Method of Manufacturing a Gasket within the Grooves of a Plastic Light Panel

Abstract

Exemplary embodiments of the present disclosure are directed towards methods and apparatus for molding-in gaskets that serve as light blockers, within the grooves of a moving planar work material. The gaskets comprise of a hot melt adhesive material that is in a molten state above a particular temperature and gets solidified below a particular temperature. Another exemplary embodiment of the present disclosure is directed towards a planar work material having grooves that are filled with molded-in gaskets, wherein the gaskets are made up of a hot melt adhesive material. The gaskets made of the hot melt adhesive material bond securely with the panels because of inherent adhesive properties, and provide structural stability to the light panels. Another exemplary embodiment of the present disclosure is directed towards the use of a hot melt adhesive material as the molding material for molding-in gaskets within the grooves of a planar work material.

1 - 27 . (canceled) 
     
     
         28 . A method of manufacturing a backlighting device to be lit by a light source, the method comprising the steps of:
 providing a plastic panel formed of a transmissive material, the plastic panel capable of guiding light emitted by the light source within the panel, the plastic panel having a first surface and a second surface opposite the first surface, at least one groove defined through the plastic panel and having a side wall extending from the first surface to the second surface; and   molding-in a gasket in the at least one groove, each gasket being at least partially opaque for blocking transmission of the light from the light source within the plastic panel, the molding-in step including: a) dispensing a thermal plastic material in a molten state into each groove; and b) curing the thermal plastic material in each groove so as to change the thermal plastic material from the molten state to a solidified state to thereby form the gasket.   
     
     
         29 . The method of  claim 28 , wherein the dispensing step includes urging the molten material into each groove in a direction parallel to the side wall. 
     
     
         30 . The method of  claim 28 , wherein the dispensing step includes at least one of pouring, injecting, squeegeeing, rolling, and laminating the thermal plastic material in the molten state. 
     
     
         31 . The method of  claim 28 , wherein the thermal plastic material is a hot melt adhesive material. 
     
     
         32 . The method of  claim 28 , the method further including placing a first masking sheet and a second masking sheet on the plastic panel before the molding-in step, the first masking sheet being removably affixed to the first surface, and the second masking sheet being removably affixed to the second surface. 
     
     
         33 . The method of  claim 32 , wherein the first masking sheet and the second masking sheet each define at least one opening, each opening being aligned with one of the at least one groove. 
     
     
         34 . The method of  claim 33 , wherein the first masking sheet and the second masking sheet respectively cover all portions of the first surface and the second surface not including one of the at least one groove. 
     
     
         35 . The method of  claim 32 , wherein the first masking sheet and the second masking sheet each include a kraft paper. 
     
     
         36 . The method of  claim 32 , further including removably affixing a first foil to the plastic panel along the first surface, and removably affixing a second foil to the plastic panel along the second surface. 
     
     
         37 . The method of  claim 36 , wherein the first foil and the second foil each include a silicone coated paper. 
     
     
         38 . The method of  claim 36 , wherein the first foil and second foil are affixed to the plastic panel respectively atop the first masking sheet and the second masking sheet. 
     
     
         39 . A method of manufacturing a backlighting device to be lit by a light source, the method comprising the steps of:
 providing a plastic panel formed of a transmissive material, the plastic panel capable of guiding light emitted by the light source within the panel, the plastic panel having a first surface and a second surface opposite the first surface, at least one groove defined through the plastic panel and having a side wall extending from the first surface to the second surface;   placing a first masking sheet and a second masking sheet on the plastic panel, the first masking sheet being removably affixed to the first surface, and the second masking sheet being removably affixed to the second surface, the first masking sheet and the second masking sheet each defining at least one opening, each opening being aligned with one of the at least one groove; and   molding-in a gasket in the at least one groove, each gasket being at least partially opaque for blocking transmission of the light from the light source within the plastic panel, the molding-in step including: a) dispensing a thermal plastic material in a molten state into each groove; b) urging the molten material into each groove in a direction parallel to the side wall; and c) curing the thermal plastic material in each groove so as to change the thermal plastic material from the molten state to a solidified state to thereby form the gasket, the molding-in step being performed after the placing step.   
     
     
         40 . The method of  claim 39 , wherein the molding-in step includes at least one of pouring, injecting, squeegeeing, rolling, and laminating the thermal plastic material in the molten state. 
     
     
         41 . The method of  claim 39 , wherein the thermal plastic material is a hot melt adhesive material. 
     
     
         42 . The method of  claim 39 , wherein the first masking sheet and the second masking sheet respectively cover all portions of the first surface and the second surface not including one of the at least one groove. 
     
     
         43 . The method of  claim 39 , wherein the first masking sheet and the second masking sheet each include a kraft paper. 
     
     
         44 . The method of  claim 39 , further including removably affixing a first foil to the plastic panel along the first surface, and removably affixing a second foil to the plastic panel along the second surface. 
     
     
         45 . The method of  claim 44 , wherein the first foil and the second foil each include a silicone coated paper. 
     
     
         46 . The method of  claim 44 , wherein the first foil and second foil are affixed to the plastic panel respectively atop the first masking sheet and the second masking sheet.