CN102981211B - 导光板的制造方法及其挤出机 - Google Patents

导光板的制造方法及其挤出机 Download PDF

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CN102981211B
CN102981211B CN201210530483.7A CN201210530483A CN102981211B CN 102981211 B CN102981211 B CN 102981211B CN 201210530483 A CN201210530483 A CN 201210530483A CN 102981211 B CN102981211 B CN 102981211B
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guide
lighting
light guide
guide plate
raw material
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CN102981211A (zh
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何书勇
康亚玲
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BOE Technology Group Co Ltd
Hefei BOE Display Lighting Co Ltd
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BOE Technology Group Co Ltd
Hefei BOE Display Lighting Co Ltd
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    • 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
    • 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
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    • B29C48/001—Combinations of extrusion moulding with other shaping operations
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • 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
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    • 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
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    • G02B6/0041—Scattering dots or dot-like elements, e.g. microbeads, scattering particles, nanoparticles provided in the bulk of the light guide
    • 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
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    • G02B6/0033—Means for improving the coupling-out of light from the light guide
    • G02B6/0063—Means for improving the coupling-out of light from the light guide for extracting light out both the major surfaces of the light guide
    • 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
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C2948/00—Indexing scheme relating to extrusion moulding
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    • B29C2948/00—Indexing scheme relating to extrusion moulding
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C2948/00—Indexing scheme relating to extrusion moulding
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明涉及显示技术领域，尤其涉及一种可利用双向微透层实现双向聚光的导光板及其制造方法、挤出机、背光模组和显示装置；该导光板包括导光板基材，所述导光板基材包括一用以接收光束的入射面、一与入射面相连的底面、一与入射面相连且与底面相对的出射面、一与入射面相对的侧面及其余相对的两侧面，所述导光板基材内设有双向微透层，该双向微透层包括多个具有双凸面的微透点。本发明采用微透点上设有双凸面的设计，利用凸透镜聚光原理，使进入微透点的多条呈不同走向的散射光线汇聚，有效提高导光板出射面的亮度；且该双凸面可实现导光板双向使用的目的，即导光板的入射面和出射面互换，实现导光板的双面发光。

Description

导光板的制造方法及其挤出机
技术领域
本发明涉及显示技术领域，尤其涉及一种可利用双向微透层实现双向聚光的导光板及其制造方法、挤出机、背光模组和显示装置。 
背景技术
由于液晶分子本身不具备发光能力，因此现有的液晶显示器中需要外加光源来得到显示画面。依据光源相对位置的不同背光源分为侧入式和直下式。侧入式背光结构中，光源放在导光板侧边，灯条发出的光源直接射入导光板内；导光板主要功能是将侧边入射的平行光转换成平面光。直下式背光结构中，光源安放液晶面板下方，光源发出的光经过一段空间距离和扩散板的扩散、混合后，成为面光源发射出来。 
侧入式背光模组中导光板至少一侧设置光源，这会导致导光板的出射面的光线不均匀；在靠近光源处亮，而远离光源处暗；为解决这种问题，现有技术是在导光板底面上设置网点，利用漫反射原理通过网点将导光板内的全反射光线散射出去，以调整光线的均匀度；这种带有网点的导光板虽然可以在一定程度上解决导光板出射面光线明暗不均的问题，但是该种导光板对辉度的调整不够彻底，且由于散射光线的方向过于分散，光线无法汇聚，导致导光板显示亮度不高，进而导致液晶显示屏的影像不清晰；针对以上不足，本发明急需提供一种新的导光板及该导光板的制造方法。 
发明内容
本发明的目的是提供一种导光板及其制造方法、挤出机、背光模组和显示装置，所述导光板通过双向微透层实现双向聚光的目的。 
本发明的目的是通过以下技术方案实现的：一种导光板，包括导 光板基材，所述导光板基材包括一用以接收光束的入射面、一与入射面相连的底面、一与入射面相连且与底面相对的出射面、一与入射面相对的侧面及其余相对的两侧面，所述导光板基材内设有双向微透层，该双向微透层包括多个具有双凸面的微透点。 
所述双向微透层为阵列双向微透层。 
所述微透点为中空的球体。 
所述导光板采用聚对苯二甲酸乙二醇酯、聚碳酸酯、聚甲基丙烯酸甲酯、聚醚醚酮、聚萘二甲酸乙二酯、聚丁二酸乙烯、聚丙烯氧化物其中之一制成。 
一种根据上述中任一所述导光板的制造方法，该方法包括如下步骤： 
S1、将导光原料装入加热装置； 
S2、加热装置将导光原料加热至熔融态； 
S3、挤压装置将熔融态导光原料挤压成熔融态导光原料板； 
S4、在挤出的过程中控制起泡器将气泡注入熔融态导光原料板； 
S5、熔融态导光原料板经成型模具口挤出成型导光板。 
在所述步骤S4中还包括如下步骤: 
S41、在自动控制电路内预设微透点分布图； 
S42、挤出机的自动控制电路根据微透点分布图自动控制起泡器排泡。 
在所述步骤S42中还包括如下步骤: 
S421、自动控制电路通过控制保压器注入气体的压强以调整气泡大小； 
S422、自动控制电路通过控制转筒旋转速度以调整气泡排布密度。 
在所述步骤S5中还包括： 
S51、经挤出的熔融态导光原料板通过连接在成型模具口上的水冷装置进行循环水冷却后形成可塑性导光原料板； 
