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CN111113837B - 一种导光板生产用精密挤出转写设备 - Google Patents

一种导光板生产用精密挤出转写设备 Download PDF

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Publication number
CN111113837B
CN111113837B CN202010009106.3A CN202010009106A CN111113837B CN 111113837 B CN111113837 B CN 111113837B CN 202010009106 A CN202010009106 A CN 202010009106A CN 111113837 B CN111113837 B CN 111113837B
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China
Prior art keywords
motor
wall
extrusion
forming box
cylinder
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CN202010009106.3A
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CN111113837A (zh
Inventor
刘勇
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Nanjing Beidi New Material Technology Co ltd
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Nanjing Beidi New Material Technology Co ltd
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Priority to CN202010009106.3A priority Critical patent/CN111113837B/zh
Publication of CN111113837A publication Critical patent/CN111113837A/zh
Priority to KR1020207024741A priority patent/KR102459396B1/ko
Priority to US16/965,775 priority patent/US11754772B2/en
Priority to JP2020600120U priority patent/JP3231540U/ja
Priority to DE212020000088.3U priority patent/DE212020000088U1/de
Priority to PCT/CN2020/095422 priority patent/WO2020177784A2/zh
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Publication of CN111113837B publication Critical patent/CN111113837B/zh
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    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
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    • G02B6/0011—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems the light guides being planar or of plate-like form
    • G02B6/0065—Manufacturing aspects; Material aspects
