive containing methyl methacrylate, and the polymethyl methacrylate which is polymerized into a polymer chain from a low molecular group, the abbreviation is PMMA.
  • the light guide plate formed in this way can have better toughness and higher spectral transmittance, thereby improving the optical performance of the light guide plate and promoting the development of the flexible liquid crystal panel.
  • the mold is used to infuse the mold and the light guide plate to completely separate the light guide plate from the mold. Demolding in this manner can prevent damage to the light guide plate.
  • the mold release liquid is hydrochloric acid, nitric acid or sulfuric acid
  • the mold is a plate made of steel or pure iron. Since the acid resistance of the polymethyl methacrylate light guide plate is stronger than that of the iron or steel mold, hydrochloric acid, nitric acid or sulfuric acid can ensure the safety of the light guide plate when the mold is etched, so that the light guide plate can be completely separated from the mold.
  • a set of grooves is formed on the smooth surface of the mold using a point-and-click method, the set of grooves being a mold core.
  • a light guide plate dot hitting machine is used to strike the groove group on the smooth surface of the mold.
  • the machining collision point method has the advantages of simple and reliable, fast processing, and suitable for mass production, thereby improving the production efficiency of the light guide plate.
  • the mold is made of 430 stainless steel.
  • the mold made of 430 stainless steel is not easy to rust, thereby ensuring the quality of the manufactured light guide plate. In this way, pre-fabrication of the mold can be achieved without having to wait until needed.
  • the method for manufacturing a light guide plate according to the present invention uses a coating curing method to manufacture a light guide plate, due to a coating method It is easy to form an ultra-thin photosensitive layer, and the ultra-thin photosensitive layer can be cured to form a light and light light guide plate, thereby improving the toughness of the light guide plate and enhancing the bending performance of the light guide plate, thereby promoting the flexible liquid crystal.
  • the development of the screen since the light guide plate manufactured has good toughness, it can be applied to a curved display screen.
  • the method for manufacturing a light guide plate according to the present invention is simple and reliable, has low production cost, high processing efficiency, and is convenient for implementation and popularization.
  • FIG. 1 is a flow chart of a method of manufacturing a light guide plate according to the present invention.
  • Fig. 2 shows a mold used in the method of manufacturing a light guide plate according to the present invention.
  • the present invention provides a method of manufacturing a light guide plate comprising the following steps.
  • a mold core for forming an optical dot of the light guide plate is constructed on the smooth surface of the mold.
  • the mold 2 is substantially in the form of a plate, preferably in the same rectangular plate as the light guide plate.
  • the mold 2 has upper and lower smooth surfaces 21 which are groove groups 21a formed on any one of the smooth surfaces 21 for forming optical dots of the light guide plate.
  • the lines of the respective grooves in the groove group 21a are similar to the screen.
  • the optical mesh point is a reflection point on the bottom of the light guide plate, and the structure of the reflection point is well known to those skilled in the art and will not be described in detail herein.
  • a photosensitive adhesive (also referred to as a photosensitive emulsion or a photoresist) is coated on the smooth surface 21 having the mold core to form a photosensitive adhesive layer.
  • the coating method includes spraying, brushing, and brushing.
  • the ultra-thin photosensitive layer can be easily formed by the coating method, and the ultra-thin photosensitive layer can be cured to form a light and light light guide plate, thereby improving the toughness of the light guide plate and strengthening the bending property of the light guide plate, thereby Can promote the development of flexible LCD screens.
  • step S3 the photosensitive adhesive layer is exposed to form a light guide plate.
  • the photosensitive layer is capable of undergoing polymerization under exposure to form a solid light guide.
  • step S4 the light guide plate is detached from the mold.
  • the light guide plate can be completely separated from the mold by heating or by using a mold release liquid.
  • a light and thin light guide plate can be made, the toughness of the light guide plate can be improved, the bending performance of the light guide plate can be enhanced, and the development of the flexible liquid crystal panel can be promoted.
  • the light guide plate manufactured since the light guide plate manufactured has good toughness, it can be applied in a curved display screen.
