CN116413843A

CN116413843A - Dodging element, pressing forming die and manufacturing method thereof

Info

Publication number: CN116413843A
Application number: CN202111669455.9A
Authority: CN
Inventors: 郝芳; 沈洪磊; 孙万方; 黄河
Original assignee: Shanghai Kunyou Technology Co ltd
Current assignee: Shanghai Kunyou Technology Co ltd
Priority date: 2021-12-31
Filing date: 2021-12-31
Publication date: 2023-07-11

Abstract

The invention discloses a dodging element, a compression molding die and a manufacturing method thereof, wherein the dodging element comprises a microstructure part and a substrate part, and the microstructure part and the substrate part are integrally formed by molding materials through one-time compression.

Description

Dodging element, pressing forming die and manufacturing method thereof

Technical Field

The invention relates to the field of optics, in particular to a light homogenizing element, a pressing forming die and a manufacturing method thereof.

Background

Diffusion plates (diffusers) are mainly used for modulating light beams emitted by light sources, which form uniform light fields in a required field angle range, and illuminate a target scene. One type of Diffuser is based on the principle of light diffraction, and has two obvious defects of low energy uniformity and low transmittance caused by low diffraction efficiency obviously due to zero order, so that the application of the Diffuser is limited. Another type of Diffuser is based on the principle of light refraction, which is commonly employed with microlens arrays.

Most of the existing Differs based on the micro-lens array are regular micro-lens arrays, but because the micro-lenses are periodically arranged in a regular and orderly mode in the row and column directions, coherent light beams emitted by a coherent light source can interfere in the space propagation process through the regular micro-lens arrays, so that stripe patterns with alternate brightness are formed in a far field, the uniform light effect of the Differs is seriously weakened, and the use is influenced.

Patent application publication number CN105093365a discloses a diffusion sheet and a manufacturing method thereof, specifically discloses a manufacturing method of the diffusion sheet, S1: coating a layer of photoresist on the upper surface of the substrate. The thickness of the photoresist is preferably within 30 to 50 micrometers, and the specific thickness can be selected according to practical situations, so as to form diffusion particles with corresponding heights. S2: and placing a mask plate on the photoresist. The size and the number of the light-transmitting parts and the light-shielding parts of the mask 4 can be designed to adjust the size of the diffusion particles and the density of the diffusion particles. S3: and exposing and developing the photoresist by utilizing ultraviolet light to penetrate through the mask. After exposure, the photoresist is irradiated by ultraviolet light by using photoresist developer, and the residual photoresist (i.e. diffusion particles) can be removed, and the cross section of the residual photoresist is inverted trapezoid.

In the patent, the diffusion sheet is manufactured by means of exposure and development, the manufacturing process is complex, and the manufacturing process is difficult to control.

The patent application document with application publication number CN211505940U discloses an optical diffuser, which specifically discloses: referring to fig. 1, the optical diffusion sheet includes a substrate 1P and microlenses 2P. The microlens 2P contains uniformly distributed scattering particles 3P therein. The microlenses 2P may be manufactured by imprinting or by spray deposition. The master in the imprint method is manufactured by direct laser writing, and thus the microlenses 2P conforming to the design surface size can be imprinted. The substrate 1P serves to carry the microlenses 2P, and the substrate 1P and the microlenses 2P may be directly bonded, i.e., directly spray-molded on the substrate 1P or the material of the microlenses 2P may be placed on the substrate 1P and then embossed. Of course, the substrate 1P and the microlenses 2P may also be formed by injection molding. The scattering particles 3P can be added into the micro lens 2P through the control of the optical tweezers, or a layer of micro lens 2P material can be sprayed and deposited, and then a layer of scattering particles 3P is sprayed, so that the amount of each layer of scattering particles 3P can be well controlled. Of course, when the microlens 2P is manufactured by the imprinting method, the material of the microlens 2P may be directly mixed with the scattering particles 3P and then placed on the substrate 1P to be imprinted, so that the scattering particles 3P are more uniformly distributed. The diffusion sheet in this patent application is manufactured by an embossing process.

