阅读说明：本技术 一种导光板的成型生产方法 (Forming production method of light guide plate ) 是由 蔡正方 黄俊昌 李清华 于 2020-09-29 设计创作，主要内容包括：本发明系提供一种导光板的成型生产方法,包括以下步骤：雕刻原板；性能测试；模具制作：向导光网点中填充耐蚀材料,固化后形成耐蚀块；耐蚀块的一侧固定连接蚀刻板,形成一次模板；一次模板蚀刻,获得二次模板；向二次模板的顶面电镀获得金属膜,金属膜的背面紧贴二次模板；分离二次模板和金属膜,在金属膜的背面成型获得模仁；反射层成型,向下模腔中注入反射金属液；本体成型；保护膜成型；亮边消除,喷砂形成蒙砂层；去膜；量产。本发明能够确保量产所获成品导光板的导光网点与原导光网点具有较高的一致性,可提高生产效率；导光板本体一体成型获得反射层,可有效缩减生产时间；粗化获得蒙砂层能够有效提高发光均匀性。(The invention provides a forming production method of a light guide plate, which comprises the following steps: engraving the original plate; testing the performance; manufacturing a mould: filling corrosion-resistant materials into the light guide mesh points, and forming corrosion-resistant blocks after solidification; one side of the corrosion resistant block is fixedly connected with an etching plate to form a primary template; etching the primary template to obtain a secondary template; electroplating the top surface of the secondary template to obtain a metal film, wherein the back surface of the metal film is tightly attached to the secondary template; separating the secondary template from the metal film, and forming the back of the metal film to obtain a mold core; molding the reflecting layer, and injecting a reflecting molten metal into the lower die cavity; molding the body; forming a protective film; eliminating bright edges, and carrying out sand blasting to form a frosting layer; removing the film; and (4) mass production. The invention can ensure that the light guide mesh points of the finished product light guide plate obtained by mass production have higher consistency with the original light guide mesh points, and can improve the production efficiency; the light guide plate body is integrally formed to obtain the reflecting layer, so that the production time can be effectively shortened; the frosted layer obtained by coarsening can effectively improve the luminous uniformity.)

1. The forming production method of the light guide plate is characterized by comprising the following steps of:

s1, engraving the original plate: laser engraving the bottom surface of the optical substrate to form light guide dots to obtain a prototype light guide plate;

s2, performance test: testing the performance of the prototype light guide plate, and if the performance is qualified, performing the step S3, otherwise, returning to the step S1;

s3, manufacturing a die:

A. filling a corrosion-resistant material into the light guide mesh points of the prototype light guide plate, removing the redundant corrosion-resistant material on the bottom surface of the prototype light guide plate, and solidifying the corrosion-resistant material in the light guide mesh points to form corrosion-resistant blocks;

B. fixedly connecting an etching plate on one side of each corrosion-resistant block far away from the prototype light guide plate, wherein the corrosion-resistant blocks and the etching plates form a primary template, and the corrosion-resistant blocks are positioned on the top surfaces of the etching plates to separate the primary template from the prototype light guide plate;

C. placing the primary template into an etching solution for etching, wherein the etching depth is d, and obtaining a secondary template after etching;

D. electroplating the top surface of the secondary template to obtain a metal film, wherein the back surface of the metal film is tightly attached to the secondary template;

E. separating the secondary template from the metal film, forming the back of the metal film to obtain a mold core, wherein the front of the mold core is in close contact with the back of the metal film, and separating the mold core from the secondary template;

F. placing the mold core into a lower mold cavity of an injection mold, wherein the front surface of the mold core is upward;

s4, forming the reflecting layer, namely injecting a reflecting metal liquid into the lower die cavity until the reflecting metal liquid is filled on the front surface of the die core to a thickness d, and forming the reflecting layer by the reflecting metal liquid;

s5, forming the body, forming a cavity after the injection mold is closed, injecting optical-grade resin into the cavity by an injection molding machine, obtaining the light guide plate body after the optical-grade resin is formed, and obtaining the primary light guide plate integrally formed by the light guide plate body and the reflecting layer after demolding;

s6, forming a protective film, covering the protective film on the front surface of the primary light guide plate, and forming a sand blasting area between the protective film and the front edge of the primary light guide plate;

s7, removing bright edges, performing sand blasting on the front surface of the primary light guide plate, and forming a frosted layer in a sand blasting area of the primary light guide plate;

s8, removing the film, cleaning and drying after removing the protective film on the surface of the primary light guide plate to obtain a finished light guide plate;

and S9, mass production, and repeating the steps S4-S8 to realize the mass production of the finished light guide plate.

