TWI465328B - Punching the polymer resin sheet to complete the bright and high light transmission of the cutting method - Google Patents

Description

Punching cut polymer resin sheet to complete bright and high light transmissive cutting surface method

The invention provides a punching and cutting method for punching a polymer resin sheet to complete a bright and high light transmittance, which is a punching device provided with a heating device and heats the punching cutter, and is rushed through the heating process. The method of melting the cut surface can obtain a bright cut surface with high light transmittance, and can effectively improve the light transmission and conduction efficiency.

The performance of the backlight module affects the overall quality of the display. The backlight module combined with different optical components must be carefully considered in terms of material selection, optical physical structure design, and heat dissipation. Several important components that make up the backlight module include a light source, a module frame, a reflection sheet, a light guide plate (LGP), a diffusion sheet, and a diaphragm. The optical principle is utilized to enable the backlight module to utilize the light source with maximum efficiency and provide a uniform plane. light source. At present, there are two main methods for producing optical light guiding elements:

Method 1: Please refer to the eighth figure, which is a schematic diagram of a general television or computer LCD screen, which comprises an optical light guiding component (60), and the side of the optical light guiding component (60) is an incident light end face (600). a light source (61) having a reflector (610) disposed at the incident light end face (600); a white reflective sheet (62) beneath the optical light guiding member (60) ), located above the optical light guiding element (60), in order, a lower diffusion sheet (63), a light collecting sheet (64), and an upper diffusion sheet ( 65) and a liquid crystal panel (66), wherein the optical light guiding element (60) is formed by a computer numerical control (CNC) processing method, and must pass through multiple processing procedures: cutting and milling are required The specification of the shape, and then the grinding and polishing process makes the smooth incident light end face (600), which can effectively improve the light transmission efficiency.

Method 2: Please refer to the ninth figure, which is a schematic diagram of a liquid crystal screen of a notebook computer of generally 17 inches or less, which comprises an optical light guiding element (70), and the side of the optical light guiding element (70) is incident light. An end face (700); a light source (71) having a reflector (710) disposed at the incident light end face (700); a white under the optical light guiding member (70) The reflective sheet (72) is located above the optical light guiding element (70) as a lower diffusion sheet (73), a lower light collecting sheet (74), an upper light collecting sheet (75), an upper diffusion sheet (76), and a liquid crystal. The panel (77), wherein the optical light guiding element (70) is formed by injection molding to obtain a desired specification, and then subjected to a grinding and polishing process to a smooth incident light end face (700). Can effectively improve the light transmission efficiency of light.

The above two production methods are the components of the first molding process, because the end surface of these processes will produce an inconsistent rough surface. When the light source is subjected to the inconsistent refractive surface, the traveling of the light is interfered, and the optical cannot be effectively entered. Light guiding element. And the tradition improves these first rough formations The rough surface method is to reserve the size of the secondary processing in the first molding, and then apply the grinding processing and the polishing processing to the end side surface. This method can make the incident light end surface on the general condition product. The surface is smoother, allowing light that needs to enter the light guiding element to effectively enter the interior of the light guiding element. However, there are still the following shortcomings in the secondary grinding and polishing processes that are used:

First, with the increase of processing procedures, the material and working time will also increase. Furthermore, although the incident light side can be used as the microstructure of the microstructure, it takes a lot of man-hours for each piece of processing, which makes it difficult to mass-produce. In addition to the trend of thinner products, the thinner the material, the higher the difficulty of grinding and polishing. Especially when the thickness of the material to be processed is less than 0.6mm, the difficulty of processing and the cost of working time are more difficult to estimate. .

2. The process of grinding and polishing will produce a large amount of fine dust. These fine dusts not only cause a large amount of contamination on the surface of the workpiece, but also need to increase the subsequent cleaning and cleaning procedures, which not only cause environmental pollution, but also affect the health of the operators. .

Third, in order to cope with the trend of thinning the product, the thinner the material, the use of injection molding method and the use of materials such as PMMA and PC, the materials can not flow in a large area of small slits in the molten state, because The narrow slit causes the resistance of material flow to become larger. When the material is to be filled into the entire mold, the difference between the flow velocity and the temperature will increase, and the pressure will also increase, which will greatly increase the cost of the equipment and the mold.