S52、可塑性导光原料板经滚压装置滚压成可塑性导光板材； 
S53、可塑性导光板材经传送装置导出； 
S54、在导出过程中，可塑性导光板材经自然冷却后形成导光板材； 
S55、导光板材经切割装置切割成导光板。 
一种实现上述中任一所述导光板制造方法的挤出机，该挤出机设有用于对导光原料加热的加热装置、用于将熔融态导光原料挤出的挤压装置、用于在熔融态导光原料板内布设气泡层的起泡器、用于将熔融态导光原料板半冷却成可塑性导光原料板的冷却装置、用于将可塑性导光原料板压制成可塑性导光板材的滚压装置、用于导出可塑性导光板材的传送装置以及用于将经自然冷却后的导光板材按规格要求切割成导光板的切割装置。 
所述起泡器设置在所述挤压装置的成型模具口内。 
所述起泡器有一个外筒体，在该外筒体内设有转筒，该转筒两端通过转轴与所述外筒体两端面穿装；在该转筒的筒壁上均匀布设有多排出气孔，在所述外筒体上设有与所述出气孔位置对应的单排排气孔。 
所述转筒内设有保压器；该保压器包括一个气泵，该气泵可持续向转筒内注入气体。 
在所述转轴上设有可带动转筒转动的驱动马达，在所述保压器上连接有电控阀；所述马达和电控阀均通过电线与所述自动控制电路连接。 
所述起泡器水平架设在所述成型模具口内，所述起泡器的单排排气孔的气泡排出方向与所述成型模具口的出料方向相一致。 
一种背光模组，包括上述中任一所述的导光板。 
一种显示装置，包括所述的背光模组。 
本发明与现有技术相比具有以下的优点： 
1、本发明采用双向微透层的设计，利用该双向微透层对导光板内所有散射光线的方向进行调整，将散射光线汇聚；增加液晶显示屏的显像亮度和影响清晰度，提高了产品质量。 
2、本发明采用微透点上设有双凸面的设计，利用凸透镜聚光原理， 使进入微透点的多条呈不同走向的散射光线汇聚，有效提高导光板出射面的亮度，从而增加液晶显示屏的显像亮度和影响清晰度；提高了产品质量；且该双凸面可实现导光板双向使用的目的，即导光板的入射面和出射面互换，实现导光板的双面发光。 
3、本发明采用起泡器通过排泡制造双向微透层的步骤；起泡器将气泡注入熔融态导光原料板的步骤；使熔融态导光原料板中形成的气泡层符合微透点分布图的设计要求；待将熔融态导光原料板制成导光板后，该气泡层就是导光板内的双向微透层，所述各个气泡就是构成双向微透层的各个微透点；该起泡器结构简单，造价便宜，便于操作，且制造出的双向微透层的微透点透光度好，质地均匀，有效提高了生产效率，简化了制造过程。 
附图说明
以下结合附图和实施例对本发明作进一步说明。 
图1是本发明中导光板的结构示意图（剖视图）； 
图2是本发明中挤出机的结构示意图（主视图）； 
图3是本发明中起泡器的结构示意图（剖视图）； 
图4是本发明中成型模具口的结构示意图（局部剖视图）； 
图5是本发明中导光板制造方法的流程框图。 
具体实施方式
参见图1所示，本实施例中的导光板，包括导光板基材1，所述导光板基材包括一用以接收光束的入射面、一与入射面相连的底面、一与入射面相连且与底面相对的出射面、一与入射面相对的侧面及其余相对的两侧面，所述导光板基材内设有双向微透层，该双向微透层包括多个具有双凸面的微透点2。所述微透点为中空的球体；该呈球体的微透点由双凸面构成，双凸面包括分别与导光板基材入射面和出射面对应的两个外凸面；该外凸面是一个可起到聚光作用的圆弧镜面；本发明采用双向微透层的设计，利用该双向微透层对导光板内所有散射 光线的方向进行调整，将散射光线汇聚；增加液晶显示屏的显像亮度和影响清晰度，提高了产品质量。采用微透点上设有双凸面的设计，利用凸透镜聚光原理，使进入微透点的多条呈不同走向的散射光线汇聚，有效提高导光板出射面的亮度，从而增加液晶显示屏的显像亮度和影响清晰度；提高了产品质量；且该双凸面可实现导光板双向使用的目的，即导光板的入射面和出射面互换，实现导光板的双面发光。本实施例中所述微透点高度在0.003mm－0.4mm之间；所述各微透点间距在0.02mm－0.2mm之间；所述双向微透层为阵列双向微透层。 
本实施例中所述导光板采用聚对苯二甲酸乙二醇酯、聚碳酸酯、聚甲基丙烯酸甲酯、聚醚醚酮、聚萘二甲酸乙二酯、聚丁二酸乙烯、聚丙烯氧化物等塑料材料制成。 
参见图2、图5所示，本发明中导光板的制造方法包括以下步骤： 
1、将导光原料装入加热装置的锥形加料槽内。所述加热装置包括加热炉101和设置在该加热炉料口上的锥形加料槽102；导光原料通过加料槽进入加热炉内，并通过加热炉充分加热；本发明中所述加热装置属于现有技术，此处不再过多赘述。 
