KR20120006634A - Wavetype diffusion plate having fresnel lens and manufacturing method thereof - Google Patents

Abstract

PURPOSE: A wave type diffusing plate and a manufacturing method thereof are provided to enhance optical diffusion, uniformity of brightness, and the intensity of light by including a Fresnel lens part which collects incidence light of a light source at the lower side of a substrate and diffuses the light which is collected at the upper side of the substrate. CONSTITUTION: A wave type diffusing plate comprises a substrate(100), a diffusing layer(130), and a Fresnel lens part(220). The substrate is formed into a shape in which a concave part and a convex part are repeated. A first adhesive layer is formed on the upper side of the substrate. A first wave type film is formed on the upper side of the first adhesive layer. The diffusing layer is spread on the upper side of the substrate. A second adhesive layer is formed in the lower side of the substrate. The Fresnel lens part is formed in the lower side of the substrate.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wave type diffusion plate including a Fresnel lens portion,

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wave type diffusion plate including a Fresnel lens portion and a manufacturing method thereof, and more particularly, to a wave type diffusion plate including a Fresnel lens portion, Type diffusion plate including a lens portion and a method of manufacturing the same.

In general, a liquid crystal display panel in a liquid crystal display (LCD) can not emit light by itself. Therefore, a backlight unit (BLU) for providing light to the liquid crystal display panel from the back side of the liquid crystal display panel Respectively.

Such a backlight unit is composed of a composite of a light source, a reflection plate, a light guide plate, a diffusion plate, and a prism sheet.

The diffusion plate, which is one of the components of the backlight unit, effectively disperses the incident light provided by the light source and provides a uniform surface light source to the liquid crystal display panel.

The diffusion plate includes a transparent substrate and a diffusing layer, and the diffusion layer is formed on a surface of the transparent substrate. The diffusing layer includes spherical material particles as scatters, and the diffusing effect of the diffusing plate is mainly caused by a difference in refractive index between the binder in the diffusing layer and the scattering body included in the binder. The scatterer is dispersed between the diffusion layers, and travels between the two media having different refractive indices when the light rays pass through the diffusion layer. At this time, the light rays simultaneously cause refraction, reflection, and scattering phenomenon to achieve an optical diffusion effect.

FIG. 1 shows the illuminance distribution of a conventional flat plate type diffuser plate.

1, the light rays emitted from the light-incident portion of the light source are concentrated. That is, it can be seen that the degree of diffusion is weak, the light intensity is weak, and the luminance uniformity is lowered.

Accordingly, in the past, a large number of optical sheets for minimizing the loss of light and diffusing light have been used in order to enhance the diffusibility of the diffusing plate, increase the light intensity, and improve the uniformity of brightness.

However, the use of a large number of optical sheets has been problematic in that the assembling process is difficult, the cause of defects in the manufacturing process is increased, and the production cost is increased, as well as the thickness of the product is difficult.

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems,

It is an object of the present invention to provide a wave type diffuser plate including a Fresnel lens unit capable of increasing the light collection efficiency of light emitted from a light source to enhance light diffusibility, increase brightness uniformity, and increase light intensity.

It is another object of the present invention to provide a method of manufacturing a wave-type diffuser plate including a Fresnel lens unit that can easily and economically manufacture a wave-type diffuser plate including a Fresnel lens unit.

According to an aspect of the present invention, there is provided a wave type diffuser plate including a Fresnel lens unit according to an exemplary embodiment of the present invention. A first diffusion layer formed on a wave upper surface of the substrate; And a Fresnel lens portion formed on a lower surface of the substrate.

Here, a second diffusion layer may be further formed on the lower surface of the substrate.

According to another aspect of the present invention, there is provided a wave type diffuser plate including a Fresnel lens unit, the substrate comprising: a substrate; A first adhesive layer formed on an upper surface of the substrate; A wave-like film formed on the upper surface of the first adhesive layer; A first diffusion layer formed on the upper surface of the wavy film; A second adhesive layer formed on a lower surface of the substrate; And a Fresnel lens portion formed on the lower surface of the second adhesive layer.