Fourth, in order to make the optical components thinner, in the injection molding, the temperature difference between the front and the back is large, and the cooling rate of each point is different, so that the thin plate optical component production has serious defects, such as uneven thickness of the injection, incomplete injection, and warp. Problems such as the production of clouds and the generation of cloud blocks have led to a low yield of the injection process, which is difficult to achieve mass production.

5. Injection molding requires a gate. After the gate is demolded, it must still be ground to avoid the formation of serious defects on the rough surface. Through the grinding process, the process will increase, environmental pollution and production cost will increase. .

Therefore, in view of the problems existing in the above-mentioned practices, how to develop an innovative structure that is more ideal and practical, the consumers are eagerly awaiting, and the relevant industry must strive to develop the goal and direction of breakthrough.

In view of this, the inventor has been engaged in the manufacturing development and design experience of related products for many years. After detailed design and careful evaluation, the inventor has finally obtained the practical invention.

Traditional optical light guides for the first time The shaped end side surfaces all produce inconsistent rough surfaces, causing the light source to be affected by this inconsistent refractive surface, causing the travel of the light to be interfered and unable to effectively enter the optical light guiding element. If the secondary grinding process and the polishing process are to be performed, the processing program will be increased, and the material and the working time will also increase, which makes the mass production difficult. Furthermore, grinding and polishing The process will produce a large amount of fine dust, which not only causes a large amount of contamination on the surface of the workpiece, but also needs to increase the subsequent cleaning and cleaning procedures, which not only causes environmental pollution, but also affects the health of the operator.

In order to improve the above problems, the present invention provides The method for punching a polymer resin sheet to complete the bright and high light transmissive cutting surface comprises the following steps: Step 1: placing an optical light guiding element in a punching device before forming, The punching device comprises a multi-functional mold base, a lower mold base, a punching cutter and a heating device, the punching cutter is mounted under the multi-functional mold base, and the optical light guiding component is placed on the punching cutter In the lower mold base; in step two, the heating device is turned on, so that the heating temperature of the heating device can be applied to the working range of the punching cutter and the optical light guiding element, and the heating temperature ranges from 25 ° C to 500 ° C In step 3, the multi-function mold base is moved downward, or the lower mold base is moved upward together with the optical light guiding element until the punching cutter cuts the optical light guiding element, in the punching process. The punching device can effectively control the speed, pressure and distance of the punching cutter; step 4, demoulding; step 5, forming is completed, the multi-function mold base is moved upward or the lower mold base and the optical light guide Components together Operation, so that the punch tool completely out of the optical light guide element, reaches the stop point of the punch apparatus. The invention can obtain the bright and high light transmissive cutting surface by heating in the punching process to bring the punching and cutting surface into a solid cutting surface, thereby effectively improving the light by the bright punching cut surface. Penetration conduction efficiency.

Finished by the method of the present invention The finished product can improve the optical non-uniformity caused by the direct directivity of the LED light source of the backlight module, thereby improving the efficiency of the light output of the light guide plate body and the effective utilization of the light, and at the same time increasing the brightness and quality of the backlight module.

The above-mentioned objects, structures and features of the present invention will be described in detail with reference to the preferred embodiments of the present invention. .

