KR101147116B1 - Method of Manufacturing Optical Plate Assembly - Google Patents

Abstract

In the present invention, the step of injecting the first resin into the pattern portion of the first pattern roller (S1), the first resin is injected into the pattern portion of the first pattern roller while rotating the first pattern roller attached to one surface of the diffusion sheet Forming an air layer forming protrusion (S2), attaching a back surface of the air layer forming protrusion with the diffusion sheet to an upper surface of the light guide plate to form an air layer (S3), and forming the air layer forming protrusion. And attaching an adhesive means to the back surface of the sheet (S4), and attaching a prism sheet layer to the back surface of the adhesive means to which the diffusion sheet is attached (S5).

Backlight unit, air layer, protrusion, pattern roller

Description

Manufacturing method of backlight unit {Method of Manufacturing Optical Plate Assembly}

The present invention relates to a method for manufacturing a backlight unit, and more particularly, to form an air layer between a light guide plate and a diffusion sheet constituting a backlight unit of a liquid crystal display device so that incident light from the light source on the side surface is uniformly spread over the entire surface. The present invention relates to a method for manufacturing a backlight unit that can be emitted and can reduce process time and cost.

Display devices are widely used in devices such as mobile phones, TVs, computer monitors, PDAs, and navigation devices as visual information transmission media. In addition, in order to preoccupy an important position in the display device industry in the future, it is required to satisfy requirements such as low power consumption, thinning, light weight, high quality, and large size.

As such display devices, recently developed and mass-produced displays include Liquid Crystal Display (LCD), Plasma Display Panel (PDP), Organic Light Emitting Diodes (OLED), and the like. The liquid crystal display device (LCD) is an electric device that changes and transmits various electrical information generated by various devices into visual information by using a change in transmittance of liquid crystal according to an applied voltage. It consists of a glass substrate, liquid crystal injected between them, and a backlight unit (BLU).

In addition, the backlight unit (BLU), which is a core component of the liquid crystal display device, includes a light source, a light guide plate, a diffusion plate, and a prism sheet. Among them, DLD (Light Diffusion Plate) is to make the color and brightness uniform across the screen by diffusing the light from the light source along the surface.It is manufactured by applying a diffusion agent to the substrate.Prism Sheet In order to improve the diffusion plate and LCD brightness, it is laminated on the diffusion plate.

In the case of the diffuser plate, a diffusing agent is applied to the extruded PMMA substrate, or the diffusing agent is dispersed by dispersing it in the molten PMMA resin. In addition, the prism sheet is subjected to a process of manufacturing a fine pattern using a prism shape roller, and then used to cut each diffusion film (or diffuser plate) and prism sheet to manufacture a backlight unit.

In addition, the backlight unit produced by this method has a structure in which a prism sheet is laminated on a flat diffusion plate, thereby increasing the number of processes and increasing the cost. In the case of integrating the prism sheet, the diffusion plate, and the light guide plate developed to solve this problem, the diffusion layer and the light guide plate are attached without a gap. In addition, the backlight unit having such a structure has a problem in that a bright line and a hot-spot phenomenon occurs when the LCD is manufactured as a liquid crystal display product, and the luminance of the entire liquid crystal display is not uniform.

1 is a cross-sectional view schematically showing a conventional integrated backlight unit and a graph showing a change in luminance with respect to a plane distance of the backlight unit.

As shown in FIG. 1, the conventional integrated backlight unit includes a light source 1, a light guide plate 2, a diffusion layer 3, and a prism pattern 4. However, in the backlight unit according to the related art, after the light emitted from the light source 1 on one side is incident into the light guide plate 2, some light (light traveling at an angle of incidence greater than the critical angle) is emitted from the emission surface and the diffusion layer 3. When it collides with the diffusion agent of the diffusion layer 3 at the boundary of the internal reflection is not reflected, but is emitted to the outside through the diffusion layer 3, the amount of internal reflection at a position close to the light source is greatly reduced. Therefore, as shown in the graph of FIG. 1, as the distance from the light source 1 increases, the amount of light emitted to the outside decreases remarkably, resulting in uneven luminance of the entire display. There was a problem in that a hot-spot phenomenon occurs.