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • B29L2011/0075—Light guides, optical cables

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Abstract

本发明公开了一种导光板生产用精密挤出转写设备，包括：供料桶；除湿干燥装置；螺旋输送机，所述螺旋输送机固定安装于除湿干燥装置外壁一侧；螺杆挤出装置；成型箱，所述成型箱外壁一侧通过螺栓固定安装有一号电机和二号电机，其中两组所述一号电机动力输出端贯穿成型箱且通过转动轴固定安装有一号精密滚轴，所述二号电机动力输出端贯穿成型箱且通过转动轴固定安装有二号精密滚轴；本发明从粒子基料到成品导光膜一步成型，并克服翘曲问题，生产效率提高，生产周期可缩短至1s；产品更薄，可薄至80μm，大大降低了用料量、人工等生产成本，全面提升导光膜辉度、透光度等产品关键性指标，在激烈的市场竞争中具有品质和成本上的优势。

Description

一种导光板生产用精密挤出转写设备
技术领域
本发明涉及导光板生产技术领域，具体为一种导光板生产用精密挤出转写设备。
背景技术
导光板是利用光学级的亚克力/PC板材，然后用具有极高折射率且不吸光的高科技材料，在光学级的亚克力板材底面用激光雕刻、V型十字网格雕刻、UV网版印刷技术印上导光点；利用光学级亚克力板材吸取从灯发出来的光在光学级亚克力板材表面的停留，当光线射到各个导光点时，反射光会往各个角度扩散，然后破坏反射条件由导光板正面射出，通过各种疏密、大小不一的导光点，可使导光板均匀发光，反射片的用途在于将底面露出的光反射回导光板中，用来提高光的使用效率；同等面积发光亮度情况下，发光效率高，功耗低。单面微结构阵列导光板一般采用押出成型的制作工艺。
但是，目前现有的注塑成型过程中所产生的残留应力是成型品缺陷的主要原因，一方面充填时因流动产生的流动应力，冷却时温度不均等产生热残留应力；另外一方面除了塑料本身的收缩会影响成品的尺寸精度外，保压压力和收缩应力则使得残留应力分布不均，造成成型品的变形。
发明内容
本发明的目的在于提供一种导光板生产用精密挤出转写设备，以解决上述背景技术中提出的问题。
为实现上述目的，本发明提供如下技术方案：一种导光板生产用精密挤出转写设备，包括：
供料桶；
除湿干燥装置；
螺旋输送机，所述螺旋输送机固定安装于除湿干燥装置外壁一侧；
螺杆挤出装置；
成型箱，所述成型箱外壁一侧通过螺栓固定安装有一号电机和二号电机，其中两组所述一号电机动力输出端贯穿成型箱且通过转动轴固定安装有一号精密滚轴，所述二号电机动力输出端贯穿成型箱且通过转动轴固定安装有二号精密滚轴，且二号精密滚轴位于两组所述一号精密滚轴之间，所述成型箱内部一端通过转轴固定安装有收卷辊，所述收卷辊外部缠绕有软膜，所述成型箱内部位于二号精密滚轴下端处转动安装有滚轮，且滚轮设有两组；
控制开关；
其中，所述供料桶固定安装于除湿干燥装置顶端一侧，所述螺杆挤出装置固定安装于成型箱顶端，所述控制开关分别与一号电机和二号电机之间电性耦接。
优选的，还包括：
出料口，所述出料口开设于成型箱外壁一端。
优选的，所述除湿干燥装置包括干燥筒，所述干燥筒底端四角固定安装有支脚，所述干燥筒顶端靠近轴心处通过螺栓固定安装有四号电机，所述四号电机动力输出端贯穿干燥筒且固定连接有搅拌器，所述干燥筒内部位于搅拌器外侧处固定安装有滤网，所述干燥筒内壁表面固定安装有喷气管，且喷气管设有三根，其中三根所述喷气管内壁表面固定安装有喷嘴，且喷嘴设有六组，所述干燥筒外壁一侧通过支架固定安装有热风机，所述热风机输出端固定连接有输入总管，且输入总管固定安装于干燥筒外壁一侧表面；
其中，所述四号电机和热风机分别与控制开关之间电性耦接。
优选的，还包括：
温度传感器，所述温度传感器固定安装于干燥筒内壁一侧；
其中，所述温度传感器与控制开关之间电性耦接。
优选的，所述螺杆挤出装置包括挤出筒和三号电机，所述三号电机通过电机支架固定安装于挤出筒一侧，所述三号电机动力输出端贯穿挤出筒且固定连接有螺杆，所述挤出筒内壁与外壁之间固定安装有加热器，所述挤出筒上端一侧固定安装有料斗，且料斗底端延伸至挤出筒内部；
其中，所述三号电机和加热器分别与控制开关之间电性耦接。
优选的，还包括：