Referring to the first figure, the present invention provides a method for punching a polymer resin sheet to complete a bright and highly transparent punching surface, comprising the following steps: Step 1 (S1): first optical before forming The light guiding element (20) is placed in a punching device (1), and the punching device (1) comprises a multifunctional die holder (11), a lower die holder (12), a punching cutter (13) and a a heating device (15), the punching cutter (13) is mounted under the multi-functional die holder (11), and the optical light guiding member (20) is placed under the punching cutter (13). (12) Above, wherein the punching cutter (13) is a combined forming cutter, wherein the metal blade and the base are respectively fabricated by mechanical processing, and then the plurality of blades and the base are combined into a geometrically shaped cutter; Or the punching cutter (13) can be an integrally formed etching tool, which is first used on the surface of the metal material. Film exposure, development or etching to create a geometric shape on the surface of the metal material, and then use a mechanical processing method to make a sharp blade; or the punching tool (13) can be an integrally formed metal tool, which directly processes the metal material. The method is to make a geometric shape and a sharp blade; Step 2 (S2): opening the heating device (15), so that the heating temperature of the heating device (15) can act on the punching tool (13) and the optical guiding light The working range of the component (20), and the heating temperature ranges from 25 ° C to 500 ° C, wherein the heating device ( 15 ) can be heated by hot fluid circulation (as shown in the first figure), flame heating (as shown in the second figure), Laser heating (such as the third figure), electric heating (such as the fourth figure), infrared heating (such as the fifth figure) or ultrasonic heating (such as the sixth figure), and the heating device (15) further includes a The control device (not shown) can effectively and accurately control the efficiency of energy conversion of the heating device, and can have stable temperature control within the working range of the punching device; Step 3 (S3): Function mold base (11) downward movement or the lower mold base (12) and optics The optical element (20) moves upward together until the punching tool (13) severs the optical light guiding element (20), and the punching device (1) can effectively control the punching device (1). The speed, pressure and distance of the punching tool (13); Step 4 (S4): demoulding, the punching tool (13) is in contact with the optical light guiding element (20) during punching, the punching tool (13) transferring thermal energy to the optical light guiding element (20) to make the optical light guiding element The punched surface of the piece (20) is melted and formed into a bright and highly transparent punching cut surface (200); and step 5 (S5): forming is completed to make the multifunctional mold base (11) upward The action or the lower die holder (12) acts downwardly with the optical light guiding element (20) such that the punching tool (13) completely leaves the optical light guiding element (20) and reaches the punching device (1). Stop point.

The optical light guiding element (20) of the present invention is a polymethylmethacrylate (PMMA), a polycarbonate (polycarbonate, PC) or a polyethylene terephthalate (PET). The light-transmitting material is formed into a thin plate and a film substrate having a thickness of 3.0 mm or less by elongation or die casting.

The punching device used to achieve the above steps should be one of the other features of the present invention, which is a punching device (1). The punching device (1) comprises a multi-function mold base (11), a die holder (12), a punching cutter (13) and a heating device (15), the punching cutter (13) is mounted under the multifunctional mold base (11), and the heating device (15) The heating temperature can be applied to the working range of the punching tool (13).

After the above steps are completed, the optical light guiding element (20) is finally taken out, and the outer material of the geometric shape is discarded, and the optical light guiding element (20) inside has a bright and transparent transparent cutting surface ( 200) Finished product. The following is an analysis of the finished product obtained by the method used in the present invention: the light guide plate is produced by using the polymer resin sheet according to the present invention, and the present invention is used. The method, the step and the equipment are completed to complete the stability test. The stability test results are shown in the seventh figure. When the material is punched at room temperature and under heating, the end surface light guiding measurement results are compared, and the use of the method can be determined. The method of the invention performs cutting, and the light guide plate can greatly enhance the light transmission property. The light guide ratio of the end face made by room temperature die cutting is 0.57, and the optimum light guide angle of the end face finished by the heat punching of this study is 0.73; after the comparison of the light guiding properties of the end face, it is determined that the light guide can be used to enhance the light guide of the end face. To clarify the relationship between the end face and the surface topography of the die-cutting in this study, the surface topography of both end faces at room temperature and the temperature-cutting was observed by a stereo microscope, and it was found that the end face after warming and cutting was significantly more than the chamber. The end face of the die-cutting under warming is flat, and the result that the surface flat appearance is reflected on the light-transmitting property is inferred, resulting in a high light-transmitting property.