2. The method of claim 1, wherein in step S3, the corrosion resistant material is acid resistant glue.

3. The method of claim 2, wherein in step S3, the etching plate is a glass plate.

4. The method of claim 3, wherein in step S3, the etching solution is nitric acid solution.

5. The method as claimed in claim 1, wherein in step S3, a mold is formed on the back of the metal film by electroforming.

6. The method of claim 1, wherein in step S3, the injection mold comprises an upper mold plate and a lower mold plate, the upper mold plate has an upper mold cavity below it, and the lower mold plate has a lower mold cavity above it.

7. The method of claim 1, wherein in step S4, the molten metal is a high light aluminum molten metal, and the reflective molten metal is cooled to 300 ℃ after forming the reflective layer.

8. The method of claim 1, wherein an adhesive layer is applied to the surface of the reflective layer before injecting the optical-grade resin in step S5.

9. The method of claim 1, wherein in step S6, the protective film is a dry film or a photoresist film.

Technical Field

The invention relates to production and processing of a light guide plate, and particularly discloses a forming production method of the light guide plate.

Background

The light guide plate can diffuse light incident from the end face of the light guide plate to various angles and then emit the light from the front face of the light guide plate by destroying the reflection condition. The light guide plate is a core component constituting a surface light emitting module, which is commonly used for products such as displays, lamps and the like.

In the prior art, the light guide plate is obtained by printing light guide dots on the back of a glass, optical acrylic plate and other plates by using laser engraving, V-shaped cross grid engraving or UV screen printing technology, namely, after the glass, acrylic and other optical substrates are molded, the light guide dots can be engraved or printed, the production efficiency is low, the dots are printed or engraved at each time, high-precision processing needs to be realized, the processing difficulty is high, and the production cost is high.

Disclosure of Invention

Therefore, it is necessary to provide a method for forming a light guide plate, which uses a mold to produce the light guide plate, and has high production efficiency, high precision of the obtained light guide plate, and good light-homogenizing effect.

In order to solve the problems of the prior art, the invention discloses a molding production method of a light guide plate, which comprises the following steps:

s1, engraving the original plate: laser engraving the bottom surface of the optical substrate to form light guide dots to obtain a prototype light guide plate;

s2, performance test: testing the performance of the prototype light guide plate, and if the performance is qualified, performing the step S3, otherwise, returning to the step S1;

s3, manufacturing a die:

A. filling a corrosion-resistant material into the light guide mesh points of the prototype light guide plate, removing the redundant corrosion-resistant material on the bottom surface of the prototype light guide plate, and solidifying the corrosion-resistant material in the light guide mesh points to form corrosion-resistant blocks;

B. fixedly connecting an etching plate on one side of each corrosion-resistant block far away from the prototype light guide plate, wherein the corrosion-resistant blocks and the etching plates form a primary template, and the corrosion-resistant blocks are positioned on the top surfaces of the etching plates to separate the primary template from the prototype light guide plate;

C. placing the primary template into an etching solution for etching, wherein the etching depth is d, and obtaining a secondary template after etching;

D. electroplating the top surface of the secondary template to obtain a metal film, wherein the back surface of the metal film is tightly attached to the secondary template;

E. separating the secondary template from the metal film, forming the back of the metal film to obtain a mold core, wherein the front of the mold core is in close contact with the back of the metal film, and separating the mold core from the secondary template;

F. placing the mold core into a lower mold cavity of an injection mold, wherein the front surface of the mold core is upward;

s4, forming the reflecting layer, namely injecting a reflecting metal liquid into the lower die cavity until the reflecting metal liquid is filled on the front surface of the die core to a thickness d, and forming the reflecting layer by the reflecting metal liquid;

s5, forming the body, forming a cavity after the injection mold is closed, injecting optical-grade resin into the cavity by an injection molding machine, obtaining the light guide plate body after the optical-grade resin is formed, and obtaining the primary light guide plate integrally formed by the light guide plate body and the reflecting layer after demolding;

s6, forming a protective film, covering the protective film on the front surface of the primary light guide plate, and forming a sand blasting area between the protective film and the front edge of the primary light guide plate;

s7, removing bright edges, performing sand blasting on the front surface of the primary light guide plate, and forming a frosted layer in a sand blasting area of the primary light guide plate;

s8, removing the film, cleaning and drying after removing the protective film on the surface of the primary light guide plate to obtain a finished light guide plate;

and S9, mass production, and repeating the steps S4-S8 to realize the mass production of the finished light guide plate.

