CN112644045A - Light diffusion plate, preparation method thereof and backlight module - Google Patents
Light diffusion plate, preparation method thereof and backlight module Download PDFInfo
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- CN112644045A CN112644045A CN202011486316.8A CN202011486316A CN112644045A CN 112644045 A CN112644045 A CN 112644045A CN 202011486316 A CN202011486316 A CN 202011486316A CN 112644045 A CN112644045 A CN 112644045A
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- 238000002360 preparation method Methods 0.000 title claims abstract description 14
- 238000009792 diffusion process Methods 0.000 title abstract description 61
- 238000001816 cooling Methods 0.000 claims abstract description 54
- 238000001125 extrusion Methods 0.000 claims abstract description 18
- 238000000034 method Methods 0.000 claims description 27
- 238000007731 hot pressing Methods 0.000 claims description 9
- 239000000463 material Substances 0.000 abstract description 27
- 238000004519 manufacturing process Methods 0.000 abstract description 18
- 230000000694 effects Effects 0.000 abstract description 3
- 238000005516 engineering process Methods 0.000 abstract description 3
- 230000010354 integration Effects 0.000 abstract description 3
- 230000005484 gravity Effects 0.000 description 5
- 230000002093 peripheral effect Effects 0.000 description 4
- 239000003963 antioxidant agent Substances 0.000 description 3
- 230000003078 antioxidant effect Effects 0.000 description 3
- 238000005452 bending Methods 0.000 description 3
- 239000004611 light stabiliser Substances 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 239000000758 substrate Substances 0.000 description 3
- 239000004793 Polystyrene Substances 0.000 description 2
- 230000002745 absorbent Effects 0.000 description 2
- 239000002250 absorbent Substances 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 238000013329 compounding Methods 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 238000000227 grinding Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- 239000012745 toughening agent Substances 0.000 description 2
- 240000004282 Grewia occidentalis Species 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- KPUWHANPEXNPJT-UHFFFAOYSA-N disiloxane Chemical class [SiH3]O[SiH3] KPUWHANPEXNPJT-UHFFFAOYSA-N 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000004973 liquid crystal related substance Substances 0.000 description 1
- 239000004579 marble Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 239000012788 optical film Substances 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 239000002210 silicon-based material Substances 0.000 description 1
- 239000012257 stirred material Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/0073—Optical laminates
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/02—Diffusing elements; Afocal elements
- G02B5/0205—Diffusing elements; Afocal elements characterised by the diffusing properties
- G02B5/021—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/02—Diffusing elements; Afocal elements
- G02B5/0268—Diffusing elements; Afocal elements characterized by the fabrication or manufacturing method
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- Physics & Mathematics (AREA)
- Engineering & Computer Science (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Manufacturing & Machinery (AREA)
- Health & Medical Sciences (AREA)
- Ophthalmology & Optometry (AREA)
- Mechanical Engineering (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
- Planar Illumination Modules (AREA)
Abstract
The invention provides a light diffusion plate, a preparation method thereof and a backlight module, and belongs to the technical field of display. The preparation method of the light diffusion plate comprises the following steps: and respectively cooling two surfaces of the plate which is subjected to extrusion molding in the thickness direction by adopting different cooling temperatures, wherein the plate is unevenly shrunk, so that the thickness of the plate is reduced, the whole plate is bent and deformed towards the side with higher cooling temperature to form an arch structure with a high middle part and low two ends, and the light diffusion plate is obtained. The light diffusion plate prepared by the preparation method provided by the invention can be applied to a backlight module without a supporting structure, and the light diffusion plate with warp deformation can be kept on a relatively flat plane under the condition of no support, so that the uniformity and the display effect of a picture are ensured. And because backlight unit does not use bearing structure, reduced manufacturing procedure, improved the integration of material, simplify rear end production process and technology, improve production efficiency, material saving and cost of labor.
Description
Technical Field
The invention relates to the technical field of display, in particular to a light diffusion plate, a preparation method thereof and a backlight module.
Background
The backlight module is a key component of the LCD panel, and has the function of providing sufficient and uniformly distributed light source to make the display panel normally display images. The backlight module mainly comprises a light source, a light guide plate or a diffusion plate, an optical film, a plastic frame and the like. In the backlight module of the traditional liquid crystal display, the diffusion plate has certain weight, and the diffusion plate, the diaphragm and the like in the whole assembly machine can collapse under the influence of self gravity under the condition of no support, so that the visual effect uniformity of a display picture can be influenced.
