CN116047807A - 交错非均匀排列的Mini-LED直下式背光模组 - Google Patents
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Abstract
本发明提出一种交错非均匀排列的Mini‑LED直下式背光模组,包括导光板、直下式背光模组、光反射微结构、角入式背光源、反射罩、反射片和光学膜片。在导光板下表面交错非均匀设置四棱锥形光反射微结构及Mini‑LED光源,并对导光板进行去边角化处理,四角磨平抛光形成平面入光面,设置角入式光源。本发明提供的交错非均匀排列的Mini‑LED直下式背光模组解决了现有直下式背光显示装置中混光效率低、边缘亮度衰减,及Mini‑LED分布密集导致散热能力差的问题。
Description
技术领域
本发明属于显示器件背光模组技术领域,特别涉及一种交错非均匀排列的Mini-LED直下式背光模组。
背景技术
近年来,随着显示技术的不断发展,平板显示在生活及军用等各个领域都得到了广泛的应用,而背光模组薄型化技术与增亮技术作为液晶显示领域的关键技术,一直备受关注。Mini-LED背光作为一种新型背光,通过大数量的Mini-LED芯片密集排布,能够在更小的范围内实现区域调光,对比于传统的背光模组,其能够在更小的混光距离内实现更好的亮度均匀性,进而大大降低背光模组的厚度,因此备受行业关注。
现有技术公开的一种直下式背光显示装置CN112631025A,采用传统LED光源,将一层光学胶层贴合设置在基板和LED光源上,利用光学胶层一体封装粘合固定LED光源和反射罩,在保持出光均匀度的条件下,密封加固LED光源和反射罩,同时通过对反射罩和光学胶层上的近光轴区域的高反射结构设计协同作用实现均匀光分布而不产生光斑的效果。但是此显示装置所需混光高度较大,难以满足人们对轻薄用品的需求,此外,此显示装置仍存在边缘亮度不足的现象。
现有技术公开的一种直下式Mini-LED背光显示装置CN213988067U,在基板上装设有若干个Mini-LED进行均匀排列,在Mini-LED上方装设点对点微结构扩散膜,并在Mini-LED与点对点微结构扩散膜之间设有间隙,在微结构扩散膜上装设一层增光膜,增光膜上装设遮光双面胶层,利用微结构将光线进一步分散均匀,并通过扩散膜与增光膜的多次光线分散及传导,提高光线均匀度。但是此显示装置需要大量Mini-LED光源,密集的Mini-LED分布导致Mini-LED混光不充分,易出现四周偏暗的现象,且此显示装置的散热能力较差,使用寿命较短,难以维持显示装置的长期使用。
发明内容
为了克服现有技术的缺陷和不足,本发明的目的在于提供一种交错非均匀排列的Mini-LED直下式背光模组。
包括导光板、直下式背光模组、光反射微结构、角入式背光源、反射罩、反射片和光学膜片。在导光板下表面交错非均匀设置四棱锥形光反射微结构及Mini-LED光源,并对导光板进行去边角化处理,四角磨平抛光形成平面入光面,设置角入式光源。本发明提供的交错非均匀排列的Mini-LED直下式背光模组解决了现有直下式背光显示装置中混光效率低、边缘亮度衰减,及Mini-LED分布密集导致散热能力差的问题。
其采用将Mini-LED光源与四棱锥形光反射微结构交错非均匀排列的方式,利用微结构反射部分Mini-LED光源散发的光,提高混光效率,增强亮度;并对导光板进行去边角化处理,四角磨平抛光形成平面入光面,将角入式背光源放置于导光板四角的平面形状边角区域的截面处。通过计算合适的光源间距L与混光距离H,提高Mini-LED的混光效率,防止明暗光斑的出现,使显示装置的全屏亮度均匀性不低于85%。
该显示装置解决了传统LED直下式背光装置边缘亮度衰减、显示效果较差的问题,同时也减少了Mini-LED光源用量,增强显示装置散热能力,提高显示装置使用寿命。
本发明解决其技术问题采用的技术方案是:
一种交错非均匀排列的Mini-LED直下式背光模组,其特征在于:导光板、直下式背光模组、光反射微结构、角入式背光源、反射罩、反射片和光学膜片;