Further, in step S3, in step a, the corrosion-resistant material is acid-resistant glue.

Further, in step S3B, the etching plate is a glass plate.

Further, in step S3, C, the etching solution is a nitric acid solution.

Further, in step S3, a mold core is obtained by electroforming on the back surface of the metal film.

Further, in step S3, the injection mold includes an upper mold plate and a lower mold plate, an upper mold cavity is provided below the upper mold plate, and a lower mold cavity is provided on the lower mold plate.

Further, in step S4, the molten metal is a high light aluminum molten metal, and the reflective molten metal is formed to obtain a reflective layer and then cooled to 300 ℃.

Further, in step S5, before injecting the optical grade resin, an adhesive layer is coated on the surface of the reflective layer.

Further, in step S6, the protective film is a dry film or a photoresist film.

The invention has the beneficial effects that: the invention discloses a molding production method of a light guide plate, wherein a prototype light guide plate passing a test is used for manufacturing a mold in a reverse pushing mode, so that the precision of the mold can be effectively ensured, and the light guide dots of a finished product light guide plate obtained by mass production and the light guide dots of the prototype light guide plate have higher consistency, thereby effectively ensuring that the light guide performance of the finished product light guide plate obtained by mass production meets the requirement; the mold core is also provided with a retreating and abdicating structure provided with a reflecting layer, so that the reflecting layer can be obtained by integrally forming the light guide plate body while the formation of light guide mesh points is not influenced, the production time can be effectively shortened, and the light collection performance of the light guide plate can be ensured; in addition, the frosted layer is obtained by roughening the edge area of the front surface of the light guide plate, so that the light emitting uniformity of the light guide plate can be effectively improved, and bright edges are prevented from being formed during working.

Drawings

FIG. 1 is a schematic view of the production process of the present invention.

Fig. 2 is a schematic structural diagram of a manufacturing process of the S3 mold in the present invention.

Fig. 3 is a schematic structural view of the S5 body of the present invention during molding.

FIG. 4 is a schematic structural diagram of a final light guide plate product according to the present invention.

Reference numerals: the light guide plate comprises a prototype light guide plate 10, a primary template 20, a corrosion-resistant block 21, an etching plate 22, a secondary template 30, a metal film 40, a mold core 50, a lower mold cavity 61, an upper mold cavity 62, a finished light guide plate 70, a primary light guide plate 71, a reflecting layer 711, a light guide plate body 712 and a frosting layer 72.

Detailed Description

For further understanding of the features and technical means of the present invention, as well as the specific objects and functions attained by the present invention, the present invention will be described in further detail with reference to the accompanying drawings and detailed description.

Refer to fig. 1 to 4.

The embodiment of the invention discloses a forming production method of a light guide plate, which comprises the following steps in sequence as shown in figure 1:

s1, engraving the original plate: designing light guide dots, and laser engraving the bottom surfaces of optical substrates, namely acrylic plates or glass plates and the like according to the design to form the light guide dots so as to obtain a prototype light guide plate 10;

s2, performance test: testing the performance of the prototype light guide plate 10, wherein the performance test comprises a light spot distribution diagram, surface defect detection and the like, and if the performance is qualified, performing step S3, otherwise, returning to step S1 to perform improvement or redesign;

s3, manufacturing a die, as shown in FIG. 2, including the following steps A-F:

A. filling a corrosion-resistant material into the light guide mesh points of the prototype light guide plate 10 which is qualified by detection, removing the redundant corrosion-resistant material on the bottom surface of the prototype light guide plate 10 by using tools such as a scraper, and solidifying the corrosion-resistant material in the light guide mesh points to form corrosion-resistant blocks 21;