A manufacturer usually adopts a support column to support the diffusion plate and the optical diaphragm during design and installation, the support column needs to be installed firstly during module assembly, then the diffusion plate and the diaphragm need to be installed, the steps need to be repeated for 2-4 times according to different module architectures, the process is complex and low in efficiency, and the labor cost is high.
Disclosure of Invention
The invention aims to solve the problems of complicated working procedures and low assembly efficiency caused by additionally arranging a support when a diffusion plate is installed in the prior art in order to avoid the influence of self gravity bending on the uniformity of a display picture of the diffusion plate.
In order to solve the above problems, the present invention provides a method for manufacturing a light diffusion plate, comprising: and respectively cooling two surfaces of the plate which is subjected to extrusion molding in the thickness direction by adopting different cooling temperatures, wherein the plate is unevenly shrunk, so that the thickness of the plate is reduced, the whole plate is bent and deformed towards the side with higher cooling temperature to form an arch structure with a high middle part and low two ends, and the light diffusion plate is obtained.
Preferably, one side of the plate is naturally cooled, and the other side of the plate is cooled by a cooling roller.
Preferably, the roll temperature of the cooling roll is 50-60 ℃.
Preferably, the preparation method of the plate comprises the following steps:
extruding a multilayer structure through an in-mold co-extrusion process, wherein the multilayer structure comprises a light entering layer, a supporting layer and a light emitting layer, and the supporting layer is positioned between the light entering layer and the light emitting layer;
and respectively hot-pressing microstructures on the surface of the light incident layer and the surface of the light emergent layer by using a roller with a microstructure carved on the surface to obtain the plate.
Preferably, the roller temperature of the roller when the surface of the light incident layer is hot-pressed is 100-110 ℃, and the roller temperature of the roller when the surface of the light emitting layer is hot-pressed is 95-105 ℃.
Preferably, the height of the microstructure formed by hot pressing the light incident layer and the light emergent layer is 1-30 μm.
Compared with the prior art, the preparation method of the light diffusion plate provided by the invention has the following beneficial effects:
the invention adopts different cooling temperatures to carry out cooling treatment on the two surfaces of the plate, so that the plate is unevenly shrunk, the whole plate is warped and deformed towards the side with higher cooling temperature, the middle part and the peripheral part of the plate are not on the same plane, the plate is approximately formed into an arch shape, and the light diffusion plate with warped deformation is obtained. The light diffusion plate can be applied to a backlight module without a supporting structure, and in the application process of the light diffusion plate, the light diffusion plate is placed into a roughly arched shape with the middle part higher than the peripheral parts, and the middle part of the light diffusion plate can naturally lay down under the action of self gravity, so that the light diffusion plate with certain degree of warping deformation is kept on a relatively flat plane under the action of self gravity, namely the diffusion plate can be kept on the relatively flat plane under the condition of no support, and the uniformity and the display effect of a picture are ensured. And because backlight unit does not use bearing structure, reduced manufacturing procedure, improved the integration of material, simplify rear end production process and technology, improve production efficiency, material saving and cost of labor.
The invention also provides a light diffusion plate which is characterized by being prepared according to the preparation method of the light diffusion plate.
Preferably, the vertical distance between the highest point and the lowest point of the arch shape of the single surface of the light diffusion plate is 0.05-1.5 mm.
Preferably, the total thickness of the light diffusion plate is 0.8-2.2mm, wherein the thicknesses of the light incident layer and the light emitting layer of the light diffusion plate are both 0.05-0.3mm, and the thickness of the support layer of the light diffusion plate is 0.6-2.0 mm.
The invention also provides a backlight module which comprises the light diffusion plate prepared by the preparation method of the light diffusion plate, or comprises the light diffusion plate.
Compared with the prior art, the light diffusion plate and the backlight module provided by the invention have the same beneficial effects as the preparation method of the light diffusion plate has in the prior art, and are not repeated herein.
Drawings
FIG. 1 is a schematic view illustrating a cooling process of a light diffusion plate according to an embodiment of the present invention.
Description of reference numerals:
1-a chill roll; 2-plate material.
Detailed Description
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail below.
The first aspect of the present invention provides a method for manufacturing a light diffusion plate, including: the two surfaces of the extrusion-molded plate 2 in the thickness direction are respectively cooled by different cooling temperatures, the plate 2 is unevenly shrunk, the thickness of the plate 2 is reduced, the plate 2 is integrally bent and deformed to the side with higher cooling temperature, an arch structure with a high middle part and low two ends is formed, and the light diffusion plate is obtained.