The light guide plate manufactured by using the method, the step and the device of the present invention and the light guide plate fabricated into the light end face by a conventional "grinding method" are compared with the original PMMA light guide plate after assembling the LCD backlight module as shown in the following Table 1, wherein the present invention Compared with the original PMMA light guide plate, the optical capacity is 98%, and the optical capacity of the light guide plate made into the optical end face by the traditional "grinding method" is 90%; the light guide plate made by the invention is obviously superior to the conventional "grinding method". "Making a light guide plate into the light end face;

The heating tool punching LGF (3 groups) of the present invention is compared with the Taiwan A company module (see Table 2 below). A1-25 is the original module of company A, 7/8/9 points is the light source entrance surface, S-35-1 ~3 is the heating tool punching LGP (3 groups), as shown in the following table, the heating tool is punched LGP-center luminance is 108.58~111.58%, the heating tool is punched LGP-average luminance is 102.43~107.42%, and the heating tool is punched LGP -1/2/3 point light end brightness is the highest, 7/8/9 point brightness is the lowest, indicating that the total amount of light input by this heating tool die cutting LGP is larger than the original module, the main reason is the entrance end of the light. The brightness and light transmittance are greater than that of the original module. It can be seen from Tables 1 and 2 that the die-cut polymer resin sheet of the present invention has a bright and high light transmittance punching surface method, and has been capable of optical capability ( The average brightness is increased to 102.43~107.42%, which is greater than the optical capacity of the original module of A company. It is also larger than the Japanese manufacturer's traditional "grinding method" to make the optical end face, the optical capacity is 98%. This shows the hot-cutting light guide plate. It can be used directly without additional processing.

In summary, the results of the research done by the method of the present invention show that the room temperature die-cutting can reach the room temperature die-cutting compared with the end-face light guiding property of the warming die-cutting. The light guide of the end face is 128%. On the other hand, from the end face which is punched and cut at room temperature, the light guide of the end face after warming and punching is better, the surface undulation is small, and the overall appearance is relatively flat, thus inferring its light entrance and The amount of light emitted is positively correlated with the degree of surface flatness. Therefore, the finished product made by the method of the invention can improve the optical non-uniformity caused by the direct directivity of the LED light source of the backlight module, thereby improving the efficiency of the light output of the light guide plate body and the effective utilization ratio of the light. At the same time, the brightness and quality of the backlight module can be increased.

The foregoing is a detailed description of the technical features of the present invention with respect to preferred embodiments of the present invention; however, those skilled in the art can The invention is subject to change and modifications of the present invention, and such changes and modifications are intended to be included within the scope of the following claims.

. Conventional part:

(60)‧‧‧Optical light guiding elements

(600) ‧‧‧ incident light end face

(61)‧‧‧Light source

(610)‧‧‧reflector

(62)‧‧‧White Reflector

(63) ‧‧‧Diffuser

(64)‧‧‧Sets

(65) ‧‧‧Upper diffuser

(66)‧‧‧ LCD panel

(70)‧‧‧Optical light guiding elements

(700)‧‧‧ incident light end face

(71)‧‧‧Light source

(710) ‧‧‧reflector

(72)‧‧‧White Reflector

(73) ‧‧‧Drops

(74) ‧‧‧ Lower concentrator

(75) ‧‧‧Upset film

(76) ‧‧‧Upper diffusion film

(77)‧‧‧ LCD panel

. Part of the invention:

(1)‧‧‧punching device

(11)‧‧‧Multifunctional mold base

(12) ‧‧‧ lower mold base

(13)‧‧‧Cutting cutter

(15)‧‧‧ heating device

(20)‧‧‧Optical light guiding elements

(200) ‧ ‧ cut surface

(S1)‧‧‧Step one

(S2)‧‧‧Step 2

(S3) ‧ ‧ Step 3

(S4)‧‧‧Step four

(S5) ‧ ‧ step five

First Figure: A schematic diagram of the steps of the method of the present invention.

Second Fig.: A schematic view of a heating device of the present invention is a flame heating embodiment.

Third: The heating device of the present invention is a schematic diagram of a thunder heat heating embodiment.

Figure 4 is a schematic view showing an embodiment of the heating device of the present invention.

Fig. 5 is a schematic view showing an embodiment of the heating device of the present invention which is an infrared heating method.

