WO2023230830A1 - 发光基板及其制备方法、背光模组、显示装置 - Google Patents
发光基板及其制备方法、背光模组、显示装置 Download PDFInfo
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- WO2023230830A1 WO2023230830A1 PCT/CN2022/096209 CN2022096209W WO2023230830A1 WO 2023230830 A1 WO2023230830 A1 WO 2023230830A1 CN 2022096209 W CN2022096209 W CN 2022096209W WO 2023230830 A1 WO2023230830 A1 WO 2023230830A1
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- Prior art keywords
- light
- substrate
- reflective layer
- printing
- emitting
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Images
Classifications
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
- G02F1/1336—Illuminating devices
Definitions
- the present disclosure relates to the field of display technology, and in particular, to a light-emitting substrate and a preparation method thereof, a backlight module, and a display device.
- Sub-millimeter light-emitting diodes Mini Light Emitting Diode, referred to as Mini LED
- micro-light emitting diodes Micro Light Emitting Diode, referred to as Micro LED
- have many advantages such as self-illumination, high efficiency, high brightness, high reliability, energy saving and fast response speed. Advantages, it has been applied to fields such as micro-displays, mobile phones, TVs and other medium-sized displays to large-screen displays in theaters.
- a light-emitting substrate including: a substrate, a plurality of light-emitting devices and a reflective layer provided on one side of the substrate.
- the reflective layer has a plurality of openings, and the plurality of openings include a plurality of first openings; one light-emitting device is located in one first opening.
- a surface of the reflective layer away from the substrate has a plurality of protruding structures.
- the reflective layer includes a plurality of first parts and a plurality of second parts.
- the first parts are parts of the reflective layer corresponding to the protruding structures, and the second parts are located in the corresponding parts of the reflective layer.
- the part between two adjacent raised structures.
- the difference between the thickness of the first part and the thickness of the second part is less than or equal to 20 ⁇ m. And/or, the difference between the thickness of the first part and the thickness of the second part is less than or equal to 20% of the thickness of the reflective layer.
- the distance between the light-emitting device and the corresponding side wall of the opening ranges from 0.05 mm to 0.3 mm.
- an included angle between at least one sidewall of the opening and the substrate is an acute angle.
- At least one side wall of the opening is arcuate.
- a side surface of the protruding structure away from the substrate is curved.
- the plurality of protruding structures include a plurality of first protruding structures and a plurality of second protruding structures.
- the plurality of first protruding structures extend along the first direction, and the plurality of first protruding structures are arranged in multiple rows along the second direction.
- the plurality of second protruding structures extend along the first direction, the plurality of second protruding structures are arranged in multiple rows along the second direction, or the plurality of second protruding structures extend along the second direction.
- the plurality of second protruding structures are arranged in multiple columns along the first direction. The first direction and the second direction intersect.
- the size of the first protrusion structure in the arrangement direction of the plurality of first protrusions is greater than or equal to the size of the second protrusion structure in the arrangement direction of the plurality of second protrusions. size in the arrangement direction.
- At least one side of the orthographic projection of the reflective layer on the substrate includes a plurality of curved segments, and at least one curved segment protrudes toward an edge of the substrate.
- an angle formed between at least one side surface close to an edge of the substrate and the substrate is an acute angle.
- the light-emitting substrate further includes: a plurality of driver chips disposed on one side of the substrate and located on the same side of the substrate as the plurality of light-emitting devices.
- a driving chip is electrically connected to at least one light-emitting device, and the driving chip is configured to drive the at least one light-emitting device to emit light.
- the plurality of openings further include a plurality of second openings.
- a driver chip is located in a second opening.
- the light-emitting substrate further includes: a plurality of driver chips disposed on one side of the substrate and located on the same side of the substrate as the plurality of light-emitting devices; one driver chip and at least one light-emitting device.
- the devices are electrically connected, and the driving chip is configured to drive the at least one light-emitting device to emit light.
- the orthographic projection of at least one driver chip on the substrate is located within the orthographic projection range of the reflective layer on the substrate.
- the thickness of the portion of the reflective layer that contacts the top surface of the at least one driver chip is less than or equal to the thickness of the portion of the reflective layer that contacts the substrate.
- the reflective layer is interrupted at at least one side of the driver chip.
- a method for preparing a light-emitting substrate including: providing a substrate.
- a plurality of light emitting devices are fixed on the substrate.
- a 3D printing process is used to form a reflective layer on the substrate; the plurality of openings include a plurality of first openings; a light-emitting device is located in a first opening; wherein the reflective layer is away from the side of the substrate
- the surface has multiple raised structures.
- the plurality of light-emitting devices are arranged in multiple columns along the first direction and arranged in multiple rows along the second direction.
- the substrate has a plurality of first printing areas, a plurality of second printing areas and a plurality of third printing areas extending along the first direction; the plurality of second printing areas and the plurality of third printing areas The areas are arranged alternately, and the first printing area is located between any adjacent second printing area and third printing area.
- a row of light-emitting devices is located in a second printing area.
- the use of a 3D printing process to form a reflective layer on the substrate includes: using a straight line printing process to form a first reflective pattern in two first printing areas on opposite sides of each row of light-emitting devices, using a dotted line printing process, and A second reflective pattern is formed between any two adjacent light-emitting devices in each second printing area; the first reflective pattern and the second reflective pattern around each light-emitting device surround the first opening; at least one of the first openings
- the angle between one side and the substrate is an acute angle, and/or at least one side wall of the opening is a curved surface.
- a linear printing process is used to form a plurality of third reflective patterns in the third printing area.
- the preparation method before using a 3D printing process to form a reflective layer on the substrate, the preparation method further includes: fixing multiple driver chips on the substrate; the multiple driver chips They are arranged in multiple columns along the first direction and in multiple rows along the second direction; one row of driver chips is located in a second printing area.
- the plurality of openings also include a plurality of second openings; the use of a 3D printing process to form a reflective layer on the substrate also includes the use of a linear printing process to form two first openings on opposite sides of each row of driver chips.
- the printing area forms a first reflection pattern, and a dotted line printing process is used to form a second reflection pattern between any two adjacent driving chips in each second printing area; the first reflection pattern and the second reflection pattern around each light-emitting device are surrounded by
- the angle between at least one side of the second opening and the substrate is an acute angle, and/or at least one side wall of the second opening is a curved surface.
- the preparation method before using a 3D printing process to form a reflective layer on the substrate, the preparation method further includes: fixing multiple driver chips on the substrate; the multiple driver chips They are arranged in multiple columns along the first direction and arranged in multiple rows along the second direction; at least one driver chip is located in the plurality of third printing areas.
- Using a 3D printing process to form a reflective layer on the substrate further includes: using a linear printing process to form a plurality of third reflective patterns in a third printing area where the at least one driver chip is located; the at least one The orthographic projection of the driving chip on the substrate is located within the orthographic projection range of the plurality of third reflection patterns on the substrate.
- the printing direction of the linear printing process and the printing direction of the dotted line process are the same or perpendicular to each other.
- a backlight module including: the light-emitting substrate according to any of the above embodiments, and an optical film located on the light-emitting side of the light-emitting substrate.
- a display device including: the backlight module described in the above embodiment, a color filter substrate located on the light exit side of the backlight module; and a color filter substrate located between the backlight module and the color filter substrate. between the array substrates.
- Figure 1 is a structural diagram of a display device according to some embodiments of the present disclosure.
- Figure 2 is a structural diagram of a backlight module according to some embodiments of the present disclosure.
- Figure 3 is a structural diagram of a light-emitting substrate according to some embodiments of the present disclosure.
- Figure 4a is a step diagram of a method for preparing a light-emitting substrate according to some embodiments of the present disclosure
- Figure 4b is a diagram of a preparation process of a light-emitting substrate according to some embodiments of the present disclosure
- Figure 4c is a diagram of a preparation process of another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 4d is a preparation process diagram of yet another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 5a is a partial structural view of a substrate and a reflective layer according to some embodiments of the present disclosure
- Figure 5b is a partial structural view of another substrate and reflective layer according to some embodiments of the present disclosure.
- Figure 5c is a partial structural view of another substrate and reflective layer according to some embodiments of the present disclosure.
- Figure 6a is an actual partial structural diagram of a light-emitting substrate in an implementation manner
- Figure 6b is another physical partial structural diagram of a light-emitting substrate in an implementation manner
- Figure 7 is a structural diagram of another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 8a is a step diagram of another method of preparing a light-emitting substrate according to some embodiments of the present disclosure.
- Figure 8b is a diagram of a preparation process of a light-emitting substrate according to some embodiments of the present disclosure.
- Figure 8c is a diagram of a preparation process of another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 9 is a structural diagram of yet another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 10a is a partial structural diagram of yet another substrate and reflective layer according to some embodiments of the present disclosure.
- Figure 10b is a partial structural diagram of yet another substrate and reflective layer according to some embodiments of the present disclosure.
- Figure 11a is a structural diagram of a reflective layer and a substrate according to some embodiments of the present disclosure.
- Figure 11b is a partial structural diagram of the actual object corresponding to the reflective layer shown in Figure 11a;
- Figure 12a is a structural diagram of yet another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 12b is a preparation process diagram of another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 13 is a diagram showing the relative position relationship between a driving chip and a light-emitting device according to some embodiments of the present disclosure
- Figure 14a is a structural diagram of yet another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 14b is a diagram of a preparation process of another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 15a is a structural diagram of yet another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 15c is a structural diagram of yet another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 16 is a preparation process diagram of another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 17a is a structural diagram of yet another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 17b is a partial structural diagram of the actual object of the light-emitting substrate shown in Figure 17a;
- Figure 18a is a structural diagram of yet another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 18b is a structural diagram of yet another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 19 is a structural diagram of yet another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 20 is a structural diagram of yet another reflective layer and substrate according to some embodiments of the present disclosure.