挤出喷嘴，所述挤出喷嘴固定安装于挤出筒底端一侧；
其中，所述挤出喷嘴底端贯穿成型箱且位于其中一组所述一号精密滚轴与二号精密滚轴之间。
优选的，所述一号精密滚轴与二号精密滚轴外壁表面开设有网点槽，且网点槽设有若干个。
优选的，所述输入总管与三根所述喷气管之间通过连接管相互连通。
优选的，所述螺旋输送机的输入端与下料管之间相互连通，所述螺旋输送机的输出端与料斗之间相互连通。
优选的，还包括：
转速调节器，所述转速调节器分别与一号电机和二号电机之间电性耦接。
与现有技术相比，本发明的有益效果是：
1.本发明能够制备超薄两面网点导光膜，从粒子基料到成品导光膜一步成型，并克服翘曲问题，生产效率提高，生产周期可缩短至1s；产品更薄，可薄至80μm，大大降低了用料量、人工等生产成本，全面提升导光膜辉度、透光度等产品关键性指标，在激烈的市场竞争中具有品质和成本上的优势，给下游客户带来差异性认识，推动液晶行业“代”的提升。
附图说明
图1为本发明的整体结构示意图；
图2为本发明的成型箱内部结构示意图；
图3为本发明的螺杆挤出装置结构示意图；
图4为本发明的除湿干燥装置结构示意图；
图5为本发明的干燥筒内部俯视图；
图6为本发明的二号精密滚轴结构示意图；
图7为本发明的元器件框架结构示意图。
图中：1-供料桶；2-除湿干燥装置；3-螺旋输送机；4-螺杆挤出装置；5-成型箱；6-一号电机；7-二号电机；8-收卷辊；9-软膜；10-一号精密滚轴；11-二号精密滚轴；12-网点槽；13-出料口；14-滚轮；15-挤出喷嘴；16-三号电机；17-挤出筒；18-料斗；19-加热器；20-螺杆；21-干燥筒；22-喷气管；23-滤网；24-四号电机；25-搅拌器；26-温度传感器；27-连接管；28-输入总管；29-热风机；30-下料管；31-喷嘴。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例1：
请参阅图1-7，本发明提供一种技术方案：一种导光板生产用精密挤出转写设备，包括：供料桶1；除湿干燥装置2；螺旋输送机3；螺杆挤出装置4；成型箱5和控制开关。
其中，供料桶1可以为铁、铜、钢、不锈钢等金属材料或合金材料制成。
进一步地，供料桶1底端延伸至干燥筒21内部且位于滤网23内侧，确保原料可从供料桶1进入到干燥筒21内的滤网23内部。
其中，所述螺旋输送机3固定安装于除湿干燥装置2外壁一侧。
其中，所述螺旋输送机3的输入端与下料管30之间相互连通，所述螺旋输送机3的输出端与料斗18之间相互连通。
进一步地，螺旋输送机3的驱动机构为电机，电机带动螺旋轴转动时，由于物料的重力及其与槽体壁所产生的摩擦力，使物料只能在叶片的推送下沿着输送机的槽底向前移动，一般都将驱动装置和卸料口安放在输送机的同一端，而把进料口尽量放在另一端的尾部附近，则能将干燥筒21内的原料输送至挤出筒17内。
其中，所述成型箱5外壁一侧通过螺栓固定安装有一号电机6和二号电机7，其中两组所述一号电机6动力输出端贯穿成型箱5且通过转动轴固定安装有一号精密滚轴10，所述二号电机7动力输出端贯穿成型箱5且通过转动轴固定安装有二号精密滚轴11，且二号精密滚轴11位于两组所述一号精密滚轴10之间，所述成型箱5内部一端通过转轴固定安装有收卷辊8，所述收卷辊8外部缠绕有软膜9，所述成型箱5内部位于二号精密滚轴11下端处转动安装有滚轮14，且滚轮14设有两组。
其中，成型箱5可以为铁、铜、钢、不锈钢等金属材料或合金材料制成。
进一步地，成型箱5的整体形状呈长方体结构。
其中，一号电机6和二号电机7可以是交流异步电机、无刷直流电机与永磁同步电机的其中一个，一号电机6和二号电机7工作可通过转动轴带动一号精密滚轴10和二号精密滚轴11进行转动，一号精密滚轴10呈顺时针转动，二号精密滚轴11呈逆时针转动。
其中，一号精密滚轴10和二号精密滚轴11弧形侧表面可根据目标产品尺寸，设置1-10个样品槽，以生产连续、独立的目标产品。
进一步地，收卷辊8、一号精密滚轴10和二号精密滚轴11均处于同一水平线上。
其中，软膜9给予二号精密滚轴11支持力，帮助产品成型，提高网点转写率。
其中，所述供料桶1固定安装于除湿干燥装置2顶端一侧，所述螺杆挤出装置4固定安装于成型箱5顶端，所述控制开关分别与一号电机6和二号电机7之间电性耦接。
其中，还包括：
出料口13，所述出料口13开设于成型箱5外壁一端。
