LIGHT DIFFUSION PLATE FOR LCD BACKLIGHT WITH IMPROVED MASKING EFFECT OF LAMP AND LIGHT TRANSMITTANCE
Technical Field The present invention relates to a light diffusion plate with improved masking effect of lamp and light transmittance that is useful for a lighting fixture cover, an advertisement panel, and especially a direct backlight type LCD.
Background Art In general, the backlight in the conventional LCD device includes an edge lighting system, and a direct lighting system. In the edge lighting system, a fluorescent lamp is disposed at the edge of a light guide plate that has a downward slope to the bottom end under which a reflecting plate of sheet is installed. If necessary, a pattern may be printed on the bottom end of the light guide plate. This system, which inevitably provides a low brightness, is mainly applied to small-sized display devices. The direct lighting system does not employ, a light guide plate but includes a reflecting plate, a plurality of lamps installed on the reflecting plate, and a light diffusion plate disposed on the lamps at a predetermined distance. The core of this system is a uniform brightness because of the lamps concealed completely. For this purpose, the light diffusion should be high resulting in lower light transmittance. This causes an inevitable reduction of the brightness. Another method is arranging the light diffusion plate farther away from the lamps, making it difficult to realize a thin display device. An improved method is using a geometric light guide plate and a light diffusion plate at once, as disclosed in Korean Patent Laid-open Publication No. 2002-71358. However, this system
, has problems regarding to complicated structure, increased complexity of the process, high production cost, and heavy weight.
Disclosure of Invention It is an object of the present invention to provide a light diffusion plate with excellent masking effect of lamp and high light transmittance to maintain high brightness uniformity, thereby enabling realization of a thin backlight with enhanced performance. To achieve the object of the present invention, there is provided a light diffusion plate for an LCD backlight that is fabricated by coextrusion or multi-layer extrusion of at least two. light diffusion layers including a binder resin with or without light diffusion beads. The light diffusion plate has a structure that the light diffusion rate of the respective light diffusion layers gradually increases from the bottom of the light diffusion plate with an incident light of a lamp striking thereon to the top of the light diffusion plate. Hereinafter, the present invention will be described in detail as follows. Generally, the light diffusion plate is fabricated by extrusion of light diffusion layers comprising a binder resin and light diffusion beads. The present invention is directed to a light diffusion plate fabricated by coextrusion or multi-layer extrusion of a plurality of light diffusion layers. In the light diffusion plate of the present invention, the first light diffusion layer with an incident light of a lamp striking thereon may not include light diffusion beads. The light diffusion plate for a LCD backlight according to the present invention, particularly the light diffusion plate useful for a direct backlight LCD display is obtained by coextrusion or multi-layer extrusion of at least two light diffusion layers each having a different light diffusion rate gradient. The coextrusion or multi-layer extrusion of the multiple light diffusion layers to
increase the light diffusion rate from the bottom of the light diffusion plate with an
incident light(λ) of a lamp striking thereon to the top of the light diffusion plate may
prevent a re-expulsion of light by reflection at the bottom of the light diffusion plate to avoid a leak of light and maximize light diffusion from bottom to top of the light diffusion plate. This case of light diffusion is illustrated in FIG. 1. This can be realized by different methods that specifically include, for example, a method of regulating the density distribution (the term "density distribution" as used herein is defined as a number density expressed as the number of the light diffusion beads per volume) and the extrusion rate of the light diffusion beads in the light diffusion layers to have a different thickness and a different light transmittance in coextrusion or multilayer extrusion of multiple light diffusion layers, and a method of forming light diffusion layers comprising light diffusion beads each having a different refractive index difference from the binder resin. In case of using the density distribution of the light diffusion beads, for example, the number of the light diffusion beads is controlled to have a density distribution increasing from the bottom of the light diffusion plate with an incident light of the lamp striking thereon to the top of the light diffusion plate. The light diffusion layer at the bottom of the light diffusion plate with an incident light of the lamp striking thereon contains light diffusion beads having a relatively low refractive index difference from the binder resin, while the light diffusion layer at the top of the light diffusion plate contains light diffusion beads having a relatively high refractive index difference from the binder resin. Namely, the coextrusion or multi-layer extrusion of multiple light diffusion layers using the density distribution difference of the light diffusion beads or the refractive index gradient of the light diffusion beads results in a light diffusion plate having multiple light