- Figure 21a is a structural diagram of yet another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 21b is a partial structural diagram of the actual object of the light-emitting substrate shown in Figure 21a;
- Figure 22a is a structural diagram of yet another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 22b is a structural diagram of yet another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 22c is a structural diagram of yet another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 23a is a structural diagram of yet another light-emitting substrate according to some embodiments of the present disclosure.
- Figure 23b is a partial structural diagram of the actual object of the light-emitting substrate shown in Figure 23a.
- first and second are used for descriptive purposes only and cannot be understood as indicating or implying relative importance or implicitly indicating the quantity of indicated technical features. Therefore, features defined as “first” and “second” may explicitly or implicitly include one or more of these features. In the description of the embodiments of the present disclosure, unless otherwise specified, "plurality" means two or more.
- connection and its derivatives may be used.
- some embodiments may be described using the term “connected” to indicate that two or more components are in direct physical or electrical contact with each other.
- the embodiments disclosed herein are not necessarily limited by the content herein.
- a and/or B includes the following three combinations: A only, B only, and a combination of A and B.
- the term “if” is optionally interpreted to mean “when” or “in response to” or “in response to determining” or “in response to detecting,” depending on the context.
- the phrase “if it is determined" or “if [stated condition or event] is detected” is optionally interpreted to mean “when it is determined" or “in response to the determination" or “on detection of [stated condition or event]” or “in response to detection of [stated condition or event]”.
- vertical and “equal” include the stated situation and situations that are approximate to the stated situation, and the range of the approximate situation is within an acceptable deviation range, where the acceptable deviation Ranges are as determined by one of ordinary skill in the art taking into account the measurement in question and the errors associated with the measurement of the particular quantity (ie, the limitations of the measurement system).
- vertical includes absolute verticality and approximate verticality, wherein the acceptable deviation range of the approximate verticality may also be a deviation within 5°, for example.
- “Equal” includes absolute equality and approximate equality, wherein the difference between the two that may be equal within the acceptable deviation range of approximately equal is less than or equal to 5% of either one, for example.
- Example embodiments are described herein with reference to cross-sectional illustrations and/or plan views that are idealized illustrations.
- the thickness of layers and regions are exaggerated for clarity. Accordingly, variations from the shapes in the drawings due, for example, to manufacturing techniques and/or tolerances are contemplated.
- example embodiments should not be construed as limited to the shapes of regions illustrated herein but are to include deviations in shapes that result from, for example, manufacturing. For example, an etched area shown as a rectangle will typically have curved features. Accordingly, the regions shown in the figures are schematic in nature and their shapes are not intended to illustrate the actual shapes of regions of the device and are not intended to limit the scope of the exemplary embodiments.
- the display device 1 may be any display device that displays whether it is moving (for example, video) or stationary (for example, still images) and whether it is text or images. More specifically, it is contemplated that the display devices of the embodiments may be implemented in or associated with a variety of electronic devices, such as (but not limited to) mobile phones, wireless devices, personal data assistants, etc.
- PDA handheld or portable computer
- GPS receiver/navigator camera
- MP4 video player video player
- video camera game console
- watch clock
- calculator TV monitor
- flat panel display computer monitor
- automotive monitor e.g., odometer display, etc.
- navigator cockpit controller and/or display
- display of camera view e.g., display of rear view camera in vehicle
- electronic photo electronic billboard or sign
- projector construction Structure
- packaging and aesthetic structure for example, for the display of an image of a piece of jewelry
- the above-mentioned display device 1 may be an LCD (Liquid Crystal Display) display device.
- the display device 1 includes: a backlight module 10 , a color filter substrate 20 located on the light exit side of the backlight module 10 , and an array located between the backlight module 10 and the color filter substrate 20 Substrate 30.
- the above-mentioned backlight module 10 can be used as a light source to provide backlight.
- the backlight provided by the backlight module 10 may be white light or blue light.
- the light-emitting side of the backlight module 10 refers to the side from which the backlight module 10 emits light.
- the array substrate 30 may include a plurality of pixel driving circuits and a plurality of pixel electrodes, and the plurality of pixel driving circuits may be arranged in an array, for example.
- a plurality of pixel driving circuits are electrically connected to a plurality of pixel electrodes in a one-to-one correspondence, and the pixel driving circuit provides pixel voltages for corresponding pixel electrodes.
- the color filter substrate 20 may include a variety of color filters and the like.
- the above-mentioned color filters may include red filters, green filters, blue-green filters, etc.
- a red filter can only transmit the red light in the incident light
- a green filter can only transmit the green light in the incident light
- a blue filter can only transmit the blue light in the incident light.
- the above-mentioned color filters may include red filters, green filters, etc.
- the color filter substrate 20 further includes: a common electrode.
- the common electrode can receive the common voltage.
- the display device 1 further includes a liquid crystal layer 40 located between the color filter substrate 20 and the array substrate 30 .
- the liquid crystal layer 40 includes a plurality of liquid crystal molecules.
- an electric field can be formed between the pixel electrode and the common electrode, and the liquid crystal molecules located between the pixel electrode and the common electrode can be deflected under the action of the electric field.
- the backlight module 10 provides backlight, which can pass through the array substrate 30 and be incident on the liquid crystal molecules of the liquid crystal layer 40 .
- the liquid crystal molecules flip, thereby changing the amount of light passing through the liquid crystal molecules, so that the light emitted through the liquid crystal molecules reaches a preset brightness.
- the above-mentioned light passes through the filters of different colors in the color filter substrate 20 and then emerges.
- the emitted light includes light of various colors, such as red light, green light, blue light, etc. The light of various colors cooperate with each other to enable the display device 1 to display.
- backlight modules 10 in the display device 1 there are many types of backlight modules 10 in the display device 1, which can be set according to actual conditions, and this disclosure does not limit this.
- the backlight module 10 can be an edge-type backlight module, or the backlight module 10 can also be a direct-type backlight module.
- the backlight module 10 As a direct-type backlight module as an example.
- the backlight module 10 includes: a light-emitting substrate 100 and an optical film 200 located on the light-emitting side of the light-emitting substrate 100 .
- the optical film 200 includes: a diffusion plate 210, a quantum dot film 220, a diffusion sheet 230, a composite film 240, etc., which are stacked on the light exit side of the light-emitting substrate 100 in sequence.
- the diffusion plate 210 and the diffusion sheet 230 are used to eliminate lamp shadows and uniformize the light emitted by the light-emitting substrate 100 to improve the uniformity of the light.
- the quantum dot film 220 is used to convert light emitted by the light-emitting substrate 100 .
- the quantum dot film 220 can convert the blue light into white light and improve the purity of the white light.
- the composite film 240 is used to increase the brightness of light emitted by the light-emitting substrate 100 .
- the brightness of the light emitted by the light emitting substrate 100 after being incident on the optical film 200 is enhanced, and the emitted light has higher purity and better uniformity.
- the backlight module 10 further includes: a support column 201 disposed between the light-emitting substrate 100 (eg, the reflective layer 130 of the light-emitting substrate 100 ) and the diffusion plate 210 of the optical film 200 .
- a support column 201 disposed between the light-emitting substrate 100 (eg, the reflective layer 130 of the light-emitting substrate 100 ) and the diffusion plate 210 of the optical film 200 .
- the reflective layer 130 please refer to the description below and will not be described again here.
- the support pillar 201 can be fixed on the light-emitting substrate 100 through glue.
- the support column 201 can be used to support the optical film 200 and allow the light emitted by the light-emitting substrate 100 to obtain a certain light mixing distance, thereby further eliminating lamp shadows and improving light uniformity.
- the above-mentioned light-emitting substrate 100 includes: a substrate 110, a plurality of light-emitting devices 120 and a reflective layer 130 provided on one side of the substrate 110.
- the substrate 110 described above may be a flexible substrate.
- the flexible substrate can be, for example, a PET (Polyethylene Terephthalate, polyethylene terephthalate) substrate, a PEN (Polyethylene Naphthalate Two Formic Acid Glycol Ester, polyethylene naphthalate) substrate or a PI (Polyimide) substrate. , polyimide) substrate, etc.
- the above-mentioned substrate 110 may be a rigid substrate.
- the substrate may be made of glass.
- the above-mentioned substrate 110 may also be a printed circuit board (PCB for short), an aluminum substrate, etc.
- the plurality of light-emitting devices 120 may be LEDs (Light Emitting Diodes, light-emitting diodes), or may be Mini LEDs or Micro LEDs.
- the plurality of light-emitting devices 120 may be arranged in multiple columns along the first direction X and arranged in multiple rows along the second direction Y.
- the angle between the first direction X and the second direction Y can be 85°, 90°, 95°, etc.
- This disclosure takes the angle between the first direction X and the second direction Y as 90° as an example.
- the light-emitting device 120 may serve as a light source of the light-emitting substrate 100 .
- the light-emitting substrate 100 also includes: an alignment mark (Mark), a substrate number (Panel ID), etc. provided on the substrate 110.
- the alignment mark is used to realize the installation alignment between the light-emitting substrate 100 and the optical film 200 and the like.
- the substrate number is used to label and identify a single light-emitting substrate 100 . Therefore, the alignment mark and the substrate number need to be exposed on the reflective layer 130 to facilitate alignment or identification.
- reflective layer 130 has a plurality of openings 131 .
- the plurality of openings 131 of the reflective layer 130 are used to expose devices such as the light-emitting devices 120 (or the above-mentioned alignment marks, substrate numbers, etc.) located on the substrate 110 from the surface of the reflective layer 130,
- the reflective layer 130 is prevented from covering the light-emitting device 120 and blocking the light emitted by the light-emitting device 120, thus avoiding affecting the luminous efficiency of the light-emitting device 120, thereby improving the luminous efficiency of the light-emitting substrate 100.