The plate 2 is of a multilayer structure obtained through multilayer coextrusion extrusion, residual stress in the plate 2 can be divided into flowing residual stress and thermal residual stress, and the warping degree of the plate 2 can be controlled by utilizing the residual stress existing in the plate 2. In this embodiment, the uneven cooling process is applied to both sides of the plate 2, and the thermal residual stress in the plate 2 is changed, so that the plate 2 is warped and deformed toward one side thereof. As shown in fig. 1, the cooling temperatures of both surfaces of the plate material 2 are different, and thereby uneven shrinkage occurs inside the plate material 2, so that the entire plate material 2 is warped toward the side having a higher cooling temperature, and the central portion and the peripheral portion of the plate material 2 are not on the same plane, and are formed into an arch structure having a high center and low ends, whereby the both surfaces of the plate material 2 are unevenly cooled, and a warped and approximately arched light diffusion plate is obtained.
The light diffusion plate prepared by the preparation method can be applied to a backlight module without a supporting structure, and in the whole machine assembly, because the light diffusion plate has a certain warping amplitude, the light diffusion plate is placed into an arch shape with the middle part higher than the peripheral parts, so that the light diffusion plate with warping deformation can be kept on a relatively flat plane under the influence of the self gravity of the light diffusion plate, namely the light diffusion plate can be kept on a relatively flat plane under the condition of no support, the uniformity and the display effect of a picture are ensured, a central bright spot can meet the use requirement, and the nine-point uniformity and the four-corner uniformity can also meet the requirements of the whole machine.
In addition, because the backlight module subtracts the use of bearing structure, reduced manufacturing procedure, and can adopt robotic arm to carry out production and complete machine assembly operation to the diffuser plate, improve the integration of material, simplify rear end production processes and technology, improve production efficiency, material saving and cost of labor.
In some embodiments, the method of making the sheet 2 comprises:
extruding a multilayer structure by an in-mold co-extrusion process, wherein the multilayer structure comprises an incident layer, a supporting layer and an emergent layer and is formed by three layers of co-extrusion in a mold, and the supporting layer is positioned between the incident layer and the emergent layer;
and respectively hot-pressing microstructures on the surface of the light incident layer and the surface of the light emergent layer by using a roller with the surface engraved with the microstructures to obtain the plate 2.
Specifically, three extruder hoppers respectively correspond to materials of the light incident layer, the support layer and the light emergent layer, and the uniformly stirred material mixtures of the substrate layers are respectively fed to the material feeding ports of the corresponding substrate layers; operating the extruder to plasticize the plastic material through a machine barrel screw rod, and extruding the plastic material by the extruder; after the materials of each layer are melted, extruding the materials into a die for compounding, and extruding the plates 2 through a discharge port of the die; wherein at least one of the extrusion mixed material of the light inlet layer, the extrusion mixed material of the support layer and the extrusion mixed material of the light outlet layer contains a light diffusion agent, and the light diffusion agent is an organic silicon material. The extrusion mixed materials of the light incident layer, the supporting layer and the light emitting layer contain light stabilizer, antioxidant and flexibilizer.
After the plate 2 is extruded, hot-pressing the upper surface and the lower surface of the plate 2 into a specific microstructure by using a roller with a microstructure carved on the surface, wherein the microstructure can be set into a sand grinding type or prismatic type surface light-gathering microstructure, the height of the microstructure is 1-30 mu m, the roller temperature of the roller during hot-pressing the surface of the light-entering layer is 100-110 ℃, and the roller temperature of the roller during hot-pressing the surface of the light-emitting layer is 95-105 ℃. In the present embodiment, the light is adjusted by the array arrangement of the micro-feature structures on the surface of the substrate to reduce the light loss caused by the reflected light from the lower surface, and the micro-structure on the surface of the plate 2 can also increase the light gathering capability and properly increase the brightness of the light diffusion plate.
The plate 2 obtained by multilayer co-extrusion and microstructure rolling is cooled by adopting a temperature difference cooling process, so that the cooling speed of two surfaces of the plate 2 is different, and the plate 2 warps towards the surface with higher temperature. Preferably, one surface of the plate 2 is naturally cooled, and the other surface of the plate 2 is cooled by the cooling roller 1, wherein the roller temperature of the cooling roller 1 is 50-60 ℃. As a result, the sheet 2 may warp if the cooling is not uniform.