2、加热装置将导光原料加热至熔融态；熔融态是指导光原料的固态颗粒在240℃高温下被熔融成液态。 
3、挤压装置将熔融态导光原料挤压成熔融态导光原料板103，该挤压装置的挤出压强在50-100pa之间；所述挤压装置包括螺旋输送机104和与该螺旋输送机输出端连接的成型模具口105；该挤压装置设置在所述加热炉底端，并与加热炉的出料口连通；本发明中所述挤压装置属于现有技术，此处不再过多赘述。 
4、在挤出的过程中控制起泡器将气泡106注入熔融态导光原料板。 
在自动控制电路内预设微透点分布图；挤出机的自动控制电路根据微透点分布图自动控制起泡器107排泡。自动控制电路通过控制保压器108注入气体的压强以调整气泡大小；自动控制电路通过控制转筒109旋转速度以调整气泡排布密度。通过上述步骤，自动控制电路 可自动按预设的微透点分布图完成气泡的排布任务；使熔融态导光原料板中形成的气泡层符合微透点分布图的设计要求；待将熔融态导光原料板制成导光板后，该气泡层就是导光板内的双向微透层，所述各个气泡就是构成双向微透层的各个微透点。参见图4所示，本发明中所述起泡器架设在所述挤压装置的成型模具口内，且处于成型模具口垂直高度的中心处，该起泡器的排泡方向与成型模具口的出料方向一致；当挤压装置将熔融态导光原料挤压至起泡器时，在挤压力的作用下，起泡器自动将熔融态导光原料中隔成上下两层，此时起泡器开始排泡，当上下两层熔融态导光原料经过起泡器后，在重力作用下自动合为一体，气泡被自动夹进熔融态导光原料内，进而形成双向微透层。 
5、熔融态导光原料板经成型模具口挤出成型导光板。 
经挤出的熔融态导光原料板通过连接在成型模具口上的水冷装置110进行循环水冷却后形成可塑性导光原料板；本发明中所述水冷装置与所述挤压装置的成型模具口对应设置；自动控制电路控制该水冷装置的温度和流速进行熔融态导光原料板的半冷却处理；将熔融态导光原料板降温至固液态，以此形成可塑性导光原料板111；本发明中所述水冷装置属于现有技术，此处不再过多赘述。 
可塑性导光原料板经滚压装置滚压成可塑性导光板材；本发明中所述滚压装置包括上下对应设置的一组滚压轮112，两滚压轮之间的轮距可调；该滚压轮通过外部电机驱动；可塑性导光原料板经滚压后形成可塑性导光板材113；自动控制电路通过控制轮距和转速对经滚压后的可塑性导光板材的形状进行调整；本发明中所述滚压装置属于现有技术，此处不再过多赘述。 
可塑性导光板材经传送装置导出；本发明中所述传送装置包括传送台114和并排架设在传送台上的多个滚轴115，滚轴外接电机驱动，以此实现可塑性导光板材的导出；在导出过程中，可塑性导光板材经自然冷却（温度20℃-30℃）后形成导光板材；自动控制电路通过控制滚轴转速对自然冷却时间进行控制；该导光板材被传送装置运送至切 割装置处。本发明中所述传送装置属于现有技术，此处不再过多赘述。 
导光板材经切割装置切割成导光板。所述切割装置（属现有技术，图中未显示）包括夹持传送装置和刀片组，通过加持装置的一组夹持输送轮将导光板材夹持输送至刀片组处，通过刀片组将导光板材切割成符合生产需要的导光板，所述传送装置外接电机驱动，刀片组通过电控阀与自动控制电路连接；自动控制电路通过控制传送装置的传送速度和刀片组的切割频率对经切割的导光板大小规格进行控制；本发明中所述切割装置属于现有技术，此处不再过多赘述。 
参见图2所示，本发明中为实现上述导光板的制造方法，特提供一种挤出机，本发明的挤出机是在现有挤出机的基础上改进的；该挤出机从左至右依次设有用于对导光原料加热的加热装置、用于将熔融态导光原料挤出的挤压装置、用于在熔融态导光原料板内布设气泡层的起泡器、用于将熔融态导光原料板半冷却成可塑性导光原料板的冷却装置、用于将可塑性导光原料板压制成可塑性导光板材的滚压装置、用于导出可塑性导光板材的传送装置以及用于将经自然冷却后的导光板材按规格要求切割成导光板的切割装置；该挤出机的自动控制电路统一控制以上各装置自动工作。所述可塑性导光板材在被传送装置导出的过程中经自然冷却后形成导光板材。 