In addition, according to the prior art, since the diffusion plate and the prism sheet were used in a separate process, the production cost is increased due to the process defect rate of optical components such as the diffusion film or the prism sheet during the large display manufacturing process. This took a long time.

In order to solve these problems, the present inventors can form an air layer between the diffusion sheet and the light guide plate to emit light of uniform and high brightness over the entire surface, and can be manufactured in a single process to reduce process time and cost. In addition, the company has developed a method of manufacturing a backlight unit capable of producing high quality products by minimizing errors in pattern formation.

SUMMARY OF THE INVENTION An object of the present invention is to provide a method of manufacturing a backlight unit capable of emitting light of uniform and high luminance over an entire surface by forming an air layer between a diffusion sheet and a light guide plate.

Another object of the present invention is to provide a method for manufacturing a backlight unit that can be manufactured in a single process to reduce the process time and cost.

Still another object of the present invention is to provide a method of manufacturing a backlight unit capable of producing a high quality product by minimizing an error in pattern formation.

The above and other objects of the present invention can be achieved by the present invention described below.

In the method of manufacturing a backlight unit according to the present invention, a step of injecting a first resin into a pattern portion of a first pattern roller (S1), and the first resin injected into the pattern portion of the first pattern roller while the first pattern roller is rotated Attaching to one surface of the diffusion sheet to form an air layer forming protrusion (S2), attaching a rear surface of the air layer forming protrusion to which the diffusion sheet is attached to an upper surface of the light guide plate to form an air layer (S3), and Attaching an adhesive means to the back surface of the diffusion sheet on which the air layer forming protrusion is formed (S4), and attaching a prism sheet layer to the back surface of the adhesion means to which the diffusion sheet is attached (S5). .

Here, the step S2 is characterized in that to form a projection for forming an air layer by pressing the first resin injected into the pattern portion of the first pattern roller to a surface of the diffusion sheet by pressing with a press roller.

The step S2 is characterized in that it further comprises the step of curing the formed air layer forming protrusions with an ultraviolet curing device or a heater.

The step of attaching the adhesive means of the step S4 is characterized in that the adhesive film unloaded from the take-up roller is attached to the back surface of the diffusion sheet on which the air layer forming protrusion is formed, or after applying an adhesive is pressed with a press roller.

In the step S5, the prism pattern formed by injecting the second resin into the pattern portion of the second pattern roller is attached to the back surface of the adhesive film with the diffusion sheet, or is pressed with a press roller while applying an adhesive.

The step S5 further comprises the step of curing the formed prism pattern with an ultraviolet curing device or a heater.

The step S3 is characterized in that to form an air layer by pressing with a press roller while attaching the back surface of the air layer forming protrusion with the diffusion sheet attached to the upper surface of the light guide plate.

The manufacturing method further includes the step of attaching the reflective lens to one surface of the adhesive means, and removing the release film while attaching the back surface of the adhesive means to which the reflective lens is attached to the lower surface of the light guide plate (S6).

In step S6, the back surface of the adhesive means to which the reflective lens is attached is attached to the lower surface of the light guide plate, and is pressed by a press roller.

The step of attaching the reflective lens on one surface of the adhesive means of step S6 is characterized in that the adhesive film is laminated on one surface of the release film, or after applying the adhesive to attach the reflective lens on the adhesive film or adhesive.

The step S6 further comprises the step of curing the formed lens pattern with an ultraviolet curing device or a heater.

According to the present invention, an air layer is formed between the diffusion sheet and the light guide plate to emit light of uniform and high luminance over the entire surface, and can be manufactured in a single process to reduce process time and cost, and to reduce errors in pattern formation. The invention has the effect of providing a method of manufacturing a backlight unit which can produce a high quality product by minimizing.