所述直下式背光模组位于导光板下表面,由多个Mini-LED光源交错非均匀排列组成,且每一颗Mini-LED与一组连接端子对电性连接;
所述光反射微结构位于导光板下表面,呈交错非均匀排列,且排列结构与Mini-LED光源相互错开;
所述导光板经过去边角化处理,四角磨平抛光形成平面入光面,并在边角平面区域设置角入式背光源;
所述反射罩位于导光板四个边角区域,完全包覆所述角入式背光源;
所述反射片位于导光板下表面,用以反射从导光板底部透射出的光线,增加光源利用率;
所述光学膜片包括扩散片和正交放置的棱镜片,位于导光板的上表面。
进一步地,设两颗相邻Mini-LED光源交错非均匀排列的间距为L,H为Mini-LED光源顶端距导光板下表面的距离,导光板下表面上的点A对应单颗Mini-LED所对应正上方点的照度,点B对应两颗Mini-LED中心点所对应正上方点的照度,EA、EB为点A、B周围Mini-LED产生的照度叠加值,θ为AB边所对应的角,则照度值满足下式:
式中,E(0)为Mini-LED光源垂直入射时的最大照度值;
通过计算合适的光源间距L范围与混光距离H,以提高Mini-LED的混光效率,防止明暗光斑的出现,使显示装置的全屏亮度均匀性不低于85%。
进一步地,在非均匀排列中,相邻两颗Mini-LED光源的间距L在0.1-1mm之间,纵向Mini-LED光源数n为300-350颗,横向Mini-LED光源数m为500-550颗。
进一步地,每一颗Mini-LED光源包括光源主体、封装在光源主体内部的光源芯片及设置在光源主体底部的两个光源引脚,两个光源引脚与匹配的连接端子组的两个连接端子分别对应电性连接。
进一步地,所述光反射微结构为向上凸起的四棱锥形,且其顶端低于Mini-LED上表面。
进一步地,对所述导光板进行去边角化处理,四角磨平抛光形成平面入光面,使导光板直角形状边角区域变为平面形状边角区域,并在边角区域设置角入式背光源。
进一步地,所述角入式背光源采用功率为0.2-0.5W的灯珠。
进一步地,所述导光板的材料为聚甲基丙烯酸甲酯、聚苯乙烯、聚氯丙烯、环烯共聚物、聚碳酸酯、聚二甲基苯硅氧烷中的一种或多种。
进一步地,所述导光板四个边角区域设置反射罩;所述反射罩的材料为聚对苯二甲酸乙二醇脂、聚氨酯树脂、聚碳酸酯、聚乙烯、聚甲基丙烯酸甲酯的一种或多种。
进一步地,采用以下步骤进行制作:
步骤S1:制作导光板单元;
步骤S2:在导光板下表面交错非均匀设置Mini-LED光源,每一颗Mini-LED与一组连接端子对电性连接;
步骤S3:在导光板下表面错开Mini-LED光源设置四棱锥形光反射微结构,且其顶端低于Mini-LED光源上表面;
步骤S4:对导光板进行去边角化处理,四角磨平抛光形成平面入光面,使导光板直角形状边角区域变为平面形状边角区域,并将角入式背光源放置于导光板四角的平面形状边角区域的截面处;
步骤S5:在导光板四个边角区域设置反射罩,完全包覆角入式背光源;
步骤S6:在导光板的下表面添加反射片,用于反射从导光板底部透射出的光线,提高光源利用率;
步骤S7:在所述导光板的上表面添加光学膜片,包括:扩散片和正交放置的棱镜片。
与现有技术相比,本发明及其优选方案所提供的交错非均匀排列的Mini-LED直下式背光模组,Mini-LED光源与四棱锥形光反射微结构交错非均匀排列的设计大大减少了Mini-LED光源的用量,利用光反射微结构反射部分Mini-LED光源发出的光,提高显示装置的亮度;通过计算合适的光源间距L与混光距离H,提高Mini-LED的混光效率,防止明暗光斑的出现,使显示装置的全屏亮度均匀性不低于85%;此外,针对现有直下式背光显示装置中存在的边缘亮度衰减问题,在导光板边角区域设置角入式光源进行边缘亮度补偿。
附图说明
下面结合附图和具体实施方式对本发明进一步详细的说明:
图1是本发明的交错非均匀排列的Mini-LED直下式背光模组的一个实施例的结构剖视图;(图中的在视觉上均匀排列的Mini-LED实际上为非均匀排列)