Here, a second diffusion layer may be further formed on the lower surface of the substrate.

A method of manufacturing a wave type diffuser plate including a Fresnel lens unit according to the present invention includes the steps of: (S100) integrally forming or attaching a wavy film on an upper surface of a substrate;

Applying a diffusion layer on the upper surface of the wavy film (S200); And forming or attaching a Fresnel lens unit integrally to a lower surface of the substrate (S200).

In the step S100, the substrate and the wavy film are integrally injection-molded.

In the step S100, the upper surface of the substrate is extruded in a wave form.

In addition, the step S100 may include: (S110) transferring the composite film in which the first release film, the first adhesive layer, and the wavy film are sequentially stacked in the direction of the upper surface of the substrate; Separating the first release film from the first adhesive layer and the wavy film (S120); And pressing the separated first adhesive layer and the wavy film with a first press roller to attach the first adhesive layer to the upper surface of the substrate (S130).

Here, the step S110 may include injecting a resin into the outer circumferential surface of the rotating first patterning roller, the vertical cutting surface of which has a wavy pattern using a first resin injecting device; Forming a predetermined thickness by cutting the resin coated on the outer circumferential surface of the first pattern forming roller with a first scriber; Curing the resin with a first curing apparatus; Separating the cured resin from the first patterning roller to form a wavy film; And pressing the formed wavy film with a first press roller and attaching the wavy film to the upper surface of the first adhesive layer.

The step S200 may include applying a second diffusion layer to the lower surface of the substrate.

The step S300 is characterized in that the substrate and the Fresnel lens portion are integrally injection-molded.

In operation S300, the composite film having the second release film, the second adhesive layer, and the Fresnel lens portion sequentially stacked is transported in the direction of the lower surface of the substrate (S310); Separating the second release film from the second adhesive layer and the Fresnel lens portion (S320); And pressing the second adhesive layer and the Fresnel lens part with the second press roller to attach the second adhesive layer to the lower surface of the substrate (S330).

In operation S310, the resin is injected into the second pattern forming roller formed by recessing the Fresnel lens pattern on the outer circumferential surface using the second resin injecting apparatus. Forming a predetermined thickness by cutting a resin coated on an outer circumferential surface of the second pattern formation roller with a second scriber; Curing the resin with a second curing device; Separating the cured resin from the second pattern forming roller to form a Fresnel lens portion; And pressing the formed Fresnel lens part with a second press roller to adhere to the upper surface of the second adhesive layer.

According to the wave type diffuser plate including the Fresnel lens unit according to the present invention and the method of manufacturing the same, the incident light of the light source is condensed to the maximum at the lower surface of the substrate, It has an effect of increasing the uniformity of diffusivity and luminance and increasing the intensity of light.

Further, the wavy film, the substrate, and the Fresnel lens portion are integrally injection-molded, or the wavy film and the Fresnel lens portion are attached to the substrate by the continuous process using the release film, so that the production is easy and economical and the productivity is improved have.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a view showing an illuminance distribution of a conventional flat type diffuser plate. FIG.
2 is a cross-sectional view of a wave type diffuser plate including a Fresnel lens unit according to an embodiment of the present invention.
3 is a cross-sectional view of a wave type diffuser plate including a Fresnel lens unit according to another embodiment of the present invention.
4 is a view showing the illuminance distribution of the wave type diffuser plate including the Fresnel lens according to the present invention.
5 is a view illustrating a method of manufacturing a wave type diffuser plate including a Fresnel lens unit according to an embodiment of the present invention.
6 is a view illustrating a method of manufacturing a wave type diffuser plate including a Fresnel lens unit according to another embodiment of the present invention.
7 is a view illustrating a method of manufacturing a wave type diffuser plate including a Fresnel lens unit according to another embodiment of the present invention.

These and other objects, features and other advantages of the present invention will become more apparent by describing in detail preferred embodiments of the present invention with reference to the accompanying drawings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a wave type diffuser plate including a Fresnel lens unit according to an embodiment of the present invention and a method of manufacturing the same will be described in detail with reference to the accompanying drawings.