Hereinafter, a method for manufacturing a backlight unit according to the present invention will be described in detail with reference to the accompanying drawings, but the present invention is not limited to the following description, and those skilled in the art will understand the technical idea of the present invention. The present invention may be embodied in various other forms without departing from the scope thereof.

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In the backlight unit according to the present invention, the first resin is injected into the pattern portion of the first pattern roller (step S1), and the first pattern roller is rotated to diffuse the first resin injected into the pattern portion of the first pattern roller. Attaching to one surface of the sheet to form an air layer forming protrusion (step S2), attaching a back surface of the air layer forming protrusion to which the diffusion sheet is attached to an upper surface of the light guide plate to form an air layer (step S3), and Attaching an adhesive means to the back surface of the diffusion sheet on which the air layer forming protrusion is formed (step S4), and attaching a prism sheet layer to the back surface of the adhesion means to which the diffusion sheet is attached (step S5). In addition, in the manufacturing method according to the present invention, after the step S5, attaching the reflective lens to one surface of the adhesive means, and removing the release film while attaching the back surface of the adhesive means with the reflective lens attached to the lower surface of the light guide plate (S6). Step) may be further included.

2 (A) is a schematic diagram showing a process of forming a diffusion sheet, an air layer forming protrusion, an adhesive film and a prism sheet layer on the upper surface of the light guide plate according to the present invention.

As shown in FIG. 2A, the upper surface of the light guide plate 30 according to the present invention has an air layer forming protrusion 40, a diffusion sheet 60, a second adhesive layer 80, and a prism sheet layer ( 90) are sequentially stacked. Hereinafter, a process of stacking the air layer forming protrusion 40, the diffusion sheet 60, the second adhesive layer 80, and the prism sheet layer 90 on the upper surface of the light guide plate 30 will be described in more detail.

First, the diffusion sheet 60 made of a flexible resin containing a diffusion agent is transferred in the direction of the first pattern roller. At this time, the first resin is transferred from the first resin injector 120 to the first pattern roller 100 and coated on the outer circumferential surface of the first pattern roller 100. The first resin applied is passed through the first scriber 130, and the resin applied to the outer circumferential surface of the first pattern roller 100 except for the first resin injected into the pattern portion 110 of the first pattern roller is removed. do. Thereafter, the first pattern roller 100 rotates to attach the first resin injected into the pattern portion 110 of the first pattern roller to one surface of the diffusion sheet 60 to form the air layer forming protrusion 40. The process may further include a step of pressing by the press roller 200 and / or hardening the air layer forming protrusion 40 with an ultraviolet (UV) curing apparatus or a heater (Heater). Here, the first resin is not particularly limited, but one type of resin selected from the group consisting of urethane acrylate (Urethane Acrylate) compounds, silicone (Silicone) compounds, and epoxy (C) compounds with adhesive properties is used. It is preferable. In addition, the selected resin is preferably composed of a resin containing a diffusing agent.

The diffusion sheet 60 having the air layer forming protrusion 40 attached to one surface is transferred in the direction of the arrow. In addition, the second adhesive layer 80 unwound from the rotating winding roller 300 is moved in the direction of the second pattern roller 400 while being pressed by the press roller 200. At this time, the second resin is transferred from the second resin injector 420 to the second pattern roller 400 and applied to the outer circumferential surface of the second pattern roller 400. The applied second resin passes through the second scriber 430, and the resin applied to the outer circumferential surface of the second pattern roller 400 except for the second resin injected into the pattern portion 410 of the second pattern roller is removed. do. Thereafter, the second pattern roller 400 attaches the second resin injected into the pattern portion 410 of the second pattern roller to one surface of the second adhesive layer 80 to form the prism sheet layer 90. . In this process, while forming the prism sheet layer 90, the process of removing the release film 70 attached to the rear surface of the second adhesive layer 80 may be further performed. The method may further include a step of pressing the press roller 200 and / or a step of curing the prism sheet layer 80 with an ultraviolet (UV) curing apparatus or a heater.