In terms of the overall manufacturing method, both the development system and the imprinting system, the substrate and the microlens or diffusion layer are formed through a plurality of process steps, respectively. Because the substrate and the expansion layer are made of two different materials, the bonding force of the two layers of substances is unstable, so that the micro lens layer or the diffusion layer is easy to fall off, and the optical performance is influenced. After cold and hot impact experiments necessary for common electronic consumer products, a certain probability of delamination of two layers of substances is found.

Further, some diffusion plates are composed of a glass substrate and a resin microlens or an expansion structure, and are manufactured by embossing a resin layer with a micro-nano structure on the surface of the glass substrate by a nano embossing method. Due to the fact that glass is fragile, considering the eye safety risk of some application scenes, glass breakage needs to be identified, corresponding sensors are added, and the cost of module ends and end products is greatly increased.

Other diffusion plates are molded integrally by conventional injection molding processes using thermoplastic materials as the starting material. The disadvantage of this technique is that the thermoplastic material has poor flowability, which results in a large problem for replication of the micro-nano structure, the finer the structure, the more difficult the injection molding, and poor replication ability. For example, the following problems exist:

the temperature of the molten resin gradually decreases as it flows in the mold, resulting in difficulty in molding;

residual air exists in the microstructure of the surface of the die, particularly in the deep hole;

shrinkage and non-uniformity of shrinkage during cooling;

the shape retention pressure is insufficient in the cooling and solidifying process;

the material is molded at high temperature, the difference between the appearance and the design after cooling is larger, the design and compensation of the die structure of the front-end two-dimensional structure are easier, and the design and compensation of the die of the front-end three-dimensional appearance are more difficult.

Disclosure of Invention

An advantage of the present invention is to provide a light homogenizing element, a press molding die thereof, and a manufacturing method thereof, which form the light homogenizing element by means of integral pressing without the need of secondarily combining a base layer and a diffusion layer.

An advantage of the present invention is to provide a light homogenizing element, a press molding die and a manufacturing method thereof, which use open type integral press to facilitate air between the die and molding material to be discharged during the press process, and avoid voids in the light homogenizing element to affect optical performance.

An advantage of the present invention is to provide a light homogenizing element, a press molding die and a manufacturing method thereof, which uses a thermosetting resin for molding at a lower temperature, does not require high temperature injection molding such as thermoplastic materials, and has small thermal expansion of the product and small difference from the design structure.

An advantage of the present invention is to provide a light homogenizing element, a press molding die and a manufacturing method thereof, wherein the light homogenizing element is formed by thermosetting resin, and the manufacturing process has simple process conditions and equipment.

An advantage of the present invention is to provide a light homogenizing element, a press molding die and a manufacturing method thereof, wherein the whole light homogenizing element is formed by thermosetting resin, and the light homogenizing element has good toughness and is not easy to crack.

An advantage of the present invention is to provide a light homogenizing element, a press molding die and a manufacturing method thereof, wherein the light homogenizing element is integrally formed of a thermosetting resin, and the material is integrally lower in cost than embossing on glass.

One advantage of the present invention is to provide a light homogenizing element, a press molding die and a manufacturing method thereof, which are not easy to crack, and as an optical device in a module, an additional sensing device for sensing crack is not needed to be added in the module, so that the cost of a module end and a terminal product is reduced.

The invention has the advantages that the invention provides the light homogenizing element, the pressing forming die and the manufacturing method thereof, the duplication of the micro-nano structure is realized by adopting a mode of nanometer integral pressing, and the structure reduction capability is strong.

In order to achieve at least one of the above advantages, the present invention provides a light homogenizing element, which includes:

a microstructure portion including a plurality of microstructure units formed by surface pressing; and

and a base portion, the microstructure portion and the base portion being integrally formed by molding material by one-time pressing.

According to one embodiment, the light homogenizing element comprises two microstructure parts, the two microstructure parts are respectively located at two sides of the base part, and the two microstructure parts and the base part are integrally pressed and molded through the molding material.