- the plurality of openings 131 include a plurality of first openings 131a.
- a light emitting device 120 is located in a first opening 131a.
- a plurality of first openings 131a and a plurality of light emitting devices 120 may be provided in one-to-one correspondence.
- the reflective layer 130 has a certain reflectivity and can reflect the light emitted by the multiple light-emitting devices 120 , thereby improving the light utilization efficiency of the light-emitting devices 120 .
- the area of the first opening 131a may be greater than or equal to the area of the corresponding light-emitting device 120, and the center of the first opening 131a coincides with the center of the corresponding light-emitting device 120.
- the light emitted by the light-emitting device 120 can be prevented from being blocked by the edges of the reflective layer 130 as much as possible, thereby improving the luminous efficiency of the light-emitting substrate 100 .
- the preparation method generally includes the following steps: material preparation ⁇ screen printing process to prepare reflective layer ⁇ Automated Optical Inspection (AOI) ⁇ die solidification ⁇ dot patching ⁇ AOI ⁇ packaging, etc.
- material preparation ⁇ screen printing process to prepare reflective layer ⁇ exposure ⁇ development ⁇ AOI ⁇ solidification Crystal ⁇ packaging, etc.
- the die bonding process includes the reflow soldering process. Due to the high temperature of the reflow soldering process, the reflow soldering process will cause the material of the previously formed reflective layer to oxidize and turn yellow, which will in turn reduce the reflectivity of the reflective layer, reduce the luminous efficiency of the light-emitting substrate, and reduce the luminescence. The brightness of modules and display devices.
- the reflective layer material in advance, is easy to adhere to the light-emitting device, and multiple light-emitting devices are easily fixed at the same time, causing errors in the fixed position of the light-emitting device.
- some embodiments of the present disclosure provide a method for preparing the light-emitting substrate 100 .
- the preparation method includes S100 to S300.
- a substrate 110 is provided.
- the substrate 110 may be a PET substrate, a PI substrate, a PEN substrate, a glass substrate, a PCB substrate, an aluminum substrate, or the like.
- a crystal bonding process may be used to fix multiple light-emitting devices 120 on the substrate 110 .
- the light-emitting device 120 can be: LED, Micro LED, Mini LED, etc.
- the structure of the Mini LED may include a formal structure, a vertical structure, or a flip-chip structure.
- the plurality of light-emitting devices 120 can be evenly distributed on the substrate 110 , so that the entire surface of the light-emitting substrate 100 emits light more uniformly, thereby improving the display quality of the backlight module 10 and the display device 1 .
- a 3D printing process is used to form the reflective layer 130 on the substrate 110.
- the reflective layer 130 has a plurality of openings 131, and the plurality of openings 131 include a plurality of first openings 131a.
- a light emitting device 120 is located in a first opening 131a.
- the surface of the reflective layer 130 away from the substrate 110 has a plurality of protruding structures 132 .
- the material of the reflective layer 130 may include: epoxy resin, phenyl silicone resin, polytetrafluoroethylene resin, etc.
- embodiments of the present disclosure may use 3D printing equipment to perform the 3D printing process.
- the 3D printing equipment includes multiple printing nozzles with the same function, and the printing nozzles are provided with printing nozzles.
- the material of the reflective layer 130 is put into the 3D printing equipment after certain pretreatment, and then by controlling the state of the printing nozzle valve, the printing nozzle valve is moved on the substrate 110 according to the set printing path, so that the material of the reflective layer 130 It is ejected from the printing nozzle in a dot-like manner.
- the reflective layer material dropped in a dot-like manner drops onto the substrate 110 and then adheres together to form a printing strip extending along the printing path OP (as shown in FIG. 5c ). All printing strips collectively form the reflective layer 130 .
- the printing nozzle valve is closed, thereby forming a plurality of openings 131.
- Figure 5a shows the morphological characteristics of a reflective layer 130.
- dot-like drops are dropped and adhered to form printing strips.
- the printing strips overlap each other to form a reflective layer, so that the reflective layer 130 is far away from the lining.
- the surface of one side of the bottom 110 has a plurality of protruding structures 132 .
- Figure 5b shows another morphological feature of the reflective layer 110.
- the overlapping portion of two adjacent printing strips will also form a
- the small protruding structure 135 is located between two adjacent protruding structures 132 .
- 3D printing has a high degree of freedom
- non-contact glue dispensing is used between the printing nozzle and the substrate 110 to be printed, and the dimensional accuracy corresponding to the reflective layer 130 formed by printing and the dimensional accuracy of the opening 131 are relatively high. It is beneficial to increase the area ratio of the substrate 110 occupied by the reflective layer 130, thereby increasing the reflectivity of the reflective layer 130 and improving the utilization rate of the light emitted by the light-emitting device 120.
- the light-emitting substrate 100 is prepared in the above manner. Since the light-emitting device 120 is first fixed on the substrate 110, and then the reflective layer 130 is formed using a 3D printing process, the reflective layer 130 is formed during the solidification process ( This refers to the process of fixing the light-emitting device 120 on the substrate 110), so that the reflective layer material will not be deposited on the pad connected to the light-emitting device, thereby avoiding the need to form the reflective layer first. , it is easy for the reflective layer material to be deposited on the pad, which may cause the risk of lamp out or false soldering, thereby improving the yield of the light-emitting substrate 100.
- the backlight module 10 and the display device 1 can also avoid the reflow soldering process in the solid crystal process that causes the reflective layer 130 to The risk of reducing the reflectivity can thereby improve the luminous efficiency of the reflective layer 130 and the luminous rate of the light-emitting substrate 100, thereby improving the display brightness of the backlight module 10 and the display device 1, and reducing the luminous efficiency of the backlight module 10 and the display device 1. power consumption.
- the thickness of the reflective layer is typically 55 ⁇ m.
- the thickness of the reflective layer is typically 55 ⁇ m.
- the reflective layer around the light-emitting device is stepped, the distance between the reflective layer and the light-emitting device is large, and the manufacturing accuracy of the reflective layer is low.
- grid-like indentations can be seen on the surface of the reflective layer.
- the thickness of a single printing using the 3D printing process can reach 55 ⁇ m, and the thickness of a single printing is greater than the thickness of a single screen printing. Therefore, using the 3D printing process can make reflection Forming the layer 130 at one time can improve the accuracy of the prepared reflective layer 130 to a certain extent, and avoid the superposition of the dimensional errors of the reflective layer caused by multiple printings in screen printing and the step-like morphological characteristics. The dimensional accuracy of forming the reflective layer 130 is further improved, and there are no grid-like indentations on the surface of the reflective layer 130 formed by the 3D printing process.
- the substrate 110 has a plurality of first printing areas P1 , a plurality of second printing areas P2 and a plurality of third printing areas P3 extending along the first direction X.
- a plurality of second printing areas P2 and a plurality of third printing areas P3 are arranged alternately, and the first printing area P1 is located between any adjacent second printing area P2 and third printing area P3. That is, two first printing areas P1 are provided on opposite sides of each second printing area P2, and two first printing areas P1 are provided on opposite sides of each third printing area P3.
- a row of light-emitting devices 120 is located in a second printing area P2. That is, one row of second light-emitting devices 120 is arranged corresponding to one second printing area P2, and the two are arranged in one-to-one correspondence.
- the first printing area P1, the second printing area P2, and the third printing area P3 on the substrate 110 can also all extend along the second direction Y.
- a row of light-emitting devices 120 can be located on one The second printing area P2.
- the following description takes the first printing area P1, the second printing area P2, and the third printing area P3 extending along the first direction X as an example.
- a 3D printing process is used to form the reflective layer 130 on the substrate 110, including S310 to S320.
- a linear printing process is used to form a first reflection pattern in the two first printing areas P1 on opposite sides of each row of light-emitting devices 120, and a dotted line printing process is used to form a first reflection pattern in any second printing area P2 of each row.
- a second reflection pattern is formed between adjacent two light emitting devices 120 .
- the first reflection pattern and the second reflection pattern around each light emitting device 120 form a first opening 131a.
- the angle between at least one side wall of the first opening 131 a and the substrate 110 is an acute angle, and/or at least one side wall of the first opening 131 a is a curved surface.
- the first reflection pattern may include one or more printing strips, whereby the edge of the first reflection pattern is the edge of the printing strips.
- the second reflective pattern may include one or more printing strips, whereby the edge of the second reflective pattern is the edge of the printing strips.
- the linear printing process means that after the 3D printing equipment completes one printing along the set printing path, the printing pattern formed is a continuous, uninterrupted printing similar to a straight line shape.
- the printing strip has a first protruding structure 132a.
- the dotted line printing process means that the 3D printing equipment controls the printing nozzle valve to open or close intermittently along the set printing path. After completing one printing, the resulting printing pattern is discontinuous and intermittent.
- a printing strip in the shape of a dotted line has a second protruding structure 132b on the printing strip.
- One printed strip corresponds to one raised structure 132 .
- the printing step d1 of the dotted line printing process is less than or equal to the printing step d2 of the straight line printing process.
- the printing step here is the distance between the center lines of two adjacent printing strips. It is actually the distance that the 3D printing device moves perpendicular to the printing path after printing a printing strip, that is, the size of the above convex structure 132 along its arrangement direction.
- the printing step diameter of the linear printing process ranges from 0.1mm to 3.0mm
- the printing step diameter of the dotted line printing process ranges from 0.1mm to 1.5mm. Therefore, the printing accuracy of the dotted line printing process is greater than the printing accuracy of the straight line printing process.
- the superimposed width of two adjacent printing strips is the difference between the width d3 of a single printing strip and the printing step.