其中，所述螺杆挤出装置4包括挤出筒17和三号电机16，所述三号电机16通过电机支架固定安装于挤出筒17一侧，所述三号电机16动力输出端贯穿挤出筒17且固定连接有螺杆20，所述挤出筒17内壁与外壁之间固定安装有加热器19，所述挤出筒17上端一侧固定安装有料斗18，且料斗18底端延伸至挤出筒17内部；
其中，所述三号电机16和加热器19分别与控制开关之间电性耦接。
其中，还包括：
挤出喷嘴15，所述挤出喷嘴15固定安装于挤出筒17底端一侧；
其中，所述挤出喷嘴15底端贯穿成型箱5且位于其中一组所述一号精密滚轴10与二号精密滚轴11之间。
其中，挤出喷嘴15可将融化的材料注入至二号精密滚轴11的网点槽12内。
其中，所述一号精密滚轴10与二号精密滚轴11外壁表面开设有网点槽12，且网点槽12设有若干个。
其中，还包括：
转速调节器，所述转速调节器分别与一号电机6和二号电机7之间电性耦接。
进一步地，用于调节一号电机6和二号电机7的转速。
综合以上实施例所述，首先将原材料（PC等）倒入集中供料桶1内，然后在除湿干燥装置2内进行干燥除湿，控制温度在90-100℃左右，干燥完成偶，通过螺旋输送机3将材料输送至料斗18里面，材料从料斗18下来以后进入挤出筒17，三号电机16工作可带动螺杆20进行旋转，再配合上加热器19的加热，可将材料融化，并控制温度使得基料流动性适合在预定时间内铺面二号精密滚轴11的网点槽12内，融化后的材料进入下一步，通过一号精密滚轴10、二号精密滚轴11和软膜具的结合作用，挤压和转写，制作出卷材产品，目标导光膜厚度可薄至80μm，连续化生产成宽幅为350mm的导光膜，产线速度为2-5米/分钟，再通过后制程的裁切将卷材裁切成客户所需要的成品，成品通过一些测量确保品质满足客户要求即可出货。
实施例2：
请参阅图1、图4、图5和图7，本发明提供一种技术方案：一种导光板生产用精密挤出转写设备，所述除湿干燥装置2包括干燥筒21，所述干燥筒21底端四角固定安装有支脚，所述干燥筒21顶端靠近轴心处通过螺栓固定安装有四号电机24，所述四号电机24动力输出端贯穿干燥筒21且固定连接有搅拌器25，所述干燥筒21内部位于搅拌器25外侧处固定安装有滤网23，所述干燥筒21内壁表面固定安装有喷气管22，且喷气管22设有三根，其中三根所述喷气管22内壁表面固定安装有喷嘴31，且喷嘴31设有六组，所述干燥筒21外壁一侧通过支架固定安装有热风机29，所述热风机29输出端固定连接有输入总管28，且输入总管28固定安装于干燥筒21外壁一侧表面。
其中，干燥筒21可以为铁、铜、钢、不锈钢等金属材料或合金材料制成。
其中，四号电机24可以是交流异步电机、无刷直流电机与永磁同步电机的其中一个，四号电机24工作能够带动搅拌器25进行转动。
其中，搅拌器25可以为铁、铜、钢、不锈钢等金属材料或合金材料制成。
进一步地，搅拌器25可对原料进行搅拌，确保原料的受热均匀性，从而提高干燥效率。
其中，喷气管22为圆环形结构，且围绕干燥筒21内壁一周。
进一步地，喷气管22设有三根，可提高热空气的喷出面积，从而提高干燥效率。
其中，滤网23可将原材料进行隔离，不会使原材料影响喷嘴31内热空气的喷出。
其中，所述四号电机24和热风机29分别与控制开关之间电性耦接。
其中，还包括：
温度传感器26，所述温度传感器26固定安装于干燥筒21内壁一侧。
其中，温度传感器26的型号为pt100。
进一步地，温度传感器26用于检测干燥筒21内的实时温度，并且控制温度在90-100℃左右；
其中，所述温度传感器26与控制开关之间电性耦接。
其中，所述输入总管28与三根所述喷气管22之间通过连接管27相互连通。
综合以上实施例所述，原材料从供料桶1集中进入到干燥筒21内，然后打开四号电机24和热风机29，热风机29可将热空气注入至输入总管28内，然后再有三根连接管27分别进入到三根喷气管22中，最后从喷嘴31喷出，喷出的热空气会穿过滤网23喷向原材料，在配合上搅拌器25对原材料的搅拌，可确保原材料能够与热空气全面的接触，提高了原材料的干燥效果。
在本发明所提供的几个实施方式中，应该理解到所揭露的装置可以通过其它的方式实现，所显示或讨论的相互之间的焊接或螺纹连接或缠绕连接可以是通过设备进行辅助完成的，如焊枪实现焊接，用扳手实现螺纹连接等，装置组成部件材料多种多样，例如铝合金、钢和铜等金属材料，通过铸造或者采用机械冲压等方式成型。
