Methods for making reflective trays

Patent metadata

Field	Value
Publication number	US-2016341854-A1
Application number	US-201415108015-A
Country	US
Kind code	A1
Filing date	Dec 18, 2014
Priority date	Dec 26, 2013
Publication date	Nov 24, 2016
Grant date	—

Abstract

A method of making a reflective tray that is useful in backlight modules for electronic devices comprises (a) providing a reflective tray template comprising a polymeric dielectric multilayer reflector on a compliant pad, the reflective tray template having a first major surface, an opposing major surface, and a reflective tray bottom area having corners; and (b) pressing a blade into the first major surface of the polymeric dielectric multilayer reflector along the perimeter of at least one side of the reflective tray bottom area to form a reflective tray side extending perpendicular to the reflective tray bottom area.

First claim

1 . A method of making a reflective tray comprising:
(a) providing a reflective tray template comprising a polymeric dielectric multilayer reflector on a compliant pad, the reflective tray template having a first major surface, an opposing major surface, and a reflective tray bottom area having corners; (b) pressing a blade into the first major surface of the polymeric dielectric multilayer reflector along the perimeter of at least one side of the reflective tray bottom area to form a reflective tray side extending perpendicular to the reflective tray bottom area.

2 . The method of claim 1 wherein portions of the polymeric dielectric multilayer reflector exterior to the reflective tray bottom area and adjacent the corners are removed.

3 . The method of claim 1 or 2 wherein the compliant pad has an effective Shore A durometer of 20 to 70.

4 . The method of claim 3 wherein the compliant pad has an effective Shore A durometer of 30 to 50.

5 . The method of claim 1 wherein pressing a blade into the first major surface of the polymeric dielectric multilayer reflector comprises using a hydraulic press.

6 . The method of claim 1 wherein the blade edge has a flat tip.

7 . The method of claim 6 wherein the flat tip is 50 μm to 500 μm wide.

8 . The method of claim 6 wherein the flat tip is 100 μm to 400 μm wide.

9 . The method of claim 1 wherein the blade edge has a radius of 0.5 μm to 2 μm.

10 . The method of claim 1 wherein the polymeric dielectric multilayer reflector compromises an opaque coating on at least one major surface.

11 . The method of claim 1 wherein the polymeric dielectric multilayer reflector comprises a liner on at least one major surface.

12 . The method of claim 1 further comprising applying heat to at least one of the blade edge, the compliant pad and the polymeric dielectric multilayer reflector.

13 . The method of claim 1 wherein the reflective tray bottom area is rectangular.

14 . The method of claim 13 further comprising pressing a blade edge into the first major surface of the polymeric dielectric multilayer reflector along the perimeter of each side of the reflective tray bottom area to form a reflective tray have four sides extending perpendicular to the reflective tray bottom area.

15 . The method of claim 1 wherein two or more sides of the reflective tray bottom areas are formed simultaneously.

16 . The method of claim 1 wherein the reflective tray template and compliant pad are provided on a plate having a recess.

Assignees

• 3M Innovative Properties Co

Inventors

• Kidane Samuel
• Laumer James W
• Stensvad Karl K

Classifications

• G02B6/0033

  Means for improving the coupling-out of light from the light guide · CPC title

• G02B6/0055

  Reflecting element, sheet or layer · CPC title

• G02B6/0088

  of the light guide or other optical sheets in the package · CPC title

• G02B6/0065

  Manufacturing aspects; Material aspects · CPC title

• F21V7/00

  Reflectors for light sources (characterised by cooling arrangements F21V29/505) · CPC title