- Figure 10b is a schematic diagram of the width of a printing strip. Except for the edge portion of the reflective layer 130, the non-overlapping portion of the two adjacent printed strips forms the first part 133 of the reflective layer 130, and the overlapping boundary line portion of the two adjacent printed strips forms the second part 134 of the reflective layer 130. .
- the second portion 134 is the portion with the smallest thickness in the reflective layer 130 .
- the first parts 133 and the second parts 134 are alternately distributed.
- the difference between the thickness of the first portion 133 and the thickness of the second portion 134 is less than or equal to 20 ⁇ m.
- different areas of the first part 133 have different thicknesses, where the thickness of the first part 133 refers to the maximum thickness of the first part 133 .
- the difference between the thickness of the first part 133 and the thickness of the second part 134 may be 20 ⁇ m, 18 ⁇ m, 15 ⁇ m, 10 ⁇ m, 8 ⁇ m or 6 ⁇ m.
- the maximum thickness of the first part 133 is about 65 ⁇ m, and the thickness of the second part 134 is about 45 ⁇ m, so that the thickness corresponding to different areas of the reflective layer 130 can fluctuate. It is smaller, thereby meeting the reflectivity requirements of the reflective layer 130 and ensuring the light efficiency of the light-emitting substrate 100 .
- the difference between the thickness of the first part 133 and the thickness of the second part 134 is less than or equal to 20% of the thickness of the reflective layer 130 .
- the difference between the thickness of the first part 133 and the thickness of the second part 134 may be 20%, 18%, 15%, 10% or 8% of the thickness of the reflective layer 130 .
- the thickness difference corresponding to different areas of the reflective layer 130 is small, which can meet the reflectivity requirements of the reflective layer 130 without affecting the light efficiency of the light-emitting substrate 100 .
- the printing direction OP is the first direction X
- the first reflection pattern formed is a continuous, uninterrupted linear pattern.
- a dotted line printing process is used to set the printing nozzle valve of the 3D printing device to close at the position corresponding to the light-emitting device 120, and to open the printing nozzle valve at the remaining positions. Therefore, along the first direction X, the second printing nozzle valve is closed. There is no connection in the middle of the reflection pattern, and the entire second reflection pattern in the second printing area P2 is like a discontinuous and intermittent dotted line.
- the first reflective pattern is formed in the two first printing areas P1 on opposite sides of each row of light-emitting devices 120 to limit the size of the first opening 131a in the second direction Y, and the first reflective pattern is A part of the edge forms two opposite side walls of the first opening 131a.
- the second reflection pattern limits the size of the first opening 131a in the first direction X, and a part of the edge of the second reflection pattern forms the first opening 131a. Two side walls.
- a dotted line printing process may also be used to form the first reflective pattern. Since the accuracy of the dotted line printing process is higher than that of the linear printing process, the accuracy of the first opening 131a surrounded by the first reflective pattern and the second reflective pattern around each light-emitting device 120 can be improved, thereby improving the reflective layer 130 production precision.
- the size of the reflective layer 130 and the size of the first opening 131a formed by printing are relatively accurate, so that the printing parameters can be controlled to achieve a distance between the edge of the reflective layer 130 and the light-emitting device 120 It is smaller, so that the area ratio of the substrate 110 covered by the reflective layer 130 can be larger, and thus the light efficiency of the light-emitting substrate 100 can be higher.
- the edges of the first reflection pattern and the edge of the second reflection pattern are both curved in the top view (as shown in Figure 8b). Therefore, from the first reflection pattern A top view of the side wall of the first opening 131a surrounded by a part of the edge of the second reflection pattern and a part of the edge of the second reflection pattern is also curved.
- the edge of the first reflection pattern and the edge of the second reflection pattern are curved in the cross-sectional view (as shown in FIG. 9). Therefore, the edge of the first reflection pattern and the edge of the second reflection pattern are curved.
- One or more side walls of the first opening 131a are curved surfaces.
- the angle between one side wall of the first opening 131 a and the substrate 110 is an acute angle.
- the angles between two or more side walls of the first opening 131a and the substrate 110 are both acute angles.
- the angle between the side wall of the first opening 131a and the substrate 110 may be 30°, 50°, 60°, 65° or 70°.
- the shape of the first opening 131a in the top view may be a rectangle or a circle.
- the first opening 131a There are four sidewalls, and the angles between one or more sidewalls of the first opening 131a and the substrate 110 are all acute angles. That is to say, the one or more sidewalls surrounding the first opening 131a are directed toward the first opening 131a.
- the center direction of the opening 131a is convex.
- the above-mentioned rectangle or circle is, for example, an irregular rectangle or an irregular circle.
- the angle between the sidewall of the first opening 131 a and the substrate 110 is related to the material properties of the reflective layer 130 .
- the included angle between the sidewalls of the first opening 131a in the reflective layer 130 formed with different reflective layer materials and the substrate 110 may be different.
- a linear printing process can be used to form multiple third reflective patterns.
- the above setting method can increase the printing rate of the third printing area P3 and thereby improve the printing efficiency of the reflective layer 130 .
- screen printing is used to form the reflective layer of the light-emitting substrate. Due to limitations of the screen printing process, the distance between the sidewalls of the openings forming the reflective layer and the corresponding light-emitting devices is about 0.5 mm. Even if Subsequently, a patching process is added to reduce the distance between the sidewall of the opening of the reflective layer and the corresponding light-emitting device to about 0.3mm.
- a 3D printing process is used to form the reflective layer 130 so that the distance between the light-emitting device 120 and the corresponding sidewall of the first opening 131a ranges from 0.05 mm to 0.3 mm.
- the distance between the light emitting device 120 and the side wall of the corresponding first opening 131a may be 0.30 mm, 0.23 mm, 0.18 mm, 0.12 mm or 0.05 mm.
- the gap between the light-emitting device 120 and the side wall of the corresponding first opening 131a can be made smaller, thereby reducing the risk of light emitted by the light-emitting device 120 incident into the gap between the light-emitting device 120 and the first opening 131a.
- the loss of light can thereby increase the reflectivity of the reflective layer 130 and increase the light efficiency of the light-emitting substrate 100 , thereby reducing the power consumption of the backlight module 10 and the display device 1 .
- edges of the reflective layer 130 prepared and formed by some of the above embodiments of the present disclosure will also exhibit a morphology unique to the 3D printing process.
- one side of the orthographic projection of the reflective layer 130 on the substrate 110 includes a plurality of curved segments.
- multiple sides of the orthographic projection of the reflective layer 130 on the substrate 110 each include multiple curve segments.
- one of the plurality of curved segments may protrude toward the edge of the substrate 110 .
- the above-mentioned plurality of curved segments may all protrude toward the edge direction of the substrate 110 .
- FIG. 11a The two sides of the two dotted lines in FIG. 11a represent a schematic diagram of the portion of the reflective layer 130 close to the edge. This figure does not illustrate the opening 130 in the reflective layer 130 .
- FIG. 11b shows a partial view of the actual reflective layer 130 corresponding to FIG. 11a.
- the preparation method of the light-emitting substrate 100 before using the 3D printing process to form the reflective layer 130 on the substrate 110 in S300, the preparation method of the light-emitting substrate 100 further includes S210a.
- driver chips 140 are fixed on the substrate 110.
- the plurality of driving chips 140 are arranged in multiple columns along the first direction X, and are arranged in multiple rows along the second direction Y.
- One row of driver chips 140 is located in a second printing area P2.
- the plurality of driving chips 140 and the plurality of light emitting devices 120 are located on the same side of the substrate 110 .
- a driving chip 140 is electrically connected to at least one light-emitting device 120, and the driving chip 140 is configured to drive the at least one light-emitting device 120 to emit light.
- one driving chip 140 can be electrically connected to four light-emitting devices 120 and drive the four light-emitting devices 120 to emit light.
- one driving chip 140 can be electrically connected to nine light-emitting devices 120 and drive the nine light-emitting devices 120 to emit light.
- one driver chip 140 drives four light-emitting devices 120 for illustration.
- four light-emitting devices driven by one driver chip 140 can be arranged in two rows and two columns.
- the driver chip 140 can be located directly below the light-emitting devices 120 in any column (as shown in Figure 13 As shown in (a) in FIG. 13 ), the driver chip 140 may also be located between two columns of light-emitting devices 120 (as shown in (b) in FIG. 13 ).
- the four light-emitting devices 120 are arranged in a staggered manner, and the driving chips 140 are randomly arranged at positions between the four light-emitting devices 120 (as shown in (c) of FIG. 13 ).
- the following description takes as an example that four light-emitting devices driven by one driver chip 140 are arranged in two rows and two columns, and the driver chip is located directly below the light-emitting devices 120 in any column.
- the plurality of openings 131 of the reflective layer 130 further include a plurality of second openings 131b.
- the step of forming the reflective layer 130 on the substrate 110 using a 3D printing process also includes S330a.
- a linear printing process is used to form a first reflection pattern in the two first printing areas P1 on opposite sides of each row of driver chips 140, and a dotted line printing process is used to arbitrarily adjacent in each second printing area.
- a second reflection pattern is formed between the two driving chips 140 .
- the first reflective pattern and the second reflective pattern around each driving chip 140 form a second opening 131b.
- the angle between at least one side wall of the second opening 131b and the substrate 110 is an acute angle, and/or at least one wall surface of the second opening 131b is a curved surface.
- the plurality of driving chips 140 correspond to the plurality of second openings 131b one-to-one, and one driving chip 140 is located in one second opening 131b.
- the size of the first opening 131a is related to the size of the light emitting device 120
- the size of the second opening 131b is related to the size of the driving chip 140.
- the orthogonal projected area of the second opening 131 b on the substrate 110 may be larger than the orthogonal projected area of the first opening 131 a on the substrate 110 .