参见图3、图4所示，所述起泡器设置在所述挤压装置的成型模具口内。所述起泡器有一个外筒体116，在该外筒体内设有转筒，该转筒两端通过转轴117与所述外筒体两端面穿装；在该转筒的筒壁上均匀布设有多排出气孔118，在所述外筒体上设有与所述出气孔位置对应的单排排气孔119，当其中一排出气孔经旋转后与单排排气孔对齐时，从该出气孔排出的气泡通过单排排气孔排出起泡器，并在熔融态导光原料板内形成一排气泡；通过旋转转筒，重复多次排泡过程，即可在熔融态导光原料板内形成气泡层，经挤出成型导光板后该气泡层即成为双向微透层。所述起泡器的转筒内设有保压器；该保压器包括一个气泵，该气泵可持续向转筒内注入气体，该气体是经干燥过的 CO2、N2等非腐蚀性气体，用以保证起泡器有充足的气体和气压进行排泡。在所述转轴上设有可带动转筒转动的驱动马达，在所述保压器上连接有电控阀；所述马达和电控阀均通过电线与所述自动控制电路连接，从而实现自动控制电路对起泡器的自动控制；所述起泡器水平架设在所述成型模具口内，所述起泡器的单排排气孔的气泡排出方向与所述成型模具口的出料方向相一致。本实施例中所述的起泡器整体采用高温耐火材料制成。 
所述导光原料采用聚对苯二甲酸乙二醇酯、聚碳酸酯、聚甲基丙烯酸甲酯、聚醚醚酮、聚萘二甲酸乙二酯、聚丁二酸乙烯、聚丙烯氧化物等透光效果好的塑料材料制成。 
另外，本发明实施例还提供了一种背光模组，所述背光模组，包括上述所述的导光板或利用上述制造方法产生的导光板。 
本发明的背光模组可以应用于显示装置中，所述显示装置可以为：液晶面板、电子纸、OLED面板、液晶电视、液晶显示器、数码相框、手机、平板电脑等任何具有显示功能的产品或部件。 

Claims (9)

1.一种实现导光板制造方法的挤出机，其特征在于：该挤出机设有用于对导光原料加热的加热装置、用于将熔融态导光原料挤出的挤压装置、用于在熔融态导光原料板内布设气泡层的起泡器、用于将熔融态导光原料板半冷却成可塑性导光原料板的冷却装置、用于将可塑性导光原料板压制成可塑性导光板材的滚压装置、用于导出可塑性导光板材的传送装置以及用于将经自然冷却后的导光板材按规格要求切割成导光板的切割装置；所述起泡器有一个外筒体，在该外筒体内设有转筒，该转筒两端通过转轴与所述外筒体两端面穿装；在该转筒的筒壁上均匀布设有多排出气孔，在所述外筒体上设有与所述多排出气孔位置对应的单排排气孔。
2.根据权利要求1所述的挤出机，其特征在于：所述起泡器设置在所述挤压装置的成型模具口内。
3.根据权利要求2所述的挤出机，其特征在于：所述转筒内设有保压器；该保压器包括一个气泵，该气泵能持续向转筒内注入气体。
4.根据权利要求3所述的挤出机，其特征在于：在所述转轴上设有能带动转筒转动的驱动马达，在所述保压器上连接有电控阀；所述马达和电控阀均通过电线与自动控制电路连接。
5.根据权利要求4所述的挤出机，其特征在于：所述起泡器水平架设在所述成型模具口内，所述起泡器的单排排气孔的气泡排出方向与所述成型模具口的出料方向相一致。
6.一种使用如权利要求1-5中任一所述挤出机的导光板的制造方法，其特征在于：该方法包括如下步骤：
S1、将导光原料装入加热装置的步骤；
S2、加热装置将导光原料加热至熔融态的步骤；
S3、挤压装置将熔融态导光原料挤压成熔融态导光原料板的步骤；
S4、在挤出的过程中控制起泡器将气泡注入熔融态导光原料板的步骤；
S5、熔融态导光原料板经成型模具口挤出成型导光板的步骤。
7.根据权利要求6所述导光板的制造方法，其特征在于：在所述步骤S4中还包括如下步骤:
S41、在自动控制电路内预设微透点分布图的步骤；
S42、挤出机的自动控制电路根据微透点分布图自动控制起泡器排泡的步骤。
8.根据权利要求7所述导光板的制造方法，其特征在于：在所述步骤S42中还包括如下步骤:
S421、自动控制电路通过控制保压器注入气体的压强以调整气泡大小的步骤；
S422、自动控制电路通过控制转筒旋转速度以调整气泡排布密度的步骤。
9.根据权利要求8所述导光板的制造方法，其特征在于：在所述步骤S5中还包括：
S51、经挤出的熔融态导光原料板通过连接在成型模具口上的水冷装置进行循环水冷却后形成可塑性导光原料板的步骤；
S52、可塑性导光原料板经滚压装置滚压成可塑性导光板材的步骤；
S53、可塑性导光板材经传送装置导出的步骤；
S54、在导出过程中，可塑性导光板材经自然冷却后形成导光板材的步骤；
S55、导光板材经切割装置切割成导光板的步骤。
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CN102298169A (zh) * 2011-08-24 2011-12-28 深圳市华星光电技术有限公司 导光板及其制造方法
CN102582087A (zh) * 2012-02-14 2012-07-18 深圳大学 一种平面显示背光功能模组的制造设备及制造方法

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