  • the photoresist comprises an acrylic resin and a photosensitizer, wherein the acrylic resin has a solid content of more than 95%. It is verified by experiments that when the solid content of the acrylic resin is more than 95%, the shrinkage amount of the photosensitive adhesive layer during the conversion into the light guide plate is relatively small, and the thickness unevenness of the manufactured light guide plate is not caused.
  • the acrylic resin is preferably methyl methacrylate. Under exposure conditions, the photosensitizer can promote the polymerization of the photosensitive adhesive containing methyl methacrylate, and the polymethyl methacrylate polymerized from a low molecular group into a polymer chain, the English name is reduced to PMMA.
  • the light guide plate formed in this way can have better toughness and higher spectral transmittance, thereby improving the optical performance of the light guide plate and promoting the development of the flexible liquid crystal panel.
  • the photosensitizer is well known to those skilled in the art and will not be described in detail herein.
  • the photoresist layer may be exposed using parallel light that vertically illuminates the smooth surface to ensure uniform density of the formed light guide plate.
  • the parallel light is preferably ultraviolet parallel light. Under normal circumstances, ultraviolet light has a better excitation effect, can accelerate the polymerization reaction, shorten the polymerization time, and improve the production efficiency.
  • the mold is a sheet of steel, pure iron or other hard material. Molds made of steel or pure iron facilitate demolding, such as the use of acids to corrode steel or pure iron molds for easy removal of the light guide. In a preferred embodiment.
  • the mold can be made of 430 stainless steel to prevent the mold from rusting and affect the quality of the light guide plate.
  • the mold release liquid can be used to infuse the mold and the light guide plate to completely separate the light guide plate from the mold.
  • the choice of mold release liquid is related to the material of the mold.
  • iron or steel mold can be used for hydrochloric acid, nitric acid or sulfuric acid, etc., which can corrode the mold and not corrode the acid of the light guide plate to corrode the mold, so that the light guide plate can be easily and completely removed. .
  • the light guide plate of polymethyl methacrylate is highly resistant to acid, and the iron or steel mold is easily corroded by acid, hydrochloric acid, nitric acid or sulfuric acid can ensure the safety of the light guide plate when the mold is etched, so that the light guide plate can be completed. Detach the mold without damage.
  • the selected hydrochloric acid, nitric acid or sulfuric acid is a dilute acid.
  • the mold core is a groove set, and the groove set can be formed by a bump point method.
  • Hit the square The type can be manufactured either manually or by machining.
  • a light guide plate dot hitting machine is used to strike a groove group on a smooth surface of a steel plate or a pure iron plate.
  • the machining collision point method has the advantages of simple and reliable, fast processing and suitable for mass production, thereby improving the production efficiency of the light guide plate.
  • the light guide plate dot impact point machine is well known to those skilled in the art, and is not described in detail herein for the sake of space saving.
  • the light guide plate can be manufactured by the method for manufacturing a light guide plate according to the present invention, whereby the toughness of the light guide plate can be improved, the bending performance of the light guide plate can be enhanced, and the development of the flexible liquid crystal panel can be promoted.