- the distance between the driver chip 140 and the corresponding side wall of the second opening 131b ranges from 0.05 mm to 0.3 mm.
- the structural features of the first opening 131 and the second opening 131b are Can be the same. Specifically, reference may be made to the previous description of the structural features of the first opening 131a, which will not be described again here.
- the process of forming the first reflective pattern in the two first printing areas P1 on opposite sides of each row of driver chips 140 can also use a dotted line printing process, because the printing accuracy of the dotted line printing process is higher than The printing accuracy of the linear printing process can improve the accuracy of the first reflective pattern and the second reflective pattern around each driving chip 140 to form the second opening 131b.
- the plurality of driving chips 140 in the above embodiment correspond to the plurality of second openings 131b one by one.
- One driving chip 140 is located in one second opening 131b, that is, the plurality of driving chips 140 are exposed on the reflective layer 130.
- the orthographic projection of at least one of the plurality of driving chips 140 on the substrate 110 is located within the orthographic projection range of the reflective layer 130 on the substrate 110 . That is to say, at least one driving chip 140 is covered by the reflective layer 130, and there is no second opening 131b at its corresponding position. In this way, the number of second openings 131b on the reflective layer 130 can be reduced, thereby simplifying the preparation process of the reflective layer 130.
- a 3D printing process is used, and before the step of forming the reflective layer 130 on the substrate 110, S210b is also included.
- driver chips 140 are fixed on the substrate 110.
- the plurality of driving chips 140 are arranged in multiple columns along the first direction X, and are arranged in multiple rows along the second direction Y.
- At least one driver chip 140 is located in the plurality of third printing areas P3.
- the plurality of driving chips 140 and the plurality of light emitting devices 120 are located on the same side of the substrate 110 .
- a driver chip 140 is electrically connected to at least one light-emitting device 120, and the driver chip 140 is configured to drive at least one light-emitting device 120 to emit light.
- one driving chip 140 can be electrically connected to four light-emitting devices 120 and drive the light-emitting devices 120 to emit light.
- the plurality of openings 131 of the reflective layer 130 further include a plurality of second openings 131b.
- the step of forming the reflective layer 130 on the substrate 110 using a 3D printing process also includes S330b.
- a linear printing process is used to form a plurality of third reflection patterns in the third printing area P3 where at least one driver chip 140 is located.
- the orthographic projection of at least one driver chip 140 on the substrate 110 is located within the orthographic projection range of the plurality of third reflection patterns on the substrate 110 .
- one or more driver chips 140 are covered by a pattern composed of a plurality of third reflective patterns, so that the one or more driver chips 140 are not exposed on the reflective layer 130 .
- the orthographic projections of all the driving chips 140 on the substrate 110 are located within the orthographic projection range of the plurality of third reflection patterns on the substrate 110 .
- Adopting the above setting method can not only simplify the preparation process of the reflective layer 130, reduce the difficulty of designing the printing path of the printed rubber valve, shorten the time for forming the reflective layer 130 by 3D printing, but also increase the area of the reflective layer 130 on the plane where the substrate 110 is located. The proportion of the area occupied can thereby increase the reflectivity and improve the light efficiency of the light-emitting device 120 .
- the above arrangement can also improve the packaging effect of the at least one driver chip 140 and further avoid undesirable phenomena such as corrosion or leakage of the driver chip 140 caused by moisture intrusion into the driver chip 140 .
- the printing step of the linear printing process is greater than or equal to the printing step of the dotted line printing process, so that the printing speed of the dotted line printing process is lower than the printing speed of straight line printing. Therefore, the dotted line printing process is used time has a greater impact on the overall printing time.
- the dotted line printing process is mainly used to define the size of the opening 131 . Therefore, the smaller the area using the dotted line printing process, the shorter the overall printing time will be, and the printing efficiency will be improved.
- the solution in which all the driving chips 140 on the light-emitting substrate 100 are covered by the reflective layer 130 that is, the orthographic projection of all the driving chips 140 on the substrate 110 mentioned above on the substrate 110 are located on multiple third
- the printing time of the reflective layer 130 in the three-reflective pattern is much shorter than the printing time of the reflective layer 130 in the solution where multiple driver chips 140 correspond to multiple second openings 131b one-to-one.
- the time of the dotted line printing process is shortened by about half, and the printing efficiency can be increased by about 50%.
- the relative morphological features of the side or top surface of the at least one driver chip 140 and the reflective layer 130 may vary.
- the relative morphological features of the above-mentioned morphological features and the reflective layer 130 may vary. Materials and specific process parameters of 3D printing. Several situations are introduced below, but the embodiments of the present disclosure are not limited to the following situations.
- the thickness of the portion of the reflective layer 130 that contacts the top surface of the at least one driving chip 140 is less than or equal to the thickness of the portion of the reflective layer 130 that contacts the substrate 110 .
- the thickness of the portion of the reflective layer 130 that is in contact with the top surface of the at least one driving chip 140 is equal to the thickness of the portion of the reflective layer 130 that is in contact with the substrate 110 .
- the thickness of the portion of the reflective layer 130 that is in contact with the top surface of the at least one driving chip 140 is smaller than the thickness of the portion of the reflective layer 130 that is in contact with the substrate 110 .
- FIGS. 15a and 15b there is a gap between the side surface of at least one driver chip 140 and the reflective layer 130 .
- the reflective layer material produced by the printing nozzle contacts the above-mentioned During the process of pre-printing the surface, some gas may not escape in time, resulting in a gap between the side of at least one driver chip 140 and the reflective layer 130 .
- the reflective layer 130 is broken at the sides of at least one driver chip 140.
- the portion of the reflective layer 130 that is in contact with the side surface of at least one driver chip 140 is not connected to the portion of the reflective layer 130 that is in contact with the top surface of at least one driver chip 140 .
- the 3D printing path along the long side direction of the rectangle or the short side direction of the rectangle also affects the printing efficiency of the reflective layer 130 to a certain extent. Specifically, the printing path can be selected according to the actual situation, thereby improving the printing efficiency of the reflective layer 130 .
- the number of printing nozzles of the 3D printing device may be one or more (here, the printing nozzles of the 3D printing device and the printing nozzles are set in a one-to-one correspondence, and one printing nozzle corresponds to one printing nozzle valve, so the printing The number of nozzles is the number of printing nozzles).
- the printing nozzles are multi-head design. The number of printing nozzles needs to be designed to match the number of rows or columns of the openings 131 in the light-emitting substrate 100.
- the number of printing nozzles for the dotted line printing process can be selected from 1, 2, 4, 8, 12, 24 or 48, etc. .
- the number of print heads selected is generally divisible by the number of rows or columns of openings. In the linear printing process, the number of rows and columns of openings 131 has nothing to do with it.
- the printing direction of the straight line printing process and the printing direction of the dotted line process are the same or perpendicular to each other.
- the printing direction of the linear printing process is the first direction X
- the printing direction of the dotted line process is also the first direction X
- the two directions are the same.
- the printing direction of the linear printing process is the first direction X
- the printing direction of the dotted line process is the second direction Y.
- the two directions are perpendicular to each other.
- the method for preparing the above-mentioned light-emitting substrate 100 further includes S400.
- an encapsulant may be used to form an encapsulation layer 160 to encapsulate the light-emitting device 120 , thereby preventing water vapor from intruding into the interior of the light-emitting device 120 and affecting the light emission of the light-emitting device 120 .
- the present disclosure illustrates a method for calculating the printing time of the reflective layer 130 of the light-emitting substrate 100.
- the light-emitting substrate 100 includes two rows of light-emitting devices 120, two rows of driver chips 140, and the number of printing nozzles of the 3D printing device is one row.
- the second printing area and the first printing area corresponding to a row of light-emitting devices 120 are printed to form the first opening 131a, and the time used by the printing nozzle is the first working time T1.
- T1 the time used by the printing nozzle The second working time is T2.
- the printing time T of the dotted line printing process is 2T1+T2.
- the printing time T of the dotted line printing process is 2T1+2T2.
- the printing time of the dotted line printing process is the shortest, which is beneficial to improving the efficiency of the 3D printing process in forming the reflective layer 130.
- the size of the light-emitting substrate 100 is 802mm*341mm
- the light-emitting device 120 has 48 lines
- the driver chip has 24 lines
- the number of printing nozzles in the dotted line printing process is 24, and the size of the light-emitting device 120 is 0.15mm*0.51mm
- the size of the driver chip 140 is 0.41mm*0.41mm
- the printing speed of dotted line printing is 100mm/s
- the invalid stroke is 500mm
- the printing step of the dotted line printing process is 0.3mm
- the cycle wrapping time is 0.1s
- when the printing direction OP is the first direction
- the chip 140 needs to be printed 5 times in a cycle.
- the first working time T1 of the printing nozzle is 52.3s (specifically calculated by (4*13+0.1*3)).
- the second working time T2 of the printing nozzle is 65.4s (specifically calculated by (5*13+0.1*4)).
- the printing time T of the dotted line printing process is 2T1, which is calculated to be 104.6 s.
- the printing time T of the dotted line printing process is 2T1 + T2, which is calculated to be 170 s.
- the printing time T of the dotted line printing process is 2T1+2T2, which is calculated to be 235.4 s.
- the printing time of the dotted line printing process when the driver chips 140 are all located in the second printing area P2 is more than twice the printing time of the dotted line printing process when the driving chips 140 are located in the third printing area P3. It can be seen that selecting an appropriate printing path and printing method can greatly improve the efficiency of the 3D printing process in forming the reflective layer 130 .
- the light-emitting substrate 100 may be, for example, a light-emitting substrate manufactured by using the preparation method described in any of the above embodiments.
- the above-mentioned light-emitting substrate 100 includes: a substrate 110, a plurality of light-emitting devices 120 and a reflective layer 130 provided on one side of the substrate 110.