According to one embodiment, the light homogenizing element has a different structural morphology of the two microstructure portions.

Another aspect of the present invention provides a method for manufacturing a light homogenizing element, including the steps of:

(A) Providing an upper die and a lower die, wherein one side of the upper die, which faces the lower die, is taken as the inner surface of the upper die, and one side of the lower die, which faces the upper die, is taken as the inner surface of the lower die, and the inner surfaces of the upper die and/or the lower die are provided with a structural form matched with the microstructure part of the light homogenizing element;

(B) Arranging a molding material at a preset position of the lower die, and arranging the upper die and the lower die oppositely; and

(C) And controlling the distance between the upper die and the lower die, pressing the thermosetting resin material for molding at normal temperature through the upper die and the lower die once, and obtaining the light homogenizing element through a heating and curing mode, so that the light homogenizing element is provided with the microstructure part matched with the inner surface of the upper die and/or the lower die and the substrate part integrally molded with the microstructure part.

The manufacturing method according to one embodiment, wherein in the step (a), the inner surfaces of the upper mold and the lower mold are each provided with a structural form matching with the microstructure portion of the light homogenizing element, and in the step (B), the upper mold and the lower mold are oppositely disposed in alignment according to alignment marks on the upper mold and/or the lower mold, and in the step (C), the distance between the upper mold and the lower mold is gradually reduced, and the thermosetting resin material is pressed to spread out from the center until a gap between the upper mold and the lower mold reaches a preset value.

According to one embodiment of the production method, in the step (C), the pressure at which the thermosetting resin material is pressed ranges from normal pressure to 30bar, the pressure uniformity at which the thermosetting resin material is pressed by the upper mold and the lower mold is controlled by means of gas pressurization or hydraulic pressure, and the temperature at which the thermosetting resin material is heat-cured ranges from room temperature to 200 ℃.

Another aspect of the present invention provides a press molding die for a dodging element, comprising an upper die and a lower die, wherein:

the inner surface of the upper die and the inner surface of the lower die are arranged oppositely, the lower die is provided with a thermosetting resin material, and the upper die and the lower die are mutually close to each other to press the thermosetting resin material to form the microstructure part and the substrate part of the light homogenizing element once.

According to one embodiment, the inner surfaces of the upper die and the lower die are provided with structural shapes matched with the microstructure parts of the dodging element, wherein the upper die and/or the lower die are provided with alignment marks so as to align the inner surfaces of the upper die and the lower die and oppositely arrange the inner surfaces of the upper die and the lower die during press molding.

The press forming die according to one embodiment, wherein the upper die and the lower die are open-closed dies.

The compression molding die according to one embodiment, wherein the upper die and the lower die are non-transparent dies.

Drawings

Fig. 1 is a schematic view of an optical diffusion sheet of the prior art.

Fig. 2A is a schematic cross-sectional view of a light homogenizing element according to a first embodiment of the present invention.

Fig. 2B is a partial enlarged view of the position a in fig. 2A.

Fig. 3 is a schematic view of a manufacturing mold of a light homogenizing element according to a first embodiment of the present invention.

Fig. 4A-4F are schematic views illustrating a manufacturing process of a dodging component according to a first embodiment of the present invention.

Fig. 5 is a schematic cross-sectional view of a light homogenizing element according to a second embodiment of the present invention.

Fig. 6 is a schematic view of a manufacturing process of a light homogenizing element according to a second embodiment of the present invention.

Detailed Description

The following description is presented to enable one of ordinary skill in the art to make and use the invention. The preferred embodiments in the following description are by way of example only and other obvious variations will occur to those skilled in the art. The basic principles of the invention defined in the following description may be applied to other embodiments, variations, modifications, equivalents, and other technical solutions without departing from the spirit and scope of the invention.

It will be appreciated by those skilled in the art that in the present disclosure, the terms "longitudinal," "transverse," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," etc. refer to an orientation or positional relationship based on that shown in the drawings, which is merely for convenience of description and to simplify the description, and do not indicate or imply that the apparatus or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore the above terms should not be construed as limiting the present invention.