diffusion layers with a light diffusion rate gradient. In the case of fabricating a light diffusion plate by coextrusion or multi-layer extrusion of two light diffusion layers, for example, a light diffusion plate having a thickness of 1 to 3 mm and a light transmittance of 20 to 75 % (light diffusion rate: 99 ~ 98%) can be produced by controlling the light diffusion layer at the bottom of the light diffusion plate with an incident light of the lamp striking thereon to have a light transmittance of 70 to 93 % (light diffusion rate: 98 ~ 6%) and a thickness of 0.5 to 1.5 mm, and the light diffusion layer at the top of the light diffusion plate to have a light transmittance of 30 to 80 % (light diffusion rate: 99 - 96%) and a thickness of 0.5 to 1.5 mm. Compared with a single-layer light diffusion plate having the same light transmittance, the light diffusion plate of the present invention thus obtained is excellent in masking effect of lamp to maintain high brightness uniformity, achieving a desired brightness without increasing the distance from the lamp to the light diffusion plate, so it can be used for a direct backlight system necessary to a thin display system. In the present invention, the number of light diffusion layers coextruded or multilayer extruded and the thickness of the respective light diffusion layers can be controlled. In the fabrication of the light diffusion plate according to the present invention, the variety of the binder resin and the light diffusion beads in the light diffusion layers are generally given and specifically described as follows. The specific examples of the binder resin as used herein include acryl-, urethane-, or epoxy melamine-based polymer or copolymer or ternary copolymer of unsarurated polyester, methylmethacrylate, ethylmethacrylate, isobutylmethacrylate, n- butylmethacrylate, n-butylmethylmethacrylate, acrylic acid, methacrylic acid, hydroxyethylmethacrylate, hydroxypropylmethacrylate, hydroxyethylacrylate, acrylamide,
methylolacrylamide, glycidylmethacrylate, ethylacrylate, isobutylacrylate, n-butylacrylate, or 2-ethylhexylacrylate. A variety of organic or inorganic beads are used as the light diffusion beads so as to enhance the light transmittance and the light diffusion rate with a refractive index difference from the general binder resin. The specific examples of the light diffusion beads as used herein include organic beads such as acryl-based polymer, copolymer or ternary copolymer beads of methylmethacrylate, ethylmethacrylate, isobutylmethacrylate, n- butylmethacrylate, n-butylmethylmethacrylate, acrylic acid, methacrylic acid, hydroxyethylmethacrylate, hydroxypropylmethacrylate, hydroxy ethylacrylate, acrylamide, methylolacrylate, glycidylmethacrylate, ethylacrylate, isobutylacrylate, n-butylacrylate, or 2-ethylhexylacrylate, olefinic beads of polyethylene, polystyrene or polypropylene, acryl- olefin copolymer beads, or multi-layer multi-component beads prepared by forming single polmer beads, and then coating the beads with a different monomer; or inorganic beads such as silicon oxide, aluminum oxide, titanium oxide, zirconium oxide, magnesium fluoride, etc.. Generally, the organic beads are superior in light diffusibility to inorganic beads.
Brief Description of the Drawings FIG. 1 is an illustration of a light diffusion state of light on a light diffusion plate having multiple light diffusion layers according to an embodiment of the present invention.
Best Mode for Carrying out the Invention Hereinafter, ■ the present invention will be described in detail by way of the following examples, which are not intended to limit the scope of the present invention. Example 1: Control of Light diffusion Rate of Light diffusion layers by Density
Distribution Difference of Light diffusion Beads. In this example, a light diffusion plate was fabricated by coextrusion of a light diffusion layer having a light transmittance of 90 % (light diffusion rate: 30%) and a thickness of 1.5 mm, and a light diffusion layer having a light transmittance of 70 % (light diffusion rate: 98%) and a thickness of 0.5 mm. Here, the transmittance and the light diffusion rate were measured for sheets obtained by a single extrusion to the corresponding thickness with an NDH 2000 (Denshoku in Japan) as measurement equipment according to the standard method of ASTM D 1003. In this example, the h-ansmittance of the light diffusion layers was regulated by controlling the density distribution of light diffusion beads, while the thickness of the light diffusion layers was regulated by controlling the extrusion rate of the extruder. The light diffusion layers were prepared using polymethylmethacrylate (VH-001 supplied by Mitsubishi Rayon in Japan) as a binder resin, and cross-linked polystyrene ■>. beads (Diasphere supplied by Kolon in Korea) as light diffusion beads. The details are '-, presented in Table 1. The light diffusion plate thus obtained had a total thickness of 2 mm, and a light transmittance of 63 %.. The light diffusion plate was cut in 17-inch long units, which were placed 13 mm above a device with 8 cold cathode fluorescent lamps arranged at predetermined intervals to measure the brightness right over the lamps and in the middle between the lamps. The average ratio of the brightness right over the lamps to the brightness in the middle of the lamps was 1.02 on average.