B. fixedly connecting an etching plate 22 on one side of each corrosion-resistant block 21 far away from the prototype light guide plate 10, wherein the etching plate 22 is a non-corrosion-resistant substrate structure, the etching plate 22 is fixedly connected with the corrosion-resistant blocks 21 in a glue mode, or the etching plate 22 is obtained by molding on the plane side of the corrosion-resistant blocks 21 in a mold molding mode, the corrosion-resistant blocks 21 and the etching plates 22 form a primary template 20, the corrosion-resistant blocks 21 are positioned on the top surfaces of the etching plates 22, and the primary template 20 is separated from the prototype light guide plate 10;

C. placing the primary template 20 into an etching solution for uniform etching, wherein the etching depth is d, namely the reduced thickness of the etching plate 22 is d, the distance between the corrosion-resistant block 21 and the top surface of the etching plate 22 is increased by d, and obtaining a secondary template 30 after etching;

D. electroplating the top surface side of the secondary template 30 to obtain a metal film 40, wherein the back surface of the metal film 40 is tightly attached to the secondary template 30, and the metal film 40 is formed into a shape matched with the top surface of the secondary template 30;

E. separating the secondary template 30 and the metal film 40, molding the back of the metal film 40 to obtain a mold core 50, wherein the front of the mold core 50 is closely contacted with the back of the metal film 40, that is, the shape and size of the front surface of the mold core 50 are matched with the shape and size of the back surface of the metal film 40, the shape and size of the front surface of the mold core 50 are the same as the shape and size of the top surface of the secondary template 30, when the mold core 50 is used for molding, can effectively ensure the precision of the finally obtained finished light guide plate 70, ensure that the size and the shape of the light guide dots in the finished light guide plate 70 are consistent with the size and the shape of the light guide dots in the prototype light guide plate 10, because the thickness of the metal film 40 is not negligible relative to the size of the light guide dots, the mold core 50 is arranged on one side of the metal film 40 originally attached to the secondary template 30, the precision of the mold core 50 is not affected by the thickness of the metal film 40, the production precision is high, and the mold core 50 and the secondary template 30 are separated;

F. placing the mold core 50 into a lower mold cavity 61 of an injection mold, wherein the front surface of the mold core 50 faces upwards;

s4, forming the reflecting layer 711, namely injecting a reflecting metal liquid into the lower die cavity 61 until the reflecting metal liquid is filled on the front surface of the die core 50 to a thickness d, namely the distance between the liquid level of the reflecting metal liquid and the front surface of the die core 50 is d, and the reflecting metal liquid is just positioned at the plane of the corrosion-resistant block 21, so that the reflecting metal liquid can be effectively prevented from influencing the forming of subsequent light guide dots, the processing and preparation precision is ensured, and the reflecting layer 711 is obtained after the reflecting metal liquid is formed;

s5, forming the light guide plate body, after the injection mold is closed, forming a cavity by the upper mold cavity 62 and the lower mold cavity 61, injecting optical resin into the cavity by the injection molding machine, as shown in fig. 3, the acrylic resin is one of the optical resins, forming the light guide plate body 712 after the optical resin is formed, obtaining the light guide plate 71 integrally formed by the light guide plate body 712 and the reflective layer 711 after demolding, wherein the light guide plate 71 has light guide dots consistent with the prototype light guide plate 10, and the reflective layer 711 is disposed on the bottom surface of the light guide plate 71 to avoid the light guide dots;

s6, forming a protection film, covering the protection film on the front surface of the light guide plate 71, that is, covering the protection film on the surface of the light guide plate body 712 away from the reflective layer 711, and forming a sand blasting area between the protection film and the front edge of the light guide plate 71, where there are two sand blasting areas on the front surface of the light guide plate 71 when the light guide plate is applied and there are four sand blasting areas when there are light emitting assemblies on the opposite sides, so as to effectively ensure the effect of eliminating bright edges and avoid the lack of brightness of some edges due to excessive sand blasting areas;

s7, removing bright edges, performing sand blasting on the front surface of the primary light guide plate 71, wherein the sand blasting is to form a high-speed jet beam by using compressed air as power to spray a blasting material such as quartz sand to the surface of a workpiece to be processed at a high speed so as to change the surface of the workpiece, after the sand blasting is performed, the sand blasting area of the primary light guide plate 71 becomes rough, and a frosted layer 72 is formed in the sand blasting area of the primary light guide plate 71;

s8, removing the film, removing the protective film on the surface of the light guide plate 71, and cleaning and drying, preferably, the cleaning may be ultrasonic cleaning, and the drying is hot air drying, to obtain the finished light guide plate 70, as shown in fig. 4;

and S9, mass production, wherein the steps S4-S8 are repeated to realize the mass production of the finished light guide plate 70.