It will be understood that the terms "a" and "an" should be interpreted as referring to "at least one" or "one or more," i.e., in one embodiment, the number of elements may be one, while in another embodiment, the number of elements may be plural, and the term "a" should not be interpreted as limiting the number.

References to "one embodiment," "an embodiment," "example embodiment," "various embodiments," "some embodiments," etc., indicate that the embodiment(s) of the invention so described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the feature, structure, or characteristic. Furthermore, some embodiments may have some, all, or none of the features described for other embodiments.

Fig. 2A is a schematic cross-sectional view of a light homogenizing element according to a first embodiment of the present invention. Fig. 2B is a partial enlarged view of the position a in fig. 2A. Fig. 3 is a schematic view of a manufacturing mold of a light homogenizing element according to a first embodiment of the present invention. Fig. 4A-4F are schematic views illustrating a manufacturing process of a dodging component according to a first embodiment of the present invention.

Referring to fig. 2A to 4F, the present invention provides a light homogenizing element 1, where the light homogenizing element 1 includes a base portion 12 and a microstructure portion 11, and the microstructure portion 11 and the base portion 12 are formed at one time by integral press molding. That is, the base portion 12 and the microstructure portion 11 are formed together in one process. The light homogenizing element 1 forms uniform outgoing light based on refraction, reflection and scattering.

Referring to fig. 2a,2b, the light homogenizing element 1 has an upper surface 101 and a lower surface 102, the upper surface 101 is formed by the microstructure portion 11, and the lower surface 102 is formed by the base portion 12.

In one embodiment of the present invention, the upper surface 101 of the light homogenizing element 1 has a concave-convex structure, and the lower surface 102 has a substantially planar structure.

During operation, incident light rays are refracted, reflected and scattered by the microstructured portion 11 and the base portion 12 of the light homogenizing element 1 to form uniform outgoing light. The microstructure portion 11 is a light-incident side, and the base portion 12 is a light-emergent side.

The microstructure portion 11 of the light homogenizing element 1 includes at least one microstructure unit 111, and a plurality of microstructure units 111 are continuously distributed to form the upper surface 101 of the light homogenizing element 1. That is, the concave-convex shape of the upper surface 101 of the light homogenizing element 1 is determined by the shape of each microstructure unit 111. In one embodiment of the present invention, the shape of the microstructure elements 111 is a substantially concave hemispherical shape or a concave spherical cap, and in other embodiments of the present invention, the shape of the microstructure elements 111 is a concave trapezoid, a concave triangle, or the like, and the present invention is not limited in this respect. The shape of each of the microstructure elements 111 may be the same or different.

Preferably, the light homogenizing element 1 is formed by a thermosetting molding material 3, that is, on the one hand, the base portion 12 and the microstructure portion 11 of the light homogenizing element 1 are structurally integrated and are composed of the same material, so that delamination problems occurring in the combination of different materials of the existing two-layer structure can be better solved; on the other hand, because the thermosetting material is in a normal temperature liquid state or a semi-solid state, that is, in a deformable state at normal temperature, and is heated or cured at a temperature rise, the compression molding temperature is lower, the heating curing temperature is lower, and no drastic temperature difference change exists in the whole processing process, so that the light homogenizing element 1 has better flexibility. These injection molding processes are two different processes relative to diffusion plates made of thermoplastic materials.

Preferably, the light homogenizing element 1 is formed of a thermosetting resin adhesive material. Thermosetting resins are suitable for optical materials that are not suitable for UV curing.

Further, referring to fig. 3-4F, the present invention provides a press molding die 2, and the light homogenizing element 1 is integrally pressed and molded by the press molding die 2. The integral press molding die 2 includes an upper die 21 and a lower die 22, the upper die 21 being used to form the microstructure portion 11, and the lower die 22 being used to form the base portion 12. At the time of molding, a molding space 201 is formed between the upper mold 21 and the lower mold 22.

