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研究生: 游秉閎
PING-HUNG YU
論文名稱: 大面積LCD自然光光固化積層製造系統背光模組開發設計與製作研究
Research on Development, Design and Manufacturing of Backlight Module for Large Area LCD Visible Light Vat Photopolymerization Additive Manufacturing System
指導教授: 鄭正元
Jeng-Ywan Jeng
林鼎晸
Ding-Zheng Lin
口試委員: 鄭逸琳
Yih-Lin Cheng
劉福興
Fwu-Hsing Liu
學位類別: 碩士
Master
系所名稱: 工程學院 - 機械工程系
Department of Mechanical Engineering
論文出版年: 2021
畢業學年度: 109
語文別: 中文
論文頁數: 109
中文關鍵詞: 大面積3D列印光固化背光模組LCD解析度區域控光
外文關鍵詞: LCD resolution, big size 3D printing, Stereolithography, back light module (BLU), local dimming
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  • 積層製造(Additive Manufacturing, AM)為一種新型加工型態,其概念為增材製造,能做出傳統減法加工所不能達成之設計與外型,但目前積層製造加工技術不能達成工業化之原因主要為加工速度慢與生產數量低兩缺點。
    本實驗室致力於將光固化LCD製程技術往工業化發展,製作出全台灣第一台32″LCD光固化列印機,大幅提升光固化列印產量;本研究將致力於製作與分析大面積LCD光固化之背光模組,為達高光強度、高光均勻性與高光準直性等光固化列印需求,本實驗將不使用常見之陣列式透鏡模組,改用光學膜片式背光模組,經過多種搭配選用,大幅提升光均勻度與光準直性,並且比較各種光型所造成之列印影響,如軸向精度、物件銳利度與表面平整性。
    且基於本實驗室開發之手機光固化列印系統之概念,並考量面板產業miniLED、microLED皆使用藍光燈源,為能順利與市場一同並進,將背光燈源由弱紫外405nm更改為可見光藍光460nm~470nm波長,且首次使用區域控光(local dimming)技術,大幅提升LCD對比度與LCD面板壽命。
    本研究結果發現,光學膜片式模組非常適用於任何尺寸之光固化3D列印機,能提供一致性均勻化光源,並能將最小列印尺寸控制在大部分面板之Pixel size內,且搭配區域控光列印後,完全能抑制未預期固化殘渣、提升樹脂回收使用率、節省能源並大幅提升列印完整性。


    Additive Manufacturing (AM) is a new type of processing. It can make designs and appearances that cannot be achieved by traditional subtractive processing. However, the main reason why the current additive manufacturing processing technology cannot achieve industrialization is there are two disadvantages: slow processing speed and low production quantity.
    Our laboratory is committed to industrializing the light-curing LCD process technology, and produced the first 32" LCD light-curing printer in Taiwan, which greatly increases the output of light-curing printing; this research will focus on the production and analysis of large-area LCD light-curing backlight modules to achieve high light intensity, high light uniformity, and high light collimation. For printing requirements, this experiment will not use common lens array modules, instead use optical film backlight modules. After a variety of film matching options, the light uniformity and light collimation are greatly improved; and various light types are compared its printing influence, such as axial accuracy, object sharpness and surface smoothness.
    And based on the concept of the mobile phone light curing printing system developed by our laboratory, and considering that the panel industry miniLED and microLED all use blue light sources, in order to smoothly advance with the market, the backlight source is changed from weak ultraviolet 405nm to visible light blue 460nm ~470nm wavelength, and the first use of local dimming technology, greatly improving LCD contrast and LCD panel life.
    The results of this study found that the optical film module is very suitable for light-curing 3D printers of any size. It can provide a uniform light source, and can control the minimum print size within the pixel size of most panels. With local dimming technology printing, it can completely suppress unexpected curing residues, increase resin recycling, save energy, and greatly improve printing integrity.

    摘要 I ABSTRACT II 誌謝 IV 目錄 V 圖目錄 VIII 表目錄 XIII 第一章 緒論 1 1.1 前言 1 1.2 研究動機 3 1.3 論文架構 5 第二章 文獻回顧 6 2.1 積層製造 6 2.2 光聚合固化成型(vat photopolymerization)技術 9 2.2.1 光固化樹脂聚合原理 9 2.2.2 上照式及下照式光固化技術 11 2.2.3 光固化成型技術 12 2.2.4 LCD成型技術使用之背光模組 15 2.3 LCD液晶顯示器之發展與技術 17 2.3.1 LCD液晶顯示器之原理 17 2.3.2 LCD液晶顯示器之背光模組(Back light unit) 18 2.3.3 液晶顯示器之液晶模組(Liquid Crystal) 23 2.3.4 區域控光技術(local dimming) 25 2.3.5 LCD 光固化3D列印機相關研究回顧 26 2.4 高速積層製造(High speed Additive manufacturing) 28 第三章 實驗系統架設與介紹 30 3.1 13.3″ 光固化3D列印機-機構 30 3.2 13.3″光固化3D列印機-顯示與背光 31 3.2.1 LED燈板 31 3.2.2 LCD液晶螢幕 32 3.2.3 電控與零件 33 3.3 大面積32″光固化機台-架構 33 3.3.1 機台外型架構 33 3.4 大面積32″光固化機台-顯示與背光 36 3.4.1 背光散熱基座 36 3.4.2 LED燈板與燈源晶片 37 3.4.3 LCD液晶螢幕 39 3.4.4 電控與零件 39 3.5 機台軟體 45 3.6 可見光光固化樹脂 45 3.7 抽換式光學膜片背光模組架構 46 3.8 實驗使用儀器介紹 47 3.8.1 光功率量測儀 47 3.8.2 光功率量測狹縫 48 3.8.3 直流電源供應器 49 3.8.4 測微儀 49 3.8.5 手持式顯微鏡 50 3.8.6 光學顯微鏡 50 3.8.7 變角光度計 51 第四章 研究內容與方法 52 4.1 藍光直下式光學膜片式模組 52 4.1.1 光學膜片排列與選用 53 4.1.2 最終光學模片性能測試 59 4.1.3 各光學模組於機台上性能量測 61 4.2 精度測試方法 64 4.2.1 精度測試曝光圖形 64 4.2.2 精度測試曝光秒數 67 4.3 區域控光實驗方法 67 第五章 研究結果分析與比較 69 5.1 多種背光模組與列印結果分析 69 5.1.1 13.3″中尺寸多種背光列印精度分析 69 5.1.2 32″大尺寸多種背光列印精度分析 74 5.1.3 2各背光模組於各角度之列印結果與變角光度量測結果 77 5.1.4 表面粗糙性探討 79 5.2 區域控光列印結果分析 82 5.2.1 32″機台區域控光 85 第六章 結論及未來展望 87 6.1 結論 87 6.2 未來展望 88 參考文獻 90

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