- the substrate 110 may be a glass substrate, a PCB substrate, or the like.
- the reflective layer 130 has a plurality of openings 131, and the plurality of openings 131 include a plurality of first openings 131a; one light-emitting device 120 is located in one first opening 131a.
- the first opening 131a is provided corresponding to the light emitting device 120.
- the light emitting device 120 is located at the center of the corresponding first opening 131a.
- the surface of the reflective layer 130 on a side away from the substrate 110 has a plurality of protruding structures 132 .
- one side surface of the reflective layer 130 has a plurality of protruding structures 132 .
- the beneficial effects that can be achieved by the light-emitting substrate 100 provided by some embodiments of the present disclosure are the same as the beneficial effects that can be achieved by the preparation methods of the light-emitting substrate 100 provided by some of the above embodiments, and will not be described again here.
- the reflective layer 130 includes a plurality of first parts 133 and a plurality of second parts 134.
- the first parts 133 are parts of the reflective layer 130 corresponding to the protruding structures 132
- the second parts 134 is a portion of the reflective layer 130 located between two adjacent protruding structures 132 .
- the second part 134 is the part with the smallest thickness in the reflective layer 130 .
- the first parts 133 and the second parts 134 are alternately distributed.
- the difference between the thickness of the first portion 133 and the thickness of the second portion 134 is less than or equal to 20 ⁇ m.
- different areas of the first part 133 have different thicknesses, where the thickness of the first part 133 refers to the maximum thickness or the average thickness of the first part 133 .
- the difference between the thickness of the first part 133 and the thickness of the second part 134 may be 20 ⁇ m, 18 ⁇ m, 15 ⁇ m, 10 ⁇ m, 8 ⁇ m or 6 ⁇ m.
- the maximum thickness of the first part 133 is approximately 65 ⁇ m, and the thickness of the second part 134 is approximately 45 ⁇ m.
- the thickness fluctuations corresponding to different areas of the reflective layer 130 are small.
- the reflectivity requirement of the reflective layer 130 can be met, thereby ensuring the light efficiency of the light-emitting substrate 100.
- the difference between the thickness of the first part 133 and the thickness of the second part 134 is less than or equal to 20% of the thickness of the reflective layer 130 .
- the thickness of the reflective layer refers to, for example, the overall average thickness of the reflective layer.
- the difference between the thickness of the first part 133 and the thickness of the second part 134 may be 20%, 18%, 15%, 10% or 8% of the thickness of the reflective layer 130 .
- the corresponding thickness differences in different areas of the reflective layer 130 are small, which can meet the reflectivity requirements of the reflective layer 130 and avoid affecting the light efficiency of the light-emitting substrate 100 .
- the difference between the thickness of the first portion 133 and the thickness of the second portion 134 is less than or equal to 20 ⁇ m. And the difference between the thickness of the first part and the thickness of the second part is less than or equal to 20% of the thickness of the reflective layer.
- the above arrangement can further ensure that the thickness difference corresponding to different areas of the reflective layer 130 is small, thereby meeting the reflectivity requirements of the reflective layer 130 and avoiding affecting the light efficiency of the light-emitting substrate 100 .
- At least one sidewall of the opening 131 is curved.
- one or more side walls of the opening 131 are curved.
- the opening 131 is surrounded by a part of the edge of the first reflection pattern and a part of the edge of the second reflection pattern, at least one side wall of the opening 131 is curved.
- the light emitted by the light-emitting device 120 is incident on the side wall of the first opening 131a, it is reflected at the side wall and emitted substantially in the light emitting direction of the light-emitting substrate 100, thereby avoiding the loss of the light.
- the light efficiency of the light-emitting substrate 100 is improved.
- the distance between the light emitting device 120 and the side wall of the corresponding first opening 131a ranges from 0.05 mm to 0.3 mm.
- the distance between the light emitting device 120 and the side wall of the corresponding first opening 131a may be 0.3 mm, 0.22 mm, 0.17 mm, 0.08 mm or 0.05 mm.
- the distance between the light-emitting device 120 and the side wall of the corresponding first opening 131a can be smaller, thereby reducing the risk of light emitted by the light-emitting device 120 being incident on the area between the light-emitting device and the first opening.
- the damage can further increase the reflectivity of the reflective layer 130, increase the light efficiency of the light-emitting substrate 100, and further reduce the power consumption of the backlight module 10 and the display device 1.
- the angle ⁇ between at least one sidewall of the first opening 131a and the substrate 110 is an acute angle.
- the angle between one side wall of the first opening 131a and the substrate 110 is an acute angle.
- the angles between two or more side walls of the first opening 131a and the substrate 110 are both acute angles.
- the shape of the first opening 131a in the top view may be a rectangle or a circle. Taking the shape of the first opening 131a in the top view as shown in FIG. 3 as a rectangle as an example, the first opening 131a There are four sidewalls, and the angles between one or more sidewalls of the first opening 131a and the substrate 110 are all acute angles. That is to say, the one or more sidewalls surrounding the first opening 131a are directed toward the center of the opening. Protruding.
- the light emitted by the light-emitting device 120 is incident on the side wall of the first opening 131a, it is reflected at the side wall and emitted substantially in the light emitting direction of the light-emitting substrate 100, thereby avoiding the loss of the light.
- the light efficiency of the light-emitting substrate 100 is improved.
- the surface of the side of the above-mentioned protruding structure 132 away from the substrate 110 is curved.
- the uniformity of the light emitted from the reflective layer 130 can be improved.
- extension direction and arrangement of the protruding structures 132 are mainly determined by the printing path of the 3D printing process.
- the plurality of protruding structures 132 extend along the first direction X and are arranged in multiple rows along the second direction Y.
- the plurality of protruding structures 132 extend along the second direction Y, and along the first direction X is arranged in multiple columns.
- the plurality of protruding structures 132 includes: a plurality of first protruding structures 132a and a plurality of second protruding structures 132b.
- the plurality of first protruding structures 132a and the plurality of second protruding structures 132b can be extended and arranged in various ways.
- the extending directions of the plurality of first protruding structures 132a and the plurality of second protruding structures 132b may be the same.
- the plurality of first protruding structures 132a may extend along the second direction Y.
- the plurality of first protruding structures 132a may be arranged in multiple rows along the first direction X.
- the second protruding structures 132b may also extend along the second direction Y.
- the plurality of second protruding structures 132b are arranged in multiple columns along the first direction X.
- the extending directions of the plurality of first protruding structures 132a and the plurality of second protruding structures 132b may be different.
- the plurality of first protruding structures 132a may extend along the first direction X
- the plurality of first protruding structures 132a may be arranged in multiple rows along the second direction Y
- the second protruding structures 132b may extend along the second direction Y
- the plurality of second protruding structures 132b are arranged in multiple columns along the first direction X.
- the size M1 of the first protrusion structure 132a along the arrangement direction of the plurality of first protrusions 132a is greater than or equal to the size M1 of the second protrusion structure 132b along the arrangement direction of the plurality of second protrusions 132b. Size M2 in the direction of fabric.
- the first protruding structure 132a and the second protruding structure 132b are all arranged along the second direction Y, and the size M1 of the first protruding structure 132a along the second direction Y is greater than or equal to the size M2 of the second protruding structure 132b along the second direction Y.
- the 3D printing device can form a convex structure 132 each time it prints a printing strip.
- the size of the first convex structure 132a along its arrangement direction is larger, thereby reducing the The number of printing strips can thereby improve the efficiency of 3D printing.
- the second protrusions 132b along its arrangement direction is small, the second protrusion structure 132b can be printed on the edge of the reflective layer 130 or around the opening 131, and the size of the formed reflective layer 130 can be accurately controlled. Accuracy, thereby improving the accuracy of forming the reflective layer 130 using the 3D printing process.
- the number of the plurality of first protruding structures 131a formed by printing can also be greater than the number of the plurality of second protruding structures 132b, thereby further reducing the number of printing strips, thereby improving the use of 3D printing processes.
- the efficiency of forming the reflective layer 130 can also be greater than the number of the plurality of second protruding structures 132b, thereby further reducing the number of printing strips, thereby improving the use of 3D printing processes.
- At least one side of the orthographic projection of the reflective layer 130 on the substrate 110 includes a plurality of curved segments, and at least one curved segment protrudes toward the edge direction of the substrate 110 .
- the two sides of the two dotted lines in FIG. 20 represent a schematic diagram of the portion of the reflective layer 130 close to the edge. This figure does not illustrate the opening 130 in the reflective layer 130 .
- one side of the orthographic projection of the reflective layer 130 on the substrate 110 includes a plurality of curved segments.
- multiple sides of the orthographic projection of the reflective layer 130 on the substrate 110 each include multiple curve segments.
- one of the plurality of curved segments may protrude toward the edge of the substrate 110 .
- the above-mentioned plurality of curved segments may all protrude toward the edge direction of the substrate 110 .
- the angle ⁇ between at least one side surface close to the edge of the substrate 110 and the substrate 110 is an acute angle.
- an angle between a side surface close to the edge of the substrate 110 and the substrate 110 is an acute angle.
- angles between the multiple side surfaces close to the edge of the substrate 110 and the substrate 110 are all acute angles.
- an angle between at least one side surface close to the edge of the substrate 110 and the substrate 110 is 30°, 50°, 60°, 70° or 80°.
- the angle ⁇ between the side surface close to the edge of the substrate 110 and the substrate 110 may be the same as the angle ⁇ between the side wall of the first opening 131a and the substrate 110, or may be different.
- the light-emitting substrate 100 further includes: a plurality of driving chips 140 disposed on one side of the substrate 110 and located on the same side of the substrate 110 as the plurality of light-emitting devices 120 .