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Manufacturing & Machinery (AREA)
  • Health & Medical Sciences (AREA)
  • Ophthalmology & Optometry (AREA)
  • Mechanical Engineering (AREA)
  • Planar Illumination Modules (AREA)
  • Light Guides In General And Applications Therefor (AREA)
  • Liquid Crystal (AREA)

Abstract

一种制造导光板的方法，其包括：在模具(2)的平滑表面(21)上构造出用于形成导光板的光学网点的模仁；在具有模仁的平滑表面(21)上涂布感光胶，形成感光胶层；对感光胶层进行曝光，形成导光板；使导光板从模具(2)上脱离。能够制成出轻薄的导光板，由此能够提高导光板的韧性，强化导光板的弯曲性能，推动柔性液晶屏的发展。

Description

一种制造导光板的方法
相关申请的交叉引用
本申请要求享有于2014年12月31日提交的名称为“一种制造导光板的方法”的中国专利申请CN201410856624.3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
本发明属于液晶屏技术领域，尤其是一种制造液晶屏的导光板的方法。
背景技术
在液晶屏技术领域中，导光板主要用于把光源发出的线光源转换成面光源，以使液晶屏的显示画面的亮度均匀。
现有的导光板一般由聚甲基丙烯酸甲酯(英文名称缩写为PMMA)或聚碳酸酯(英文名称缩写为PC)制成，采用射出成型方法把聚甲基丙烯酸甲酯或聚碳酸酯射入到导光板模具内，然后在高压条件下固化，形成导光板。
当使用射出成型方法制造轻薄的导光板、尤其制造厚度小于0.3mm的导光板时，需要使用超高压把聚甲基丙烯酸甲酯或聚碳酸酯射入到导光板模具内。正常情况下，现有的射出成型装置都难以达到这种超高压，导致现有的导光板的厚度较厚。
然而，由于导光板的厚度严重影响导光板的韧性，从而制约柔性液晶屏的发展，因此急需一种能够制造轻薄的导光板的方法。
发明内容
为了解决上述问题，本发明的目的是提供一种制造导光板的方法，其能够制造出轻薄的导光板，提高导光板的韧性，强化导光板的弯曲性能，从而可以推动柔性液晶屏的发展。
本发明提供了一种制造导光板的方法，其包括：在模具的平滑表面上构造出用于形成导光板的光学网点的模仁；在具有模仁的平滑表面上涂布感光胶，形成 感光胶层；对感光胶层进行曝光，形成导光板；使导光板从模具上脱离。通过这种涂布方式很容易形成超薄的感光胶层，超薄的感光胶层经固化后可形成轻薄的导光板，由此可以提高导光板的韧性，强化导光板的弯曲性能，从而可以推动柔性液晶屏的发展。
在一个实施例中，感光胶包括丙烯酸树脂和光敏剂，其中丙烯酸树脂的固含量占95％以上。通过实验验证，丙烯酸树脂的固含量大于95％时，感光胶层在转变成导光板过程中的收缩量比较小，不会引起制造的导光板的厚度不均。
在一个实施例中，利用垂直照射平滑表面的平行光对感光胶层进行曝光。由此，可以确保制造的导光板的致密度均匀。
在一个实施例中，平行光为紫外线平行光。由于紫外光具有更好的激发效果，因此其能加速聚合反应，缩短固化时间，提高生产效率。
在一个实施例中，丙烯酸树脂为甲基丙烯酸甲酯。在曝光条件下，光敏剂能够促使含有甲基丙烯酸甲酯的感光胶进行聚合反应，从低分子团聚合成高分子链的聚甲基丙烯酸甲酯，英文名称缩写为PMMA。通过这种方式形成的导光板能够具有较好韧性和较高的光谱穿透率，从而提高导光板的光学性能，推动柔性液晶屏的发展。
在一个实施例中，利用脱模液侵泡模具和导光板，使导光板完整地脱离模具。采用这种方式脱模能够避免导光板受到损伤。