Table 1
Example 2: Control of Light diffusion Rate of Light diffusion layers by Refractive Index Gradient of Light diffusion Beads. In this example, a light diffusion plate was fabricated by coextrusion of a light diffusion layer having a light transmittance of 90 % (light diffusion rate: 30 %) and a thickness of 1.5 mm, and a light diffusion layer having a light transmittance of 70 % (light diffusion rate: 98 %) and a thickness of 0.5 mm in the same manner as described in Example 1. Here, the transmittance and the light diffusion rate were measured for sheets obtained by a single extrusion to the corresponding thickness with an NDH 2000 (Denshoku in Japan) as measurement equipment according to the standard method of ASTM D 1003. In this example, the transmittance of the light diffusion layers was regulated by controlling the refractive index difference between the light diffusion beads and the binder resin, while the thickness of the light diffusion layers was regulated by controlling the extrusion rate of the extruder. The light diffusion layers were prepared using polymethylmethacrylate (VH-001 (refractive index: 1.49 %) supplied by Mitsubishi Rayon in Japan) as the binder resin, and polystyrene-methylmethacrylate copolymer beads (Diasphere MSP-X10) and polystyrene
beads (Diasphere SPB-XIO) as the light diffusion beads for the respective layers. The refractive index of the light diffusion beads can be regulated depending on the content of monomers used in the preparation of the light diffusion beads. For example, the lower styrene content may result in a lower refractive index and a higher transmittance. The details are presented in Table 2. The light diffusion plate thus obtained- had a total thickness of 2 mm, and a light transmittance of 63 %. The light diffusion plate was cut in 17-inch long units, which were placed 13 mm above a device with 8 cold cathode fluorescent lamps arranged at predetermined intervals to measure the brightness right over.the lamps and in the middle between the lamps. The ratio of the brightness right over the lamps to the brightness in the middle of the lamps was 1.02 on average. Table 2
Comparative Example 1 In this example, a light diffusion layer using the same binder resin and the same light diffusion beads as described in the above example was extruded to produce a light diffusion plate having a thickness of 2 mm and a light transmittance of 63 % (light diffusion rate: 99 %).
The transmittance and the light diffusion rate were measured with an NDH 2000 (Denshoku in Japan) as measurement equipment according to the standard method of ASTM D 1003. The light diffusion layer was prepared using polymethylmethacrylate (VH-001 (refractive index: 1.49 %) supplied by Mitsubishi Rayon in Japan) as the binder resin, and polystyrene beads (Diasphere SPB-X10) as the light diffusion beads. The details are presented in Table 3. The distance of the lamps and the light diffusion plate to give an average brightness ratio of 1.02 was determined as 18 mm in the same manner as described in Example 1.
• ' Table 3
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According to the results of Example 1 and 2 and Comparative Example 1, the distance between the lamps and the light diffusion plate to acquire the defined brightness ratio was about 13 mm in the Examples 1 and 2, but 18 mm for the light diffusion plate produced by extrusion of a single light diffusion layer in the Comparative Example 1. Hence, the use of the light diffusion plate of the present invention decreases the thickness of the backlight by about 5 mm.
Industrial Applicability As described above, the light diffusion plate manufactured by coextrusion or multi-layer extrusion of multiple light diffusion layers each having a different light diffusion rate gradient according to the present invention can reduce the thickness of the
backlight unit without a loss of light transmittance and haze relative to the light diffusion plate produced by extrusion of a single light diffusion layer having a same light
transmittance.