Thereafter, the air layer forming protrusion 40, the diffusion sheet 60, the second adhesive layer 80, and the prism sheet layer 90 are sequentially stacked, and then pass through the feed roller 200, and then the diffusion sheet 60. The back surface of the air layer forming protrusion 40 to which is attached is attached to the upper surface of the light guide plate 30 to manufacture a backlight unit in which the air layer 50 is formed. Here, the second resin is not particularly limited, but one type of resin selected from among urethane acrylate (Urethane Acrylate) compounds, silicone (Silicone) compounds, and epoxy (Epoxy) compounds having adhesive properties is used. It is preferable.

 FIG. 2B is a configuration diagram schematically illustrating a process of attaching a diffusion sheet and an air layer forming protrusion to an upper surface of the light guide plate, forming an adhesive layer, and then forming a prism sheet layer on the back surface of the adhesive layer.

As shown in FIG. 2B, the diffusion sheet 60 having the air layer forming protrusion 40 attached to one surface thereof is injected from the adhesive injection apparatus 310 on the back side to which the air layer forming protrusion 40 is attached. You may use the method of apply | coating the adhesive which becomes. After the adhesive is applied to form the second adhesive layer 80, the prism sheet layer 90 is attached to the second adhesive layer 80. In addition, the prism sheet layer 90 of the present invention may be formed by patterning with a pattern roller, and may also adopt a method of laminating an already manufactured prism sheet layer 90 on the second adhesive layer 80.

3 is a configuration diagram schematically illustrating a process of attaching a reflective lens to a lower surface of a light guide plate according to the present invention.

As shown in FIG. 3, the reflective lens 10 and the adhesive layer 20 are attached to the lower surface of the light guide plate 30. Hereinafter, a process of attaching the reflective lens 10 and the first adhesive layer 20 to the lower surface of the light guide plate 30 will be described in more detail.

First, the first adhesive layer 20 is moved in the direction of the third pattern roller, and at this time, the third resin is transferred from the third resin injector 620 to the third pattern roller 600 and the third pattern roller 600. It is applied to the outer circumferential surface of The coated third resin passes through the third scriber 630 and the resin applied to the outer circumferential surface of the third pattern roller 600 is removed except for the third resin injected into the pattern portion 610 of the third pattern roller. do. Thereafter, the third pattern roller 600 rotates to attach the third resin injected into the pattern portion 610 of the third pattern roller to one surface of the adhesive layer 20 to form the reflective lens 10. In this process, the reflective lens 10 may be attached to one surface of the first adhesive layer 20, and then the process of removing the release film 70 attached to the rear surface of the first adhesive layer 20 may be further performed. In addition, the method may further include a process of pressing by the press roller 200 and / or a process of curing the reflective lens 10 with an ultraviolet (UV) curing apparatus or a heater. Thereafter, the rear surface of the adhesive layer 20 to which the reflective lens 10 is attached is attached to the lower surface of the light guide plate 30. Herein, the third resin is not particularly limited, but may be selected from one of a urethane acrylate compound, a silicone compound, and an epoxy compound having adhesive properties. It is preferable.

4 is a configuration diagram schematically showing a process of manufacturing a backlight unit according to the present invention.

As shown in FIG. 4, the backlight unit according to the present invention includes an air layer forming protrusion 40, an air layer 50, a diffusion sheet 60, a second adhesive layer 80, and a prism on an upper surface of the light guide plate 30. The sheet layer 90 is sequentially stacked and manufactured by attaching the first adhesive layer 20 and the reflective lens 10 to the lower surface of the light guide plate 30. As shown in the enlarged view of FIG. 4, the backlight unit manufactured according to the manufacturing process of the present invention has a pattern formed by the pattern roller, and is manufactured in a continuous process, thereby minimizing the error in pattern formation, thereby lowering the defective rate, and the production time. And an advantage in production cost, and since the air layer 50 is formed between the diffusion sheet 60 and the light guide plate 30, it is possible to produce a liquid crystal display product capable of emitting uniform and high luminance light over the entire surface. There is an advantage.