在一个实施例中，脱模液为盐酸、硝酸或硫酸，而模具为钢铁或纯铁制成的板件。由于聚甲基丙烯酸甲酯的导光板的耐酸性强于铁质或钢质的模具，因此盐酸、硝酸或硫酸能够在腐蚀模具时确保导光板的安全，使得导光板能够完整无损地脱离模具。
在一个实施例中，使用撞点方式在模具的平滑表面上构造出凹槽组，所述凹槽组为模仁。例如，使用导光板网点撞点机在模具的平滑表面上撞击出凹槽组。这种机加工撞点方式具有简单可靠、加工快速、适用于大批量生产的优点，从而能够提高导光板的生产效率。
在一个实施例中，模具由430不锈钢制成。430不锈钢制成的模具不易生锈，由此可以保证制造出的导光板的质量合格。通过这种方式，可以实现模具的提前预制，不必等到需要时再进行制造。
根据本发明的制造导光板的方法采用涂布固化方式制造导光板，由于涂布方 式很容易形成超薄的感光胶层，而超薄的感光胶层经固化后便可形成轻薄的导光板，由此可以提高导光板的韧性，强化导光板的弯曲性能，从而可以推动柔性液晶屏的发展。同时，由于制造出的导光板具有较好的韧性，因此其可应用在弧形显示屏内。
另外，根据本发明的制造导光板的方法简单可靠，生产成本低廉，加工效率较高，便于实施推广应用。
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为根据本发明的制造导光板的方法的流程图；以及
图2显示了根据本发明的制造导光板的方法中所使用的模具。
在附图中相同的部件使用相同的附图标记。附图并未按照实际的比例绘制。
具体实施方式
以下将结合附图及实施例来详细说明本发明的实施方式，借此对本发明如何应用技术手段来解决技术问题，并达成技术效果的实现过程能充分理解并据以实施。需要说明的是，只要不构成冲突，本发明中的各个实施例以及各实施例中的各个特征可以相互结合，所形成的技术方案均在本发明的保护范围之内。
如图1所示，本发明提供了一种制造导光板的方法，其包括以下步骤。
步骤S1，在模具的平滑表面上构造出用于形成导光板的光学网点的模仁。如图2所示，模具2大致呈板状，优选成与导光板形成相同的矩形板。模具2具有上下两个平滑表面21，模仁是形成在任意一个平滑表面21上的凹槽组21a，以用于形成导光板的光学网点。在凹槽组21a内各个凹槽的连线类似于筛网。其中，所述的光学网点是处于导光板的底部上的反射点，而反射点的结构属于本领域技术人员熟知的，在此不作详细描述。
步骤S2，在具有模仁的平滑表面21上涂布感光胶(又称感光乳胶或光致抗蚀剂)，形成感光胶层。所述涂布方式包括喷涂、滚刷和涂刷。通过这种涂布方式很容易形成超薄的感光胶层，超薄的感光胶层经固化后可形成轻薄的的导光板，由此可以提高导光板的韧性，强化导光板的弯曲性能，从而可以推动柔性液晶屏的发展。
步骤S3，对感光胶层进行曝光，形成导光板。感光胶层在曝光下能够进行聚合反应，从而形成固态的导光板。
步骤S4，使导光板从模具上脱离。其中，可利用加热方式或使用脱模液侵泡方式，使导光板完整地脱离模具。
由此可知，通过这种方法能够制成出轻薄的导光板，提高导光板的韧性，强化导光板的弯曲性能，进而推动柔性液晶屏的发展。同时，由于制造出的导光板具有较好的韧性，因此其可应用在弯曲显示屏内。
在一个实施例中，感光胶包括丙烯酸树脂和光敏剂，其中丙烯酸树脂的固含量占95％以上。通过实验验证，丙烯酸树脂的固含量大于95％时，感光胶层在转变成导光板过程中的收缩量比较小，不会引起制造出的导光板的厚度不均。其中，丙烯酸树脂优选为甲基丙烯酸甲酯。在曝光条件下，光敏剂能够促使含有甲基丙烯酸甲酯的感光胶进行聚合反应，从低分子团聚合成高分子链的聚甲基丙烯酸甲酯，其英文名称缩为PMMA。通过这种方式形成的导光板能够具有较好韧性和较高的光谱穿透率，从而提高导光板的光学性能，推动柔性液晶屏的发展。其中，所述的光敏剂属于本领域技术人员熟知的，在此不作详细描述。
在一个实施例中，可利用垂直照射平滑表面的平行光对感光胶层进行曝光，以便确保形成的导光板的致密度均匀。其中，所述的平行光优选为紫外线平行光。通常情况下，紫外光具有更好的激发效果，能够加速聚合反应，缩短聚合时间，提高生产效率。