图2是本发明的交错非均匀排列的Mini-LED直下式背光模组的一个实施例的直下式背光源结构示意图;
图3是本发明的交错非均匀排列的Mini-LED直下式背光模组的一个实施例的结构俯视图;(图中的在视觉上均匀排列的Mini-LED实际上为非均匀排列)
图4是本发明的交错非均匀排列的Mini-LED直下式背光模组的一个实施例的直下式背光模组排布图;(图中的在视觉上均匀排列的Mini-LED实际上为非均匀排列)
图5是本发明的交错非均匀排列的Mini-LED直下式背光模组的一个实施例的正向剖面图;
图中:1-导光板;2-Mini-LED光源;3-光源引脚;4-直下式背光模组;5-光反射微结构;6-角入式背光源;7-反射罩;8-反射片;9-光学膜片。
具体实施方式
为让本专利的特征和优点能更明显易懂,下文特举实施例,作详细说明如下:
应该指出,以下详细说明都是例示性的,旨在对本申请提供进一步的说明。除非另有指明,本说明书使用的所有技术和科学术语具有与本申请所属技术领域的普通技术人员通常理解的相同含义。
需要注意的是,这里所使用的术语仅是为了描述具体实施方式,而非意图限制根据本申请的示例性实施方式。如在这里所使用的,除非上下文另外明确指出,否则单数形式也意图包括复数形式,此外,还应当理解的是,当在本说明书中使用术语“包含”和/或“包括”时,其指明存在特征、步骤、操作、器件、组件和/或它们的组合。
如图1-图5所示,本发明实施例提供的交错非均匀排列的Mini-LED直下式背光模组,包括:导光板1、直下式背光模组4、光反射微结构5、角入式背光源6、反射罩7、反射片8和光学膜片9;
直下式背光模组位于导光板下表面,由多个Mini-LED光源2交错非均匀排列组成,且每一颗Mini-LED与一组连接端子对电性连接;
光反射微结构位于导光板下表面,呈交错非均匀排列组成,并与Mini-LED光源相互错开;导光板进行去边角化处理,四角磨平抛光形成平面入光面,在边角平面区域设置角入式背光源;
反射罩位于导光板四个边角区域,完全包覆角入式背光源;
反射片位于导光板下表面,用以反射从导光板底部透射出的光线,增加光源利用率;
光学膜片包括扩散片和正交放置的棱镜片,位于导光板的上表面。
本实施例中,作为一种优选方案,Mini-LED光源交错非均匀排列,彼此间距为L(L并非常量,是在一个数值范围内的取值,从而实现非均匀排列),取点A为单颗Mini-LED所对应正上方点的照度,点B为两颗Mini-LED中心点所对应正上方点的照度,EA、EB为点A、B周围Mini-LED产生的照度叠加值,θ为AB边所对应的角,H为Mini-LED光源顶端距导光板下表面的距离,则照度值满足下式:
式中,E(0)为Mini-LED光源垂直入射时的最大照度值。
本实施例中,作为一种优选方案,相邻两颗Mini-LED光源的间距L在0.1-1mm之间,纵向Mini-LED光源数n为300-350颗,横向Mini-LED光源数m为500-550颗。
本实施例中,作为一种优选方案,每一颗Mini-LED光源包括光源主体、封装在光源主体内部的光源芯片及设置在光源主体底部的两个光源引脚3,两个光源引脚与匹配的连接端子组的两个连接端子一一对应电性连接。
本实施例中,作为一种优选方案,光反射微结构为向上凸起的四棱锥形,且其顶端略低于Mini-LED上表面。
本实施例中,作为一种优选方案,对导光板进行去边角化处理,四角磨平抛光形成平面入光面,使导光板直角形状边角区域变为平面形状边角区域,并在边角区域设置角入式背光源。
本实施例中,作为一种优选方案,角入式背光源选用功率为0.2-0.5W的灯珠。
本实施例中,作为一种优选方案,导光板的材料为聚甲基丙烯酸甲酯、聚苯乙烯、聚氯丙烯、环烯共聚物、聚碳酸酯、聚二甲基苯硅氧烷的一种或多种组合。
本实施例中,作为一种优选方案,导光板四个边角区域设置反射罩,反射罩的材料为聚对苯二甲酸乙二醇脂、聚氨酯树脂、聚碳酸酯、聚乙烯、聚甲基丙烯酸甲酯的一种或多种组合。
本实施例中,作为一种优选方案,背光显示装置的制作方法如下:
(1)制作导光板单元;
(2)在导光板下表面交错非均匀设置Mini-LED光源,每一颗Mini-LED与一组连接端子对电性连接;
(3)在导光板下表面错开Mini-LED光源设置四棱锥形光反射微结构,且其顶端略低于Mini-LED光源上表面;
(4)对导光板进行去边角化处理,四角磨平抛光形成平面入光面,使导光板直角形状边角区域变为平面形状边角区域,并将角入式背光源放置于导光板四角的平面形状边角区域的截面处;
(5)在导光板四个边角区域设置反射罩,完全包覆角入式背光源;
(6)在导光板的下表面添加反射片,用于反射从导光板底部透射出的光线,提高光源利用率;
(7)在导光板的上表面添加扩散片、正交放置的棱镜片等光学膜片。
以下以一个具体实例作为说明,对本实施例方案进行更为细致的介绍:
如图1所示,为本发明提供的一种交错非均匀排列的Mini-LED直下式背光模组剖视图,确定1-导光板为聚甲基丙烯酸甲酯PMMA材质的导光板,取30千克聚甲基丙烯酸甲酯PMMA与20千克聚碳酸酯PC放置熔融器具中混合,加入3千克光扩散剂、1千克光稳定剂、0.5千克热稳定剂,此外,为了增强导光板的硬度,加入2.5千克硅酮母粒及7.5千克熔融石英砂,搅拌至材料完全混合,将材料加热至460℃,随后以190mm/s的速度注射至模具中使其冷却成形。
在8-反射片上间距L交错非均匀排列2-Mini-LED光源,交错非均匀分布有效防止因Mini-LED光源分布太多密集导致混光不充分,中间区域亮度过高而四周偏暗的问题,同时极大程度减少了Mini-LED光源的用量,避免散热不良造成寿命下降。Mini-LED光源通过3-光源引脚与匹配的连接端子组的两个连接端子一一对应电性连接。此外,通过对光照度EA、EB的计算,得出最佳间距L及混光距离H,进一步提高显示装置的亮度均匀性。
在8-反射片上错开2-Mini-LED光源交错非均匀排列5-光反射微结构,利用光刻技术制作四棱锥形凸起微结构,微结构朝向导光板,高度略低于2-Mini-LED光源上表面,用以反射Mini-LED光源散发的部分光线,提高光线利用率,防止因减少Mini-LED光源而造成的亮度不足问题。
在导光板四角区域选用2835LED灯珠作为6-角入式背光源,该LED灯珠尺寸L*W*H为2.8mm*3.5mm*0.7mm,单颗亮度为22流明,且具有更强的散热能力,以便延长显示装置的寿命。由于该灯珠发光全角为120°,对导光板进行去边角化处理,四角磨平抛光形成平面入光面,使导光板直角形状边角区域变为平面形状边角区域,经处理后的角度为120°。导光板四角的平面形状边角区域的截面处各放置两个角入式背光源,从而实现Mini-LED直下式背光的边缘亮度补偿。
将聚氨酯树脂置于模具中,加热模具及聚氨酯树脂至120℃,在恒温加热状态下对聚氨酯树脂进行压合成型,待聚氨酯树脂压合之后进行抽真空处理,以便聚氨酯树脂吸附成型。在合模状态下恒温恒热一段时间后对模具进行冷却,待冷却至一定温度后进行分模动作,最后利用吹风冷却装置对聚氨酯树脂进行常温冷却,完成脱模步骤,从而形成7-反射罩,设置于导光板的四个边角区域,完全包覆6-角入式背光源,以增强角入式背光源的光线利用率。
以上所述,仅是本发明的较佳实施例而已,并非是对本发明作其它形式的限制,任何熟悉本专业的技术人员可能利用上述揭示的技术内容加以变更或改型为等同变化的等效实施例。但是凡是未脱离本发明技术方案内容,依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与改型,仍属于本发明技术方案的保护范围。
本专利不局限于上述最佳实施方式,任何人在本专利的启示下都可以得出其它各种形式的交错非均匀排列的Mini-LED直下式背光模组,凡依本发明申请专利范围所做的均等变化与修饰,皆应属本专利的涵盖范围。
Claims (10)
1.一种交错非均匀排列的Mini-LED直下式背光模组,其特征在于:导光板、直下式背光模组、光反射微结构、角入式背光源、反射罩、反射片和光学膜片;