1 is a cross-sectional view schematically showing a conventional integrated backlight unit and a graph showing a luminance variation with respect to a planar distance of the backlight unit;

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Figure 2 (A) is a schematic diagram showing a process of forming a diffusion sheet, an air layer forming protrusion, an adhesive film and a prism sheet layer on the upper surface of the light guide plate according to the present invention, Figure 2 (B) is a light guide plate. A schematic diagram illustrating a process of attaching a diffusion sheet and a projection for forming an air layer on an upper surface of the substrate, and forming a prism sheet layer on a rear surface of the adhesive layer after forming an adhesive layer.

3 is a schematic view illustrating a process of attaching a reflective lens to a lower surface of a light guide plate according to the present invention;

4 is a configuration diagram schematically showing a process of manufacturing a backlight unit according to the present invention

Explanation of symbols on the main parts of the drawings

10: reflective lens 20: first adhesive layer

30: light guide plate 40: protrusion for forming air layer

50: air layer 60: diffusion sheet

70: release film 80: second adhesive layer

90: prism sheet layer 100: first pattern roller

110: first pattern portion 120: first resin injector

130: first scriber 200: press roller

300: adhesive film winding roller 310: adhesive injection device

400: second pattern roller 410: second pattern portion

420: second resin injector 430: second scriber

500: curing apparatus 600: third pattern roller

610: third pattern portion 620: third resin injection device

630: third scriber

Claims (11)

Injecting a first resin into the pattern portion of the first pattern roller (S1); Attaching the first resin injected into the pattern portion of the first pattern roller to one surface of the diffusion sheet while rotating the first pattern roller to form an air layer forming protrusion (S2); Attaching a back surface of the air layer forming protrusion to which the diffusion sheet is attached to an upper surface of the light guide plate to form an air layer (S3); Attaching an adhesive means to the back surface of the diffusion sheet on which the air layer forming protrusion is formed (S4); And Attaching a prism sheet layer to a rear surface of the bonding means to which the diffusion sheet is attached (S5); Method of manufacturing a backlight unit comprising a. The backlight unit of claim 1, wherein in the step S2, the first resin injected into the pattern portion of the first pattern roller is attached to one surface of the diffusion sheet and pressed by a press roller to form an air layer forming protrusion. Manufacturing method. The method of claim 1, wherein the step S2 further comprises curing the formed air layer forming protrusion with an ultraviolet curing device or a heater. The method of claim 1, wherein the attaching of the adhesive means of step S4 comprises attaching the adhesive film unwound from the winding roller or applying an adhesive to the back surface of the diffusion sheet on which the air layer forming protrusion is formed, and then compressing the adhesive means with a press roller. Method for manufacturing a backlight unit, characterized in that. The method of claim 1, wherein the step S5 is to attach the prism pattern formed by injecting the second resin into the pattern portion of the second pattern roller to the back surface of the adhesive film to which the diffusion sheet is attached or to press the pressing roller while applying the adhesive Method for producing a backlight unit, characterized in that. The method of claim 5, wherein the step S5 further comprises curing the formed prism pattern with an ultraviolet curing device or a heater. The method of claim 1, wherein the step S3 is performed by pressing the back surface of the air layer forming protrusion having the diffusion sheet attached to the upper surface of the light guide plate to form an air layer by pressing with a press roller. The method of claim 1, further comprising attaching a reflective lens to one surface of the adhesive means and removing the release film while attaching the rear surface of the adhesive means to which the reflective lens is attached to the lower surface of the light guide plate (S6). Method for producing a backlight unit, characterized in that. The method of claim 8, wherein the step S6 is performed by pressing the back surface of the adhesive means to which the reflective lens is attached to the lower surface of the light guide plate with a press roller. 10. The method of claim 8 or 9, wherein the step of attaching the reflective lens to one surface of the bonding means of the step S6 is laminated on one surface of the release film, or after applying the adhesive is reflected on the adhesive film or adhesive A method for manufacturing a backlight unit, comprising attaching a lens. The method of claim 8, wherein the step S6 further comprises curing the formed lens pattern with an ultraviolet curing device or a heater.

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