2 is a cross-sectional view of a wave type diffuser plate including a Fresnel lens unit according to an embodiment of the present invention. FIG. 3 is a cross-sectional view of a wave type diffuser plate including a Fresnel lens unit according to another embodiment of the present invention. Fig.

As shown in FIG. 2, the wave type diffuser plate including the Fresnel lens unit of the present invention includes a substrate 100 on which a wave is repeatedly formed, the wave being repeatedly formed into a concave portion and a convex portion, A first diffusion layer 130 to which a diffusing agent is applied, and a Fresnel lens unit 220 formed on a lower surface of the substrate.

3, the wave type diffuser plate including the Fresnel lens unit of the present invention includes a substrate 100, a first adhesive layer 110 formed on the upper surface of the substrate, A second adhesive layer 210 formed on a lower surface of the substrate 100; a second adhesive layer 210 formed on the lower surface of the substrate 100; a second adhesive layer 210 formed on the lower surface of the substrate 100; And a Fresnel lens unit 220 formed on the lower surface.

A second diffusion layer 230 to which a diffusion material is applied may be formed on the lower surface of the substrate 100.

Here, the Fresnel lens unit 220 has a Fresnel lens pattern 221 having a concentric shape and a sawtoothed cross-section, and functions to condense the light source emitted from the light source to the maximum.

The wavy film 120 has a function of increasing the light diffusing property by effectively dispersing the light source condensed by the Fresnel lens portion 220 on the upper surface of a wave whose vertical cross section is repeated on the concave and convex portions. do.

The substrate 100, the wavy film 120, and the Fresnel lens unit 220 are made of polycarbonate (PC) having excellent heat resistance, polyethylene terephthalate (PET) having excellent strength, weather resistance, Ethylene Terephthalate, a substrate, or a material made of polymethyl methacrylate (PMMA) having a high refractive index.

The wave type diffusing plate including the Fresnel lens unit configured as described above can effectively reduce the loss of light by effectively focusing the incident light emitted from the light source on the Fresnel lens unit 220, So that the light is effectively diffused by the wave shape formed on the upper surface of the substrate 100.

4 is a view showing the illuminance distribution of the wave type diffuser plate including the Fresnel lens according to the present invention.

4, the light rays emitted from the light-incident portion of the light source are better diffused by the Fresnel lens and the wave-like substrate. That is, it can be seen that the degree of diffusion is high, the light intensity is high, and the luminance uniformity is improved.

Therefore, the present invention can minimize the loss of light without using a plurality of optical sheets, increase the light diffusibility, increase the light intensity, and provide a uniform surface light source to the liquid crystal display panel .

FIG. 5 is a view illustrating a method of manufacturing a wave type diffuser plate including a Fresnel lens unit according to an embodiment of the present invention. FIG. 6 is a cross-sectional view of a wave type diffuser including a Fresnel lens unit according to another embodiment of the present invention. FIG. 7 is a view illustrating a method of manufacturing a wave type diffuser plate including a Fresnel lens unit according to another embodiment of the present invention. Referring to FIG.

5, a manufacturing method according to an embodiment of the present invention includes the steps of: (a) integrally forming a wavy film 120 on an upper surface of a substrate 100; (b) (C) a Fresnel lens unit 220 is integrally formed on the lower surface of the substrate. Referring to FIG. The first diffusion layer 130 is formed on the upper surface of the wavy film 120 by injection molding the wavy film 120, the substrate 100, and the Fresnel lens part 220, Or the like.

6, the first adhesive layer 110 may be formed on the upper surface of the substrate 100, and then the first diffusion layer may be applied on the upper surface of the first adhesive layer 110, Type film 120 is attached. A second adhesive layer 210 may be formed on the lower surface of the substrate 100 and a Fresnel lens 220 may be attached to the lower surface of the second adhesive layer 210. The second adhesive layer 210 and the Fresnel lens part 220 may be formed on the lower surface of the substrate 100 by first coating the second diffusion layer 230 before forming the second adhesive layer 210 have.