At the time of molding, the molding material 3 is placed between the upper die 21 and the lower die 22, and then the upper die 21 and/or the lower die 22 are pressed, and the light homogenizing element 1 is formed from the molding material 3 at a time, that is, the microstructure portion 11 and the base portion 12 are formed at a time. According to one embodiment of the present invention, the molding material 3 is a thermosetting resin material. That is, the molding material 3 is molded at a relatively low temperature and cured at a relatively high temperature or in a heated state. It should be noted that, the conventional thermoplastic materials need to be melted at a higher temperature and cooled and molded in a closed mold, and a relatively large temperature difference change is required to be passed through the higher heating temperature, so that the manufactured product generates a large thermal expansion, and the difference between the finished product and the theoretical design structure is large. In the embodiment of the invention, the thermosetting resin material is adopted, so that the molding can be performed at a lower heating temperature, the heating and curing temperature is also relatively lower, and the temperature difference is smaller, so that the formed dodging element 1 has smaller thermal expansion and better conforms to the original design structure, that is, the accuracy of the optical performance of the actual product is improved. And high temperature is not needed in the manufacturing process, so that the energy consumption in the manufacturing process is low. According to one embodiment of the invention, the heating means is oven or hot plate heating at a temperature of 45-150 ℃, and the heat curable material is not easily melted as a single heat curable molding in comparison with the thermoplastic material, but is not easily melted again like the thermoplastic material.

It should be noted that the whole of the light homogenizing element 1 is made of thermosetting materials, so that the whole has good toughness, does not have a layered structure of different types of materials, and is not easy to crack. The cost of the thermoset material is lower than the cost of imprint-on-glass manufacturing in terms of overall cost. In addition, in the manufacturing of the backlight module, the light homogenizing element 1 is not easy to crack, the light homogenizing element 1 is used as an optical device in the module, an additional sensing device for sensing crack is not needed to be added in the module, and the cost of the module end and the end product is reduced.

Preferably, the molding material 3 is a thermosetting liquid resin material in a normal temperature state.

According to the embodiment of the present invention, the upper mold 21 and the lower mold 22 are press-molded in an open manner, that is, the upper mold 21 and the lower mold 22 do not form a closed space during press molding, so that air between the pressed molding material 3 and the mold can be timely discharged, forming of air voids inside the molded light homogenizing element 1 is avoided, and influence on optical performance is avoided.

The upper mold 21 has an inner surface 2101 and an outer surface 2102, the inner surface 2101 being used to form the upper surface 101 of the light homogenizing element 1, i.e. the surface forming the microstructure portion 11, and the outer surface 2102 being used for an in-out operation, such as a pressing operation.

The inner surface 2101 of the upper mold 21 has at least one molding unit 211, the molding unit 211 corresponding to the microstructure units 111 of the light homogenizing element 1. A plurality of the molding units 211 are continuously distributed to form an inner surface 2101 of the upper mold. That is, the shape of the inner surface 2101 of the upper mold is determined by each of the molding units 211.

The configuration of the inner surface 2101 of the upper mold is related to the performance of the microstructure portion 11, that is, the shape of the inner surface is designed according to the optical expansion performance requirement of the microstructure portion 11, that is, the concave-convex shape of the upper surface 101 of the light equalizing element 1 is determined by the shape of each of the microstructure units 111, whereby a correspondence relationship is formed between the molding unit 211 and the microstructure units 111. In one embodiment of the present invention, the microstructure elements 111 are generally concave hemispheres or concave crowns in shape, and the shaped elements 211 are generally convex hemispheres or convex crowns in shape, respectively. In other embodiments of the present invention, the shape of the microstructure elements 111 is a concave trapezoid, a concave triangle, etc., and accordingly, the shape of the molding elements 211 is a convex trapezoid, a convex triangle, etc., and the present invention is not limited in this respect. The shape of each of the molding units 211 may be the same or different.

It should be noted that, in one embodiment of the present invention, the molding unit 211 of the inner surface 2101 of the upper mold can implement nano design, that is, the precision of the molding surface is controlled to be nano level, so that the microstructure unit 111 of the light homogenizing element 1 can implement better replication of micro-nano structure and has strong structure reduction capability. In one embodiment, the nano-precision of the mold is controlled by a mold replication process.