在一个实施例中，模具是由钢铁、纯铁或其他硬质材料的板件。采用钢铁或纯铁制造的模具有利于脱模，比如使用酸类可以腐蚀钢铁或纯铁制造的模具，从而方便取出导光板。在一个优选的实施例中。所述的模具可采用由430不锈钢制成，以防止模具生锈，影响导光板的质量。
在步骤S4中，可利用脱模液侵泡模具和导光板，使导光板完整地脱离模具。脱模液的选择与模具材质有关，例如铁质或钢质的模具可选用于盐酸、硝酸或硫酸等能腐蚀模具而不易腐蚀导光板的酸来腐蚀模具，从而可以轻松、完整地取出导光板。由于聚甲基丙烯酸甲酯的导光板的耐酸性强，而铁质或钢质的模具容易被酸腐蚀，因此盐酸、硝酸或硫酸能够在腐蚀模具时确保导光板的安全，使得导光板能够完整无损地脱离模具。优选地，所选用的盐酸、硝酸或硫酸均为稀酸。
在一个实施例中，模仁为凹槽组，凹槽组可采用撞点方式制造成形。撞点方 式既可以采用人工方式制造，也可以采用机加工方式制造。例如，使用导光板网点撞点机在钢板或纯铁板的平滑表面上撞击出凹槽组。这种机加工撞点方式具有简单可靠、加工快速和适用于大批量生产的优点，从而能够提高导光板的生产效率。其中，所述的导光板网点撞点机属于本领域技术人员熟知的，为了节约篇幅在此不作详细描述。
综上可知，利用根据本发明的制造导光板的方法能够制成出轻薄的导光板，由此能够提高导光板的韧性，强化导光板的弯曲性能，进而推动柔性液晶屏的发展。
虽然本发明所公开的实施方式如上，但所述的内容只是为了便于理解本发明而采用的实施方式，并非用以限定本发明。任何本发明所属技术领域内的技术人员，在不脱离本发明所公开的精神和范围的前提下，可以在实施的形式上及细节上作任何的修改与变化，但本发明的专利保护范围，仍须以所附的权利要求书所界定的范围为准。

Claims (15)

  1. 一种制造导光板的方法，包括：
    在模具的平滑表面上构造出用于形成导光板的光学网点的模仁；
    在具有所述模仁的所述平滑表面上涂布感光胶，形成感光胶层；
    对所述感光胶层进行曝光，形成导光板；以及
    使所述导光板从所述模具上脱离。
  2. 根据权利要求1所述的方法，其中，所述感光胶包括丙烯酸树脂和光敏剂，其中所述丙烯酸树脂的固含量占95％以上。
  3. 根据权利要求2所述的方法，其中，利用垂直照射所述平滑表面的平行光对所述感光胶层进行曝光。
  4. 根据权利要求3所述的方法，其中，所述平行光为紫外线平行光。
  5. 根据权利要求4所述的方法，其中，所述丙烯酸树脂为甲基丙烯酸甲酯。
  6. 根据权利要求5所述的方法，其中，利用脱模液侵泡所述模具和导光板，使所述导光板完整地脱离所述模具。
  7. 根据权利要求6所述的方法，其中，所述脱模液为盐酸、硝酸或硫酸，所述模具为钢铁或纯铁制成的板件。
  8. 根据权利要求7所述的方法，其中，使用撞点方式在所述模具的平滑表面上构造出凹槽组，所述凹槽组为所述模仁。
  9. 根据权利要求8所述的方法，其中，使用导光板网点撞点机在模具的平滑表面上撞击出所述凹槽组。
  10. 根据权利要求9所述的方法，其中，所述模具由430不锈钢制成。
  11. 根据权利要求1所述的方法，其中，利用脱模液侵泡所述模具和导光板，使所述导光板完整地脱离所述模具。
  12. 根据权利要求11所述的方法，其中，所述脱模液为盐酸、硝酸或硫酸，所述模具为钢铁或纯铁制成的板件。
  13. 根据权利要求12所述的方法，其中，使用撞点方式在所述模具的平滑表面上构造出凹槽组，所述凹槽组为所述模仁。
  14. 根据权利要求13所述的方法，其中，使用导光板网点撞点机在模具的平滑表面上撞击出所述凹槽组。
  15. 根据权利要求14所述的方法，其中，所述模具由430不锈钢制成。
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