As shown in FIG. 7, another embodiment of the present invention is a method in which a first release film 101, a first adhesive layer 110, and a wavy film 120 coated with a first diffusion layer 130 are sequentially stacked (S 110) of separating the first release film 101 from the first adhesive layer 110 and the wavy film 120 (S 120) , Pressing the separated first adhesive layer 110 and the wavy film 120 with a first press roller 106 to attach the first adhesive layer 110 to the upper surface of the substrate 100 A step S310 of transferring the second composite film in which the second release film 201, the second adhesive layer 210 and the Fresnel lens portion 220 are sequentially stacked in the direction of the lower surface of the substrate 100, Separating the second release film 201 from the second adhesive layer 210 and the Fresnel lens part 220 in step S320, And pressing the second lens layer 220 with the second press roller 206 to attach the second adhesive layer 210 to the lower surface of the substrate 100 (S330).

In step S110, resin is injected into the first pattern forming roller 102, which has a vertical cut surface in a wavy pattern, and is rotated, so that the outer surface of the first pattern forming roller 102 . In this process, the resin applied to the outer circumferential surface of the first pattern forming roller 102 is cut to a desired thickness by the first scriber 104. Thereafter, the resin is cured by the first curing apparatus 105, and the cured resin is separated from the first pattern forming roller 102 to form the wavy film 120. The formed wavy film 120 is pressed onto the first press roller 106 and attached to the upper surface of the first adhesive layer 110 formed on the first release film 101. The first diffusion layer 130 is formed on the upper surface of the wavy film 120 attached to the upper surface of the substrate 100 by applying a diffusing agent injected from the diffusion mechanism package 109. The first composite film in which the first release film 101, the first adhesive layer 110, and the wavy film 120 formed with the first diffusion layer 130 are sequentially laminated is conveyed by the first conveyance roller 107 to the substrate (Not shown).

In step S120, the first release film 101 is transferred from the first composite film to the upper surface of the substrate 100 by the first release film recovery roller 108, And is separated from the wavy film 120 in which the diffusion layer 130 is formed.

The wavy film 120 formed with the first adhesive layer 110 and the first diffusion layer 130 separated from the first release film 101 is pressed against the first press roller 106 to form the first The adhesive layer 110 is attached to the upper surface of the substrate 100.

In step S310, resin is injected into the second pattern forming roller 202 formed by recessing the Fresnel lens pattern on the outer circumferential surface by using the second resin injecting apparatus 203. [ In this process, the resin coated on the outer circumferential surface of the second pattern forming roller 202 is cut into the second scriber 204 to form a constant thickness. Thereafter, the resin is cured by the second curing device 205, and the cured resin is separated from the second pattern forming roller 202 to form the Fresnel lens portion 220. The Fresnel lens portion 220 is pressed onto the second press roller 206 and attached to the upper surface of the second adhesive layer 210. The second composite film in which the second release film 201, the second adhesive layer 210 and the Fresnel lens portion 220 are sequentially stacked is transported to the lower surface of the substrate 100 by the second transport roller 207 .

In step S320, the second release film 201 is transferred from the second composite film to the lower surface of the substrate 100 by the second release film collection roller 208 to the second adhesive layer 210, And is separated from the lens portion 220.

The second adhesive layer 210 and the Fresnel lens portion 220 separated from the second release film 201 are pressed against the second press roller 206 so that the second adhesive layer 210 is pressed against the substrate (Not shown).

The second adhesive layer 210 and the Fresnel lens unit 220 may be attached to the lower surface of the substrate 100 after the second diffusion layer 230 is applied to the second adhesive layer 210 .

As described above, according to the present invention, the wavy film 120 is integrally formed on the upper surface of the substrate 100 and the Fresnel lens unit 220 is integrally formed on the lower surface of the substrate 100, The incident light is condensed to the maximum extent and the light condensed on the upper surface of the substrate 100 is diffused as much as possible to increase the light diffusibility and uniformity of brightness and increase the intensity of light.

Although the preferred embodiments of the present invention have been described, the present invention is not limited to the specific embodiments described above. It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the appended claims, And equivalents should also be considered to be within the scope of the present invention.