As shown in fig. 1, fig. 1 is a schematic view of a cooling process of a plate 2, the plate 2 is horizontally placed in fig. 1, and a cooling roller 1 is additionally arranged above the plate 2, so that the upper surface of the plate 2 is cooled by the cooling roller, the roller temperature of the cooling roller 1 is 50-60 ℃, the lower surface of the plate 2 is naturally cooled, a temperature difference exists between the upper surface and the lower surface of the plate 2 due to a higher cooling temperature above the plate 2 and a lower cooling temperature below the plate 2, and the cooling speeds of the two sides are different due to the temperature difference, so that the plate 2 is warped. The dashed box in fig. 1 is the outline of the sheet 2 before cooling, after which it can be seen that the lower surface of the sheet 2 shrinks and the thickness of the sheet 2 decreases. I.e., the lower surface of the sheet 2 shrinks, and both ends of the sheet 2 are bent downward (as indicated by the two curved arrows in fig. 1), so that the sheet 2 is integrally formed into an upwardly arched structure.
In a second aspect of the present invention, there is provided a light diffuser plate prepared by the above preparation method, wherein the light diffuser plate has a certain warping amplitude.
The warping amplitude of the light diffusion plate is related to the temperature difference of cooling of the two surfaces of the plate 2, on one hand, the material temperature of the plate 2 during extrusion is accurately adjusted according to the difference of the thickness of the plate 2, and the problem that the warping requirement cannot be met due to the fact that the temperature difference between the light incident surface and the light emergent surface of the plate 2 is small during subsequent warping processing because the plate 2 is cooled too fast is avoided. In the specific implementation mode, according to the thickness characteristics of different plates 2, the diameter of a proper cooling roller 1 is selected, and the cooling roller 1 is connected with a temperature controller so as to realize accurate temperature control. The cooling roller 1 has different diameters and different temperature control areas, and the temperature distribution can be uniform by selecting the proper cooling roller 1. On the other hand, according to different requirements on the warpage amplitude of the light diffusion plate, a sufficiently large temperature difference between the light incident layer and the light emergent layer can be ensured by controlling the cooling temperature, and in addition, when the temperature of the cooling roller 1 is constant, the extrusion speed of the plate 2 needs to be adjusted to ensure that the plate 2 has sufficient cooling time on the cooling roller 1 to achieve the required warpage amplitude.
In this embodiment, the warpage range of the light diffusion plate is 0.05-1.5mm, the warpage range is measured by a deformation amount X, and the deformation amount X is a distance between a highest point and a lowest point of an arch shape of a single surface of the plate 2, that is, a vertical distance between a position of the surface of the plate 2 adjacent to a side with a higher cooling temperature at the beginning of cooling and a position after cooling and shaping. The deformation amount X may be greater than, equal to, or less than the thickness of the plate 2, which is mainly related to the magnitude of the cooling temperature difference between the two sides of the plate 2, and the larger the cooling temperature difference between the two sides of the plate 2, the larger the bending deformation degree of the plate 2, and accordingly, the larger the bending deformation amount X of the plate 2. Setting the warpage range of the light diffusion plate within the above range can balance the pressing down by the self-weight of the plate 2 by utilizing the warpage deformation of the light diffusion plate without affecting the properties of the plate 2, such as strength.
In the light diffusion plate of the embodiment, the thicknesses of the light incident layer and the light emergent layer are both 0.05 mm to 0.3mm, the thickness of the supporting layer is 0.6 mm to 2.0mm, and the total thickness of the light diffusion plate is 0.8mm to 2.2 mm. Under the thickness, the application requirements of the light diffusion plate are met on one hand, and on the other hand, the plate 2 can be ensured to be easily subjected to warping deformation in the subsequent temperature difference cooling process.
In a third aspect of the invention, a backlight module is provided, which includes the light diffusion plate. When the backlight module is assembled, a supporting structure is not required to be additionally arranged, the processing procedures are reduced, the rear-end production procedures and the process are simplified, and the production efficiency is improved.