The outer surface 2202 of the lower mold is of a generally planar configuration to facilitate application of a uniform force.

The lower die 22 has an inner surface 2201 and an outer surface 2202, the inner surface 2201 of the lower die 22 being used to form the surface of the base portion 12 and the outer surface 2202 of the lower die being used for placement or pressing operations. That is, in the molding, the lower die 22 may be placed on a work table, the upper die 21 may be operated to be close to the lower die 22, or the upper die 21 and the lower die 22 may be operated to be close to each other, respectively, for press molding.

In this embodiment of the invention, both the upper surface 101 and the lower surface 102 of the lower mold 22 are generally planar in configuration, that is, the lower mold 22 may be plate-shaped to form the base portion 12 with a flat surface.

In one embodiment, the upper die 21 has a larger planar dimension than the lower die 22, that is, the press forming die 1 has a structure with a large top and a small bottom. For example, during molding, the lower mold 22 is positioned on a working platform, and the upper mold 21 is controlled to open and close to the lower mold 22. And the dodging element 1 is formed by pressing the upper die 21 with pressure while applying pressure. Since the upper mold 21 has a larger size, it has a larger control operation surface, and the force of press-fit and the specific shape of the light homogenizing element 1, such as the proportion of the microstructure portion 11 and the base portion 21 of the light homogenizing element 1, are controlled by controlling the gap and the stress between the upper mold 21 and the lower mold 22. Since the lower mold 22 is positioned on the working platform, the shape of the formed light homogenizing element 1 can be controlled by controlling the parallelism and height position of the upper mold 21. Of course, in other embodiments of the present invention, the upper die 21 and the lower die 22 may be controlled separately.

Preferably, the upper die 21 and the lower die 22 are open-closed, that is, the molding space 201 between the upper die 21 and the lower die 22 is not a closed space.

In one embodiment, the inner surfaces of the upper die and the lower die are provided with a structural form matched with the microstructure part of the dodging element, wherein the upper die and/or the lower die are provided with an alignment mark so as to align the inner surfaces of the upper die and the lower die and oppositely arrange the inner surfaces of the upper die and the lower die during compression molding. The alignment mark may be included in the microstructure portion of the light homogenizing element, or may be independent of the microstructure portion of the light homogenizing element.

In one embodiment, the upper and lower molds may be non-transparent molds, the mold material including, but not limited to, metal molds, quartz molds, silicon molds, resin material molds, and the like.

It should be noted that, as mentioned above, most of the existing Diffuser based on the micro-lens array is a regular micro-lens array, but because the micro-lenses are arranged in the row and column directions periodically and regularly, the coherent light beams emitted by the coherent light source will interfere in the space propagation process through the regular micro-lens array, so that a stripe pattern with alternate brightness is formed in the far field, which seriously weakens the uniform light effect of the Diffuser and affects the use. In the embodiment of the present invention, the light homogenizing element 1 is integrally formed by the press molding die 2, so that the surface shape change of the microstructure portion 11 of the light homogenizing element 1 can be precisely controlled by the design of the molding surface of the press molding die 2, and the shape and layout of the plurality of microstructure units 111 can be adjusted in time based on the optical action between the respective microstructures. Further, according to the embodiment of the present invention, the upper die 21 and the lower die 22 of the press molding die 2 are each of a plate-like structure extending substantially in a plane, that is, are each independent and have substantially planar surfaces, so that the controllability of the surface configuration is good, and accordingly, the surfaces of the microstructure portions 11 of the light homogenizing element 1 of different design shapes can be better realized.