需要说明的是，在本文中，诸如第一和第二等之类的关系术语仅仅用来将一个实体或者操作与另一个实体或操作区分开来，而不一定要求或者暗示这些实体或操作之间存在任何这种实际的关系或者顺序。而且，术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含，从而使得包括一系列要素的过程、方法、物品或者设备不仅包括那些要素，而且还包括没有明确列出的其他要素，或者是还包括为这种过程、方法、物品或者设备所固有的要素。
以上所述仅为本发明的实施方式，并非因此限制本发明的专利范围，凡是利用本发明说明书及附图内容所作的等效结构或等效流程变换，或直接或间接运用在其他相关的技术领域，均同理包括在本发明的专利保护范围内。

Claims (1)

1.一种导光板生产用精密挤出转写设备，其特征在于，包括：
供料桶(1)；
除湿干燥装置(2)；
螺旋输送机(3)，所述螺旋输送机(3)固定安装于除湿干燥装置(2)外壁一侧；
螺杆挤出装置(4)；
成型箱(5)，所述成型箱(5)外壁一侧通过螺栓固定安装有一号电机(6)和二号电机(7)，其中两组所述一号电机(6)动力输出端贯穿成型箱(5)且通过转动轴固定安装有一号精密滚轴(10)，所述二号电机(7)动力输出端贯穿成型箱(5)且通过转动轴固定安装有二号精密滚轴(11)，且二号精密滚轴(11)位于两组所述一号精密滚轴(10)之间，所述成型箱(5)内部一端通过转轴固定安装有收卷辊(8)，所述收卷辊(8)外部缠绕有软膜(9)，所述成型箱(5)内部位于二号精密滚轴(11)下端处转动安装有滚轮(14)，且滚轮(14)设有两组，出料口(13)，所述出料口(13)开设于成型箱(5)外壁一端；
控制开关；
其中，所述供料桶(1)固定安装于除湿干燥装置(2)顶端一侧，所述螺杆挤出装置(4)固定安装于成型箱(5)顶端，所述控制开关分别与一号电机(6)和二号电机(7)之间电性耦接；
所述除湿干燥装置(2)包括干燥筒(21)，所述干燥筒(21)底端四角固定安装有支脚，所述干燥筒(21)顶端靠近轴心处通过螺栓固定安装有四号电机(24)，所述四号电机(24)动力输出端贯穿干燥筒(21)且固定连接有搅拌器(25)，所述干燥筒(21)内部位于搅拌器(25)外侧处固定安装有滤网(23)，所述干燥筒(21)内壁表面固定安装有喷气管(22)，且喷气管(22)设有三根，其中三根所述喷气管(22)内壁表面固定安装有喷嘴(31)，且喷嘴(31)设有六组，所述干燥筒(21)外壁一侧通过支架固定安装有热风机(29)，所述热风机(29)输出端固定连接有输入总管(28)，且输入总管(28)固定安装于干燥筒(21)外壁一侧表面；
其中，所述四号电机(24)和热风机(29)分别与控制开关之间电性耦接；
温度传感器(26)，所述温度传感器(26)固定安装于干燥筒(21)内壁一侧；
其中，所述温度传感器(26)与控制开关之间电性耦接；
所述输入总管(28)与三根所述喷气管(22)之间通过连接管(27)相互连通；
供料桶(1)底端延伸至干燥筒(21)内部且位于滤网(23)内侧，除湿干燥装置(2)内进行干燥除湿，控制温度在90-100℃；
所述螺杆挤出装置(4)包括挤出筒(17)和三号电机(16)，所述三号电机(16)通过电机支架固定安装于挤出筒(17)一侧，所述三号电机(16)动力输出端贯穿挤出筒(17)且固定连接有螺杆(20)，所述挤出筒(17)内壁与外壁之间固定安装有加热器(19)，所述挤出筒(17)上端一侧固定安装有料斗(18)，且料斗(18)底端延伸至挤出筒(17)内部；
其中，所述三号电机(16)和加热器(19)分别与控制开关之间电性耦接；
挤出喷嘴(15)，所述挤出喷嘴(15)固定安装于挤出筒(17)底端一侧；
其中，所述挤出喷嘴(15)底端贯穿成型箱(5)且位于其中一组所述一号精密滚轴(10)与二号精密滚轴(11)之间；所述一号精密滚轴(10)与二号精密滚轴(11)外壁表面开设有网点槽(12)，且网点槽(12)设有若干个；所述螺旋输送机(3)的输入端与下料管(30)之间相互连通，所述螺旋输送机(3)的输出端与料斗(18)之间相互连通；还包括：转速调节器，所述转速调节器分别与一号电机(6)和二号电机(7)之间电性耦接。
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