The present invention will be described in detail with reference to specific embodiments, which provide a method for manufacturing a light diffusion plate, including the steps of:
three extruder hoppers respectively correspond to the extrusion mixed materials of the light incident layer, the supporting layer and the light emitting layer, wherein the extrusion mixed materials of the light incident layer and the light emitting layer consist of the following components in parts by weight: 98.7 percent of Polystyrene (PS), 0.2 percent of ultraviolet absorbent, 0.2 percent of light stabilizer, 0.4 percent of antioxidant and 0.5 percent of toughening agent. The extrusion mixed material of the supporting layer consists of the following components in parts by weight: 88.7 percent of PS, 8 percent of siloxane light diffusant, 0.2 percent of ultraviolet absorbent, 0.2 percent of light stabilizer, 0.4 percent of antioxidant and 2.5 percent of toughening agent.
And (3) running an extruder, melting the mixed materials of all layers, extruding into a die, and compounding to obtain the plate 2. The total width of the extruded sheet 2 is 430mm, the effective width is 413mm, the length is 725mm, and the extruded sheet is cut with the edge strips and recycled. Wherein, the thickness of the incident layer is 0.1mm, the thickness of the supporting layer is 0.8mm, the thickness of the emergent layer is 0.1mm, and the total thickness is 1 mm.
And respectively hot-pressing the upper surface and the lower surface of the plate 2 into a specific micro-grinding structure by using a roller with a microstructure carved on the surface.
As shown in figure 1, a cooling roller 1 is additionally arranged on the upper side of a plate 2, the roller temperature is 50-60 ℃, and the plate 2 is warped and deformed.
And then, conveying the plate 2 to the rear section of the production line through a conveying device, gradually cooling and shaping in the traction process, conveying the plate 2 to a cutting unit of the rear section of the production line, cutting the plate into required sizes, grabbing and stacking the plate by using a mechanical arm, and cleaning, packaging and warehousing the plate.
And (3) flatly placing the plate 2 on a marble detection platform with the light incident layer facing upwards, and testing the warpage amplitude of four corners to be 0.2-0.3 mm.
In this embodiment, the light diffusion plate is formed in one step by adopting a multi-layer co-extrusion process, a microstructure rolling process and a temperature difference cooling process, and the obtained light diffusion plate can be matched with a backlight module without a support structure for use.
Although the present disclosure has been described above, the scope of the present disclosure is not limited thereto. Various changes and modifications may be effected therein by one of ordinary skill in the pertinent art without departing from the spirit and scope of the present disclosure, and these changes and modifications are intended to be within the scope of the present disclosure.
Claims (10)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011486316.8A CN112644045A (en) | 2020-12-16 | 2020-12-16 | Light diffusion plate, preparation method thereof and backlight module |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202011486316.8A CN112644045A (en) | 2020-12-16 | 2020-12-16 | Light diffusion plate, preparation method thereof and backlight module |
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| CN112644045A true CN112644045A (en) | 2021-04-13 |
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|---|---|---|---|---|
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| US20070014034A1 (en) * | 2005-07-15 | 2007-01-18 | Chi Lin Technology Co., Ltd. | Diffusion plate used in direct-type backlight module and method for making the same |
| CN101065236A (en) * | 2004-11-24 | 2007-10-31 | 特里斯帕国际公司 | Method for deforming a plastic plate |
| JP2008063119A (en) * | 2006-09-08 | 2008-03-21 | Sumitomo Chemical Co Ltd | Loading method of resin plate |
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| CN215152041U (en) * | 2020-12-16 | 2021-12-14 | 南通创亿达新材料股份有限公司 | Light diffusion plate and backlight module |
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2020
- 2020-12-16 CN CN202011486316.8A patent/CN112644045A/en active Pending
Patent Citations (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2003005295A (en) * | 2001-06-26 | 2003-01-08 | Sumitomo Chem Co Ltd | Method of manufacturing sheet member for optical screen |
| KR20060037179A (en) * | 2004-10-27 | 2006-05-03 | 삼성전자주식회사 | Light diffusing unit, display device having same and manufacturing device thereof |
| CN101065236A (en) * | 2004-11-24 | 2007-10-31 | 特里斯帕国际公司 | Method for deforming a plastic plate |
| US20070014034A1 (en) * | 2005-07-15 | 2007-01-18 | Chi Lin Technology Co., Ltd. | Diffusion plate used in direct-type backlight module and method for making the same |
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| CN105612131A (en) * | 2013-08-15 | 2016-05-25 | 康宁股份有限公司 | Methods of manufacturing glass articles using anisothermal temperature profiles |
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| CN109422448A (en) * | 2017-08-31 | 2019-03-05 | Ａｇｃ株式会社 | The manufacturing method of 3D protection glass |
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