所述直下式背光模组位于导光板下表面,由多个Mini-LED光源交错非均匀排列组成,且每一颗Mini-LED与一组连接端子对电性连接;
所述光反射微结构位于导光板下表面,呈交错非均匀排列,且排列结构与Mini-LED光源相互错开;
所述导光板经过去边角化处理,四角磨平抛光形成平面入光面,并在边角平面区域设置角入式背光源;
所述反射罩位于导光板四个边角区域,完全包覆所述角入式背光源;
所述反射片位于导光板下表面,用以反射从导光板底部透射出的光线,增加光源利用率;
所述光学膜片包括扩散片和正交放置的棱镜片,位于导光板的上表面。
2.根据权利要求1所述的交错非均匀排列的Mini-LED直下式背光模组,其特征在于:设两颗相邻Mini-LED光源交错非均匀排列的间距为L,H为Mini-LED光源顶端距导光板下表面的距离,导光板下表面上的点A对应单颗Mini-LED所对应正上方点的照度,点B对应两颗Mini-LED中心点所对应正上方点的照度,EA、EB为点A、B周围Mini-LED产生的照度叠加值,θ为AB边所对应的角,则照度值满足下式:
式中,E(0)为Mini-LED光源垂直入射时的最大照度值;
通过计算合适的光源间距L范围与混光距离H,以提高Mini-LED的混光效率,防止明暗光斑的出现,使显示装置的全屏亮度均匀性不低于85%。
3.根据权利要求2所述的交错非均匀排列的Mini-LED直下式背光模组,其特征在于:在非均匀排列中,相邻两颗Mini-LED光源的间距L在0.1-1mm之间,纵向Mini-LED光源数n为300-350颗,横向Mini-LED光源数m为500-550颗。
4.根据权利要求2所述的交错非均匀排列的Mini-LED直下式背光模组,其特征在于:每一颗Mini-LED光源包括光源主体、封装在光源主体内部的光源芯片及设置在光源主体底部的两个光源引脚,两个光源引脚与匹配的连接端子组的两个连接端子分别对应电性连接。
5.根据权利要求2所述的交错非均匀排列的Mini-LED直下式背光模组,其特征在于:所述光反射微结构为向上凸起的四棱锥形,且其顶端低于Mini-LED上表面。
6.根据权利要求1所述的交错非均匀排列的Mini-LED直下式背光模组,其特征在于:对所述导光板进行去边角化处理,四角磨平抛光形成平面入光面,使导光板直角形状边角区域变为平面形状边角区域,并在边角区域设置角入式背光源。
7.根据权利要求1所述的交错非均匀排列的Mini-LED直下式背光模组,其特征在于:所述角入式背光源采用功率为0.2-0.5W的灯珠。
8.根据权利要求1所述的交错非均匀排列的Mini-LED直下式背光模组,其特征在于:所述导光板的材料为聚甲基丙烯酸甲酯、聚苯乙烯、聚氯丙烯、环烯共聚物、聚碳酸酯、聚二甲基苯硅氧烷中的一种或多种。
9.根据权利要求1所述的交错非均匀排列的Mini-LED直下式背光模组,其特征在于:所述导光板四个边角区域设置反射罩;所述反射罩的材料为聚对苯二甲酸乙二醇脂、聚氨酯树脂、聚碳酸酯、聚乙烯、聚甲基丙烯酸甲酯的一种或多种。
10.根据权利要求1所述的交错非均匀排列的Mini-LED直下式背光模组,其特征在于:采用以下步骤进行制作:
步骤S1:制作导光板单元;
步骤S2:在导光板下表面交错非均匀设置Mini-LED光源,每一颗Mini-LED与一组连接端子对电性连接;
步骤S3:在导光板下表面错开Mini-LED光源设置四棱锥形光反射微结构,且其顶端低于Mini-LED光源上表面;
步骤S4:对导光板进行去边角化处理,四角磨平抛光形成平面入光面,使导光板直角形状边角区域变为平面形状边角区域,并将角入式背光源放置于导光板四角的平面形状边角区域的截面处;
步骤S5:在导光板四个边角区域设置反射罩,完全包覆角入式背光源;
步骤S6:在导光板的下表面添加反射片,用于反射从导光板底部透射出的光线,提高光源利用率;
步骤S7:在所述导光板的上表面添加光学膜片,包括:扩散片和正交放置的棱镜片。
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