- a driving chip 140 is electrically connected to at least one light-emitting device 120, and the driving chip 140 is configured to drive the at least one light-emitting device 120 to emit light.
- a driving chip 140 can be electrically connected to a light-emitting device 120 and drive the light-emitting device 120 to emit light.
- one driving chip 140 can be electrically connected to four light-emitting devices 120 and drive the four light-emitting devices 120 to emit light.
- one driving chip 140 can be electrically connected to nine light-emitting devices 120 and drive the nine light-emitting devices 120 to emit light.
- one driver chip 140 drives four light-emitting devices 120 for illustration.
- the plurality of openings 131 further includes a plurality of second openings 131b.
- a driver chip 140 is located in a second opening 131b.
- the distance between the driver chip 140 and the side wall of the corresponding second opening 131 b ranges from 0.05 mm to 0.30 mm.
- the distance between the driving chip 140 and the side wall of the corresponding second opening 131b may be 0.05mm, 0.12mm, 0.18mm, 0.23mm or 0.30mm.
- the distance between the driver chip 140 and the corresponding second opening 131b can be made smaller, which can make the reflective layer 130 occupy a larger proportion of the area on the substrate 110 , thereby improving the reflection of the reflective layer 130 efficiency, further improving the luminous efficiency of the light-emitting substrate 100.
- the orthographic projection of at least one driver chip 140 on the substrate 110 is located within the orthographic projection range of the reflective layer 130 on the substrate 110 .
- FIG. 21b is a partial view of the light-emitting substrate 100 corresponding to FIG. 21a.
- the orthographic projection of a driver chip 140 on the substrate 110 is located within the orthographic projection range of the reflective layer 130 on the substrate 110. That is to say, one driver chip 140 is covered by the reflective layer 130, and the rest are covered by the reflective layer 130. Each driver chip 140 is located in the second opening 131b.
- the orthographic projection of one row of driving chips 140 on the substrate 110 is located within the orthographic projection range of the reflective layer 130 on the substrate 110. That is to say, one row of driving chips 140 is covered by the reflective layer 130, and the rest are covered by the reflective layer 130. Each driver chip 140 is located in the second opening 131b.
- the number of second openings 131b on the reflective layer 130 can be reduced, thereby simplifying the preparation process of the reflective layer 130.
- the reflective layer 130 can also protect the driving chip 140 to a certain extent, preventing external water vapor from intruding into the driving chip 140, thereby preventing the driving chip 140 from failing.
- the thickness of the portion of the reflective layer 130 that contacts the top surface of the at least one driving chip 140 is less than or equal to the thickness of the portion of the reflective layer 130 that contacts the substrate 110 .
- the thickness of the portion of the reflective layer 130 that is in contact with the top surface of the at least one driving chip 140 is equal to the thickness of the portion of the reflective layer 130 that is in contact with the substrate 110 .
- the thickness of the portion of the reflective layer 130 that is in contact with the top surface of the at least one driving chip 140 is smaller than the thickness of the portion of the reflective layer 130 that is in contact with the substrate 110 .
- the reflective layer material produced by the printing nozzle contacts the pre-printed surface.
- some gas may not escape in time, resulting in a gap between the side of at least one driver chip 140 and the reflective layer 130 .
- the reflective layer 130 is broken at the sides of at least one driver chip 140.
- the portion of the reflective layer 130 that is in contact with the side surface of at least one driver chip 140 is not connected to the portion of the reflective layer 130 that is in contact with the top surface of at least one driver chip 140 .
- the orthographic projections of the plurality of driver chips 140 on the substrate 110 are located within the orthographic projection range of the reflective layer 130 on the substrate 110 .
- FIG. 23b is a partial view of the light-emitting substrate 100 corresponding to FIG. 23a.
- the number of openings 131 on the reflective layer 130 can be reduced, thereby simplifying the preparation process of the reflective layer 130 .
- the reflective layer 130 can also protect the driver chip 140 to a certain extent, preventing corrosion or leakage of the driver chip 140 caused by external water vapor invading the driver chip 140 .
- the light emitting substrate 100 further includes: a binding structure 150.
- the binding structure 150 is electrically connected to the driver chip 140, for example.
- the binding structure 150 is located on a side of the light-emitting substrate 100 close to the edge.
- the binding structure 150 is used to transmit different types of working signals to the driving chip 140.
- the driving chip 140 can generate driving signals according to the different types of working signals and transmit the driving signals to the corresponding light-emitting devices 120.
- the area where the binding structure 150 is located is not covered by the reflective layer 130 .
- the above-mentioned binding structure 150 can use COF (Chip On Film, chip on film) to achieve binding with PCB or FPC (Flexible Printed Circuit, flexible circuit board).
- COF Chip On Film, chip on film
- FPC Flexible Printed Circuit, flexible circuit board
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Abstract
一种发光基板,包括:衬底,以及设置所述衬底一侧的多个发光器件、反射层。所述反射层具有多个开口,所述多个开口包括多个第一开口;一个发光器件位于一个第一开口内。其中,所述反射层远离所述衬底一侧的表面具有多个凸起结构。