Fig. 6 is a schematic view showing an embodiment of the heating device of the present invention which is an ultrasonic heating.

Fig. 7 is a graph showing the results of measuring the light guiding property of the end face of the present invention at room temperature and under heating.

The eighth picture is a schematic diagram of the general computer LCD screen decomposition.

The ninth picture is a schematic diagram of the decomposition of the general notebook computer LCD screen.

(1)‧‧‧punching device

(11)‧‧‧Multifunctional mold base

(12) ‧‧‧ lower mold base

(13)‧‧‧Cutting cutter

(15)‧‧‧ heating device

(20)‧‧‧Optical light guiding elements

(200) ‧ ‧ cut surface

(S1)‧‧‧Step one

(S2)‧‧‧Step 2

(S3) ‧ ‧ Step 3

(S4)‧‧‧Step four

(S5) ‧ ‧ step five

Claims (9)

The method for punching a polymer resin sheet to complete a bright and high light transmissive cutting surface comprises the following steps: Step 1: placing an optical light guiding element in a punching device before forming, the punching The cutting device comprises a multi-functional mold base, a lower mold base, a punching cutter and a heating device, the punching cutter is installed under the multi-functional mold base, and the optical light guiding component is placed under the punching cutter The second mold base; step two: opening the heating device, the heating temperature of the heating device can be applied to the working range of the punching cutter and the optical light guiding element, and the heating temperature ranges from 25 ° C to 500 ° C; Step 3: causing the multi-function mold base to move downward or the lower mold base to move upward together with the optical light guiding element until the punching cutter cuts the optical light guiding element, and during the punching process, The speed, pressure and distance of the punching cutter are effectively controlled by the punching device; step 4: demoulding; step 5: forming is completed, the multi-function mold base is moved upward or the lower mold base is combined with the optical light guiding element Down action The punching tool completely out of the optical light guide element, reaches the stop point of the punch apparatus. The punching polymer resin sheet according to the first aspect of the patent application completes the method of punching and cutting surface which is bright and has high light transmittance, wherein the heating means can be heated fluid circulation heating, flame heating, laser heating , ultrasonic heating, electric heating or infrared heating. The punching polymer resin sheet according to the second aspect of the invention claims to complete the bright and high light transmissive cutting surface method, wherein the heating device further comprises a control device capable of effectively and accurately controlling the heating The efficiency of the energy conversion of the device enables stable temperature control within the working range of the die cutting device. The die-cut polymer resin sheet according to the first aspect of the patent application is a bright and high-transparency punching and cutting method, wherein the punching cutter can be a combined forming cutter, which is separately manufactured by mechanical processing. The metal blade and the base combine the multiple blades and the base into a geometrically shaped tool. The die-cut polymer resin sheet according to the first aspect of the patent application is a bright and high-transparency punching surface method, wherein the punching cutter can be an integrally formed etching tool, which is first on the surface of the metal material. The use of film exposure, development or etching to create a geometric shape on the surface of the metal material, and then use mechanical processing to make a sharp blade. For example, the die-cut polymer resin sheet according to the first aspect of the patent application completes the method of punching and cutting surface which is bright and has high light transmittance, wherein the punching cutter can be an integrally formed metal cutter, and the metal material is directly used as a mechanical tool. The processing method is to make a geometric shape and a sharp blade. The die-cutting polymer resin sheet according to the first aspect of the patent application, wherein the punching and cutting surface method is bright and has high light transmittance, wherein the optical guide The optical element is formed by laminating or die-casting a light-transmissive material into a thin plate having a thickness of 3.0 mm or less and a film substrate. The punching polymer resin sheet according to the seventh aspect of the patent application is a bright and high light transmissive cutting surface method, wherein the light transmissive material is polymethyl methacrylate [PMMA], polycarbonate. Ester [PC] or polyethylene terephthalate [PET]. A punching device for completing the method described in claim 1, comprising: a punching device comprising a multi-functional die holder, a die holder, a punching cutter and a heating device, The punching cutter is installed under the multi-functional mold base, and the heating temperature of the heating device can be applied to the working range of the punching cutter.