滾壓成形超薄導光板設計與製作之研究

Abstract

光電產品為了因應市場需求，必須符合重量輕、體積小、使用效率高等設計要求，所以許多廠商爭先投入研究、改良產品以增加產品在市場上的優勢，其中改良產品本身的背光模組之導光板部分，不但可以達到節省成本、減輕重量、減少厚度，若能結合更快速、更有效率的製作 製程，可提高產能、減少製作時間，將可大幅提高產品競爭優勢。 不同於傳統射出成形製作導光板，本研究目的在於利用滾壓製程製作超薄導光板，研究過程從導光板設計、模仁製作、UV滾壓製作導光板到導光板光學檢測各方面均有討論，並針對鋼板蝕刻與熱熔製程兩種不同方式製作的模仁所滾壓製作的導光板做比較，分析兩者間的差異，以便未來應用於導光板或是微光學元件製作上。 實驗結果顯示，滾壓UV轉印製作導光板製程可以製作薄形、大面積尺寸的導光板，雖然技術上需要經過複雜的測試過程與精細的參數設定，不過滾壓UV轉印技術仍是未來製作導光板的重點技術之一。

From market consideration, electron products such as light guide plate (LGP) of black light unit must conform to light-weight, small-volume, and high-efficiency, therefore a lot of manufacturers invested time and money for the improvement. The purpose of this research is to design and manufacture a LGP by using roll-to-roll UV embossing process which is different than the conventional injection molding processing. This research started with the designing of a mold, and then a LGP was fabricated by the UV roll-to-roll embossing process. Finally, the optical properties were measured. Another molds made with etching process and reflow process were also fabricated for the comparison. The difference among these molds are discussed. The feasibility of future use of micro optics device was studied. From the result of this study, the manufacturing of a thin and large LGP using roll-to-roll UV embossing process was achieved. Although more tests are needed to demonstrate its advantage, it is still an important technology for LGP in the future.