Further, referring to fig. 4A-4F, the present invention provides a method for manufacturing the light homogenizing element 1 by using the press molding die 2, which includes the following steps:

step 1, preparing the upper die 21 and the lower die 22 as shown in fig. 4A;

step 2, disposing a thermosetting molding material 3 of a preset weight at the center of the lower mold 22, for example, the thermosetting molding material 3 is a thermosetting liquid resin glue, or the thermosetting molding material 3 of a preset weight is disposed at a specific position point of the lower mold 22 according to the size of the design structure, as shown in fig. 4A;

step 3, the inner surface 2101 of the upper mold is aligned toward the lower mold 22, and the inner surface 2101 of the upper mold is relatively parallel to the lower mold 22, as shown in fig. 4B; preferably, in the process of controlling the molds to be close to each other, the external force is controlled by the pressure uniformly applied by the surface, and the pressure applied by each point is dynamically controlled according to the gap value of each point.

Step 4, gradually reducing the gap between the upper die 21 and the lower die 22, wherein the forming material 3 diffuses outwards from the center in the space between the lower die 22 and the upper die 21, and the surfaces of the upper die 21 and the lower die 22 are always kept relatively parallel in the process of reducing the gap, as shown in fig. 4C;

step 5, the upper die 21 contacts the molding material 3 on the lower die 22, and the gap between the upper die 21 and the lower die 22 is continuously reduced gradually until the gap between the upper die 21 and the lower die 22 reaches a preset value, the molding material 3 does not exceed the surface of the lower die 22, and the surfaces of the upper die 21 and the lower die 22 are always kept relatively parallel, as shown in fig. 4D;

step 6, thermally curing the molding material 3, and stopping heating after a certain time at a certain temperature, as shown in fig. 4E;

step 7, the upper mold 21, the cured dodging component 1 and the lower mold 22 are separated from each other, as shown in fig. 4F;

the upper mold 21 and the lower mold 22 can be reused, and the light homogenizing element 1 after detachment is the product to be obtained.

In one embodiment, the pressure for pressing the thermosetting resin material ranges from normal pressure to 30bar, the pressure uniformity when the upper mold and the lower mold press the thermosetting resin material is controlled by means of gas pressurization or hydraulic pressure, and the temperature for heating and curing the thermosetting resin material ranges from room temperature to 200 ℃.

It should be noted that the dodging component 1 is integrally formed by pressing the pressing mold 2, and is formed by heat-curing type materials, which has many advantages:

first, in the manufacturing process of the present invention, since the structure of the light homogenizing element 1 corresponds to the molding surfaces of the upper mold 21 and the lower mold 22, the shape of the light homogenizing element 1 can be strictly controlled by controlling the shape of the molding surfaces, and thus the light homogenizing element 1 can be manufactured with a mold exhibiting better reproducibility and controllability of optical performance.

Secondly, in the pressing process, the upper mold 21 and the lower mold 22 are pressed in parallel and open, so that air between the contact surfaces of the molding material 3 and the upper mold 21 and the lower mold 22 can be gradually discharged, and the degree of discharge can be controlled by the progress in the pressing process, thereby avoiding the occurrence of a pore structure inside the light homogenizing element 1.

Thirdly, the thermosetting material is in a liquid state at normal temperature and is formed by heating at a relatively low temperature, that is, the whole integral pressing process is carried out at a relatively low temperature, so that the process working condition is better, no extra energy consumption is needed, a non-transparent master plate can be adopted, batch curing is carried out, and the output efficiency is higher.

Fourth, the light homogenizing element 1 is entirely made of thermosetting resin material, no delamination phenomenon exists, and the whole toughness is good, and can bear strict reliability tests of materials, such as thermal shock, high temperature and high humidity, reflow soldering and slight drop. According to the actual measurement, the integrally pressed light homogenizing element 1 has better reliability than a diffusion sheet formed by embossing resin on glass.

Fifth, the molding material 3 is pressed and molded at a relatively low heating temperature, and there is no temperature difference in the pressing process, so that the molding is easier, the overall processing temperature is uniform, and the problem of uneven cold and heat shrinkage caused by temperature difference is avoided.

Sixth, the open plate type structure mold can stably and controllably apply the mold closing pressure on the whole mold, and the problem of insufficient mold retention pressure in the injection molding process is avoided.

Seventh, since the light homogenizing element 1 is not easy to crack, as an optical device in the module, an additional sensing device for sensing crack is not needed to be added in the module, and the cost of the module end and the end product is reduced.