100: substrate 110, 210: first and second adhesive layers
120: Wave type film 130, 230: First and second diffusion layers
220: Fresnel lens unit 101, 201: First and second release films
102, 202: first and second pattern forming rollers 103, 203: first and second resin injection devices
104, 204: first and second scriber 105, 205: first and second curing devices
106, 206: first and second press rollers 107, 207: first and second conveying rollers
108, 208: first and second release film collection rollers

Claims (12)

A substrate having a top surface in which a concave portion and a convex portion are repeated;
A first diffusion layer applied to an upper surface of the wave of the substrate; And
And a Fresnel lens portion formed on a lower surface of the substrate. Board;
A first adhesive layer formed on an upper surface of the substrate;
A wave-like film formed on the upper surface of the first adhesive layer;
A first diffusion layer applied to the upper surface of the wavy film;
A second adhesive layer formed on a lower surface of the substrate; And
And a Fresnel lens portion formed on the lower surface of the second adhesive layer. 3. The method according to claim 1 or 2,
And a second diffusion layer is applied to the lower surface of the substrate. (S100) integrally molding or adhering the wavy film on the upper surface of the substrate;
Applying a diffusion layer on the upper surface of the wavy film (S200); And
And a step (S200) of integrally forming or attaching a Fresnel lens unit to the lower surface of the substrate. 5. The method of claim 4,
The method of manufacturing a wave type diffuser plate according to claim 1, wherein the substrate and the wavy film are integrally injection-molded. 5. The method of claim 4,
The method of manufacturing a wave type diffuser plate according to claim 1, wherein the step of forming the Fresnel lens portion comprises a Fresnel lens portion in which the upper surface of the substrate is extruded in a wave form. 5. The method of claim 4,
In operation S100, the composite film having the first release film, the first adhesive layer, and the wavy film sequentially stacked is transported in the direction of the upper surface of the substrate (Sl 10);
Separating the first release film from the first adhesive layer and the wavy film (S120);
And a step (S130) of pressing the separated first adhesive layer and the wavy film with a first press roller to attach the first adhesive layer to the upper surface of the substrate (S130). Method of manufacturing diffuser plate. 8. The method of claim 7,
In the step S110, the resin is injected into the outer circumferential surface of the rotating first pattern forming roller, the vertical cutting surface of which has a wavy pattern using a first resin injecting apparatus.
Forming a predetermined thickness by cutting the resin coated on the outer circumferential surface of the first pattern forming roller with a first scriber;
Curing the resin with a first curing apparatus;
Separating the cured resin from the first patterning roller to form a wavy film;
And pressing the formed wavy film with a first press roller and attaching the wavy film to the upper surface of the first adhesive layer. 5. The method of claim 4,
Wherein the step S200 includes a step of applying a second diffusion layer to the lower surface of the substrate. 5. The method of claim 4,
The method of manufacturing a wave type diffuser plate according to claim 1, wherein the Fresnel lens unit is formed by integrally molding the substrate and the Fresnel lens unit. 5. The method of claim 4,
In operation S300, the composite film in which the second release film, the second adhesive layer, and the Fresnel lens portion are sequentially stacked is transported in the direction of the lower surface of the substrate (S310);
Separating the second release film from the second adhesive layer and the Fresnel lens portion (S320);
And pressing the separated second adhesive layer and the Fresnel lens portion with a second press roller to attach the second adhesive layer to the lower surface of the substrate (S330). Method of manufacturing diffuser plate. 12. The method of claim 11,
In the step S310, the resin is injected into the second pattern forming roller formed by recessing the Fresnel lens pattern on the outer circumferential surface by using the second resin injecting apparatus.
Forming a predetermined thickness by cutting a resin coated on an outer circumferential surface of the second pattern formation roller with a second scriber;
Curing the resin with a second curing device;
Separating the cured resin from the second pattern forming roller to form a Fresnel lens portion;
And pressing the formed Fresnel lens part with a second press roller to adhere to the upper surface of the second adhesive layer.

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