The prototype light guide plate 10 is manufactured according to the pre-designed model, a real object can be tested in practical application, the test effect is reliable and real, the light guide plate is subjected to mass production only after the test is qualified, the mould is manufactured by the prototype light guide plate 10 passing the test in a reverse pushing mode, the precision of the mould can be effectively ensured, and the light guide mesh points of the finished product light guide plate 70 obtained by mass production and the light guide mesh points of the prototype light guide plate 10 have higher consistency, so that the light guide performance of the finished product light guide plate 70 obtained by mass production can be effectively ensured to meet the requirements, the light guide plate is directly obtained by mould processing without additional light guide mesh point processing, the production efficiency can be effectively improved, and the production cost is reduced; the mold core 50 is further provided with a backward arrangement for forming the reflecting layer 711, so that the reflecting layer 711 can be obtained by integrally forming the light guide plate body 712 while the formation of light guide dots is not influenced, the production time can be effectively shortened, and the light collection performance of the light guide plate can be ensured; in addition, the frosted layer 72 is obtained by roughening the edge area on the front surface of the light guide plate, so that the light emitting uniformity of the light guide plate can be effectively improved, bright edges are prevented from being formed during working, and roughening processing is efficient and reliable.

In the present embodiment, in step a of step S3, the corrosion-resistant material is an acid-resistant glue, preferably, an acid-resistant UV glue, which can be cured and formed after being irradiated by UV light and has good acid-resistant performance.

Based on the above embodiment, in step B of step S3, the etching plate 22 is a glass plate, but may be another plate material that is not acid-resistant.

Based on the above embodiment, in step C of step S3, the etching solution is a nitric acid solution, and preferably, the etching solution is a nitric acid solution with a volume concentration of 15 to 30%, so that the etching effect on the etching plate 22 can be effectively ensured.

In the present embodiment, in step E of step S3, the core 50 is obtained by electroforming on the back surface of the metal film 40, where electroforming refers to a process of performing electrodeposition on the core and then separating to obtain a metal product.

In this embodiment, in step F of step S3, the injection mold includes an upper mold plate and a lower mold plate, an upper mold cavity 62 is disposed below the upper mold plate, a lower mold cavity 61 is disposed on the lower mold plate, depths of the upper mold cavity 62 and the lower mold cavity 61 are designed according to actual requirements to prepare a light guide plate with a corresponding thickness, after the mold core 50 is placed in the lower mold cavity 61, a new lower mold cavity 61 is formed, and a bottom surface of the lower mold cavity 61 is formed on a front surface of the mold core 50.

In this embodiment, in step S4, the molten metal is a high light aluminum molten metal, and the reflective layer 711 is obtained by molding the reflective molten metal and then cooled to 300 ℃ for operation S5, which can effectively improve the stability of the connection structure formed between the light guide plate body 712 and the reflective layer 711.

In this embodiment, in step S5, before injecting the optical-grade resin, an adhesive layer is coated on the surface of the reflective layer 711, preferably, the adhesive layer is an OCA optical adhesive, which has good optical performance and can effectively improve the firmness of the connection structure between the light guide plate body 712 and the reflective layer 711.

In this embodiment, in step S6, the protection film is a dry film or a photoresist film, and the dry film is directly attached to the front surface of the primary light guide plate 71 to realize the protection function; the covering process of the photoresist is as follows: coating photoresist on the front side of the prefabricated light guide plate, covering a mask plate above the photoresist, exposing the photoresist through the mask plate by using a UV lamp, and developing to obtain a protective film. In step S8, the dry film can be directly taken out, and the photoresist film is removed by a specific solvent, if the photoresist is not alkali-resistant, an alkali solution is prepared to remove the photoresist film.

The above-mentioned embodiments only express several embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the present invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.