Fig. 5 is a schematic side view of a light homogenizing element according to a second embodiment of the present invention.

In this embodiment of the invention, the light homogenizing element 1 comprises a base part 12 and two micro-structured 11 parts, the two micro-structured parts 11 being located on both sides of the base part 12, respectively. The base portion 12 and the two microstructure portions 11 are integrally formed by press molding with the press molding die 2. That is, in this embodiment of the present invention, both the upper and lower surfaces 102 of the light homogenizing element 1 are optically diffusing structures. Therefore, more complicated uniformity of light can be realized, the design freedom degree is higher, a larger view field angle is realized, and the influence caused by interference fringes can be reduced.

Accordingly, the inner surface 2201 of the lower mold has at least one lower molding unit 211, and the lower molding unit 211 corresponds to the microstructure unit 111 of the light homogenizing element 1 located below. A plurality of the lower molding units 211 are continuously distributed to form an inner surface 2201 of the lower mold.

The shape of the inner surface 2101 of the upper mold and the shape of the inner surface 2201 of the lower mold may be identical or different, and the shape of the inner surface 2101 of the upper mold and the shape of the inner surface 2201 of the lower mold are determined by the specific optical properties of the microstructure portion located at the upper layer and the microstructure portion 11 located at the lower layer, which are molded separately.

It will be appreciated by persons skilled in the art that the embodiments of the invention described above and shown in the drawings are by way of example only and are not limiting. The objects of the present invention have been fully and effectively achieved. The functional and structural principles of the present invention have been shown and described in the examples and embodiments of the invention may be modified or practiced without departing from the principles described.

Claims

1. A light homogenizing element, comprising:

and a base portion, wherein the microstructure portion and the base portion are obtained by integrally pressing a thermosetting resin material at normal temperature and then heat-curing the integrally pressed and formed base portion.

2. The light equalizing element according to claim 1, wherein one side of the light equalizing element is the microstructure portion, and the other side corresponding to the side is the base portion.

3. The light homogenizing element of claim 1, wherein the light homogenizing element comprises two of the microstructure portions, the two microstructure portions are located on both sides of the base portion, respectively, and the two microstructure portions and the base portion are integrally press-molded by the thermosetting resin material.

4. A light homogenizing element in accordance with claim 3, wherein the two microstructured portions differ in structural morphology.

5. A method of manufacturing a light homogenizing element, comprising the steps of:

(B) Setting a thermosetting resin material at a predetermined position of the lower mold, and arranging the upper mold and the lower mold to be opposite to each other; and

6. The manufacturing method according to claim 5, wherein in the step (a), the inner surfaces of the upper mold and the lower mold are each provided with a structural form matching with the microstructure portion of the light homogenizing element, and in the step (B), the upper mold and the lower mold are oppositely disposed in alignment according to alignment marks on the upper mold and/or the lower mold, and in the step (C), the distance between the upper mold and the lower mold is gradually reduced, and the thermosetting resin material is pressed to spread out from the center until a gap between the upper mold and the lower mold reaches a preset value.

7. The manufacturing method according to claim 5, wherein in the step (C), the pressure for pressing the thermosetting resin material ranges from normal pressure to 30bar, the pressure uniformity at the time of pressing the thermosetting resin material by the upper die and the lower die is controlled by means of gas pressurization or hydraulic pressure, and the temperature for heat curing the thermosetting resin material ranges from room temperature to 200 ℃.

8. The utility model provides a press forming mould of dodging component which characterized in that, includes upper mould and bed die, wherein:

9. The press-molding die according to claim 8, wherein the inner surfaces of the upper die and the lower die are each provided with a structural form matching with the microstructure portion of the light homogenizing element, and wherein the upper die and/or the lower die are provided with alignment marks so as to be disposed opposite to each other with respect to the inner surfaces of the upper die and the lower die at the time of press molding.

10. The compression molding die of claim 8, wherein the upper die and the lower die are open-closed dies.

11. The compression molding die of claim 8, wherein the upper die and the lower die are non-transparent dies.