Description
本公开涉及显示技术领域,尤其涉及一种发光基板及其制备方法、背光模组、显示装置。
次毫米发光二极管(Mini Light Emitting Diode,简称Mini LED)和微型发光二极管(Micro Light Emitting Diode,简称Micro LED)因具有自发光、高效率、高亮度、高可靠度、节能及反应速度快等诸多优点,被应用至微显示、手机、电视等中等尺寸显示到影院大屏幕显示等领域中。
发明内容
一方面,提供一种发光基板,包括:衬底,以及设置所述衬底一侧的多个发光器件、反射层。所述反射层具有多个开口,所述多个开口包括多个第一开口;一个发光器件位于一个第一开口内。其中,所述反射层远离所述衬底一侧的表面具有多个凸起结构。
在一些实施例中,所述反射层包括多个第一部分和多个第二部分,第一部分为所述反射层中与凸起结构相对应的部分,第二部分为所述反射层中位于相邻两个凸起结构之间的部分。所述第一部分的厚度,与所述第二部分的厚度的差值,小于或等于20μm。和/或,所述第一部分的厚度与所述第二部分的厚度的差值,小于或等于所述反射层的厚度的20%。
在一些实施例中,所述发光器件与相应的所述开口的侧壁的间距范围为,0.05mm~0.3mm。
在一些实施例中,所述开口的至少一个侧壁与所述衬底之间的夹角为锐角。
在一些实施例中,所述开口的至少一个侧壁呈弧面状。
在一些实施例中,凸起结构远离所述衬底的一侧表面呈曲面状。
在一些实施例中,所述多个凸起结构包括多个第一凸起结构及多个第二凸起结构。所述多个第一凸起结构沿第一方向延伸,所述多个第一凸起结构沿第二方向呈多行排布。所述多个第二凸起结构沿第一方向延伸,所述多个第二凸起结构沿第二方向呈多行排布,或,所述多个第二凸起结构沿第二方向延伸,所述多个第二凸起结构沿第一方向呈多列排布。所述第一方向和所述第二方向相交。
在一些实施例中,所述第一凸起结构在所述多个第一凸起的排布方向上的尺寸,大于或等于,所述第二凸起结构在所述多个第二凸起的排布方向上的尺寸。
在一些实施例中,所述反射层在所述衬底上的正投影的至少一条边包括多个曲线段,至少一个曲线段朝向所述衬底的边缘方向凸出。
在一些实施例中,所述反射层中,靠近所述衬底的边缘的至少一个侧面与所述衬底的夹角为锐角。
在一些实施例中,所述发光基板还包括:设置在所述衬底一侧、且与所述多个发光器件位于所述衬底同一侧的多个驱动芯片。一个驱动芯片与至少一个发光器件电连接,且所述驱动芯片被配置为,驱动所述至少一个发光器件发光,所述多个开口还包括多个第二开口。一个驱动芯片位于一个第二开口内。
在一些实施例中,所述发光基板还包括:设置在所述衬底一侧、且与所述多个发光器件位于所述衬底同一侧的多个驱动芯片;一个驱动芯片与至少一个发光器件电连接,且所 述驱动芯片被配置为,驱动所述至少一个发光器件发光。至少一个驱动芯片在所述衬底上的正投影,位于所述反射层在所述衬底上的正投影范围之内。
在一些实施例中,所述反射层中与所述至少一个驱动芯片的顶面接触的部分的厚度,小于或等于所述反射层中与所述衬底接触的部分的厚度。
在一些实施例中,所述驱动芯片的至少一个侧面,与所述反射层之间具有间隙。
在一些实施例中,所述反射层在所述驱动芯片的至少一个侧面处断开。
另一方面,提供一种发光基板的制备方法,包括:提供衬底。在所述衬底上固定多个发光器件。采用3D打印工艺,在所述衬底上形成反射层;所述多个开口包括多个第一开口;一个发光器件位于一个第一开口内;其中,所述反射层远离所述衬底一侧的表面具有多个凸起结构。
在一些实施例中,所述多个发光器件沿第一方向呈多列排列,沿第二方向呈多行排布。所述衬底具有沿所述第一方向延伸的多个第一打印区域、多个第二打印区域及多个第三打印区域;所述多个第二打印区域和所述多个第三打印区域交替设置,第一打印区域位于任意相邻的第二打印区域和第三打印区域之间。一行发光器件位于一个第二打印区域内。所述采用3D打印工艺,在所述衬底上形成反射层,包括:采用直线打印工艺,在各行发光器件相对两侧的两个第一打印区域形成第一反射图案,采用虚线打印工艺,在各第二打印区域中任意相邻两个发光器件之间形成第二反射图案;各发光器件周围的第一反射图案与第二反射图案围成所述第一开口;所述第一开口的至少一个侧面,与所述衬底之间的夹角为锐角,和/或,所述开口的至少一个侧壁为曲面。采用直线打印工艺,在所述第三打印区域形成多个第三反射图案。
在一些实施例中,在所述采用3D打印工艺,在所述衬底上形成反射层之前,所述制备方法还包括:在所述衬底上固定多个驱动芯片;所述多个驱动芯片沿第一方向呈多列排列,沿第二方向呈多行排布;一行驱动芯片位于一个第二打印区域。所述多个开口还包括多个第二开口;所述采用3D打印工艺,在所述衬底上形成反射层,还包括:采用直线打印工艺,在各行驱动芯片相对两侧的两个第一打印区域形成第一反射图案,采用虚线打印工艺,在各第二打印区域中任意相邻两个驱动芯片之间形成第二反射图案;各发光器件周围的第一反射图案与第二反射图案围成所述第二开口;所述第二开口的至少一个侧面,与所述衬底之间的夹角为锐角,和/或,所述第二开口的至少一个侧壁为曲面。
在一些实施例中,在所述采用3D打印工艺,在所述衬底上形成反射层之前,所述制备方法还包括:在所述衬底上固定多个驱动芯片;所述多个驱动芯片沿第一方向呈多列排列,沿第二方向呈多行排布;至少一个驱动芯片位于所述多个第三打印区域。所述采用3D打印工艺,在所述衬底上形成反射层,还包括:采用直线打印工艺,在所述至少一个驱动芯片所在的第三打印区域形成多个第三反射图案;所述至少一个驱动芯片在所述衬底上的正投影,位于所述多个第三反射图案在所述衬底上的正投影范围之内。
在一些实施例中,所述直线打印工艺的打印方向与所述虚线工艺的打印方向,相同或相互垂直。
又一方面,提供一种背光模组,包括:上述任一实施例所述的发光基板,以及位于所述发光基板的出光侧的光学膜片。
又一方面,提供一种显示装置,包括:上述实施例所述的背光模组,位于所述背光模组出光侧的彩膜基板;以及,位于所述背光模组与所述彩膜基板之间的阵列基板。
为了更清楚地说明本公开中的技术方案,下面将对本公开一些实施例中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本公开的一些实施例的附图,对于本领域普通技术人员来讲,还可以根据这些附图获得其他的附图。此外,以下描述中的附图可以视作示意图,并非对本公开实施例所涉及的产品的实际尺寸、方法的实际流程等的限制。
图1为根据本公开的一些实施例的一种显示装置的结构图;
图2为根据本公开的一些实施例的一种背光模组的结构图;
图3为根据本公开的一些实施例的一种发光基板的结构图;
图4a为根据本公开的一些实施例的一种发光基板的制备方法的步骤图;
图4b为根据本公开的一些实施例的一种发光基板的制备过程图;
图4c为根据本公开的一些实施例的另一种发光基板的制备过程图;
图4d为根据本公开的一些实施例的又一种发光基板的制备过程图;
图5a为根据本公开的一些实施例的一种衬底与反射层的局部结构图;
图5b为根据本公开的一些实施例的另一种衬底与反射层的局部结构图;
图5c为根据本公开的一些实施例的另一种衬底与反射层的局部结构图;
图6a为一种实现方式中发光基板的一种实物局部结构图;
图6b为一种实现方式中发光基板的另一种实物局部结构图;
图7为根据本公开的一些实施例的另一种发光基板的结构图;
图8a为根据本公开的一些实施例的另一种发光基板的制备方法的步骤图;
图8b为根据本公开的一些实施例的一种发光基板的制备过程图;
图8c为根据本公开的一些实施例的另一种发光基板的制备过程图;
图9为根据本公开的一些实施例的又一种发光基板的结构图;
图10a为根据本公开的一些实施例的又一种衬底与反射层的局部结构图;
图10b为根据本公开的一些实施例的又一种衬底与反射层的局部结构图;
图11a为根据本公开的一些实施例的一种反射层与衬底的结构图;
图11b为图11a所示反射层对应实物的局部结构图;
图12a为根据本公开的一些实施例的又一种发光基板的结构图;
图12b为根据本公开的一些实施例的另一种发光基板的制备过程图;
图13为根据本公开的一些实施例的一种驱动芯片与发光器件的相对位置关系图;
图14a为根据本公开的一些实施例的又一种发光基板的结构图;
图14b为根据本公开的一些实施例的另一种发光基板的制备过程图;
图15a为根据本公开的一些实施例的又一种发光基板的结构图;
图15b为根据本公开的一些实施例的又一种发光基板的结构图;
图15c为根据本公开的一些实施例的又一种发光基板的结构图;
图16为根据本公开的一些实施例的另一种发光基板的制备过程图;
图17a为根据本公开的一些实施例的又一种发光基板的结构图;
图17b为图17a所示发光基板对应实物的局部结构图;
图18a为根据本公开的一些实施例的又一种发光基板的结构图;
图18b为根据本公开的一些实施例的又一种发光基板的结构图;
图19为根据本公开的一些实施例的又一种发光基板的结构图;
图20为根据本公开的一些实施例的又一种反射层与衬底的结构图;
图21a为根据本公开的一些实施例的又一种发光基板的结构图;
图21b为图21a所示发光基板对应实物的局部结构图;
图22a为根据本公开的一些实施例的又一种发光基板的结构图;
图22b为根据本公开的一些实施例的又一种发光基板的结构图;
图22c为根据本公开的一些实施例的又一种发光基板的结构图;
图23a为根据本公开的一些实施例的又一种发光基板的结构图;
图23b为图23a所示发光基板对应实物的局部结构图。
下面将结合附图,对本公开一些实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本公开一部分实施例,而不是全部的实施例。基于本公开所提供的实施例,本领域普通技术人员所获得的所有其他实施例,都属于本公开保护的范围。
除非上下文另有要求,否则,在整个说明书和权利要求书中,术语“包括(comprise)”及其其他形式例如第三人称单数形式“包括(comprises)”和现在分词形式“包括(comprising)”被解释为开放、包含的意思,即为“包含,但不限于”。在说明书的描述中,术语“一个实施例(one embodiment)”、“一些实施例(some embodiments)”、“示例性实施例(exemplary embodiments)”、“示例(example)”、“特定示例(specific example)”或“一些示例(some examples)”等旨在表明与该实施例或示例相关的特定特征、结构、材料或特性包括在本公开的至少一个实施例或示例中。上述术语的示意性表示不一定是指同一实施例或示例。此外,所述的特定特征、结构、材料或特点可以以任何适当方式包括在任何一个或多个实施例或示例中。
以下,术语“第一”、“第二”仅用于描述目的,而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量。由此,限定有“第一”、“第二”的特征可以明示或者隐含地包括一个或者更多个该特征。在本公开实施例的描述中,除非另有说明,“多个”的含义是两个或两个以上。
在描述一些实施例时,可能使用了“连接”及其衍伸的表达。例如,描述一些实施例时可能使用了术语“连接”以表明两个或两个以上部件彼此间有直接物理接触或电接触。这里所公开的实施例并不必然限制于本文内容。
“A和/或B”,包括以下三种组合:仅A,仅B,及A和B的组合。
如本文中所使用,根据上下文,术语“如果”任选地被解释为意思是“当……时”或“在……时”或“响应于确定”或“响应于检测到”。类似地,根据上下文,短语“如果确定……”或“如果检测到[所陈述的条件或事件]”任选地被解释为是指“在确定……时”或“响应于确定……”或“在检测到[所陈述的条件或事件]时”或“响应于检测到[所陈述的条件或事件]”。
本文中“适用于”或“被配置为”的使用意味着开放和包容性的语言,其不排除适用于或被配置为执行额外任务或步骤的设备。
另外,“基于”的使用意味着开放和包容性,因为“基于”一个或多个所述条件或值的过程、步骤、计算或其他动作在实践中可以基于额外条件或超出所述的值。
如本文所使用的那样,“约”、“大致”或“近似”包括所阐述的值以及处于特定值 的可接受偏差范围内的平均值,其中所述可接受偏差范围如由本领域普通技术人员考虑到正在讨论的测量以及与特定量的测量相关的误差(即,测量***的局限性)所确定。
如本文所使用的那样,“垂直”、“相等”包括所阐述的情况以及与所阐述的情况相近似的情况,该相近似的情况的范围处于可接受偏差范围内,其中所述可接受偏差范围如由本领域普通技术人员考虑到正在讨论的测量以及与特定量的测量相关的误差(即,测量***的局限性)所确定。例如,“垂直”包括绝对垂直和近似垂直,其中近似垂直的可接受偏差范围例如也可以是5°以内偏差。“相等”包括绝对相等和近似相等,其中近似相等的可接受偏差范围内例如可以是相等的两者之间的差值小于或等于其中任一者的5%。
应当理解的是,当层或元件被称为在另一层或基板上时,可以是该层或元件直接在另一层或基板上,或者也可以是该层或元件与另一层或基板之间存在中间层。
本文参照作为理想化示例性附图的剖视图和/或平面图描述了示例性实施方式。在附图中,为了清楚,放大了层和区域的厚度。因此,可设想到由于例如制造技术和/或公差引起的相对于附图的形状的变动。因此,示例性实施方式不应解释为局限于本文示出的区域的形状,而是包括因例如制造而引起的形状偏差。例如,示为矩形的蚀刻区域通常将具有弯曲的特征。因此,附图中所示的区域本质上是示意性的,且它们的形状并非旨在示出设备的区域的实际形状,并且并非旨在限制示例性实施方式的范围。
本公开的一些实施例提供了一种显示装置1。该显示装置1可以是显示不论运动(例如,视频)还是固定(例如,静止图像)的且不论文字的还是图像的任何显示装置中。更明确地说,预期所述实施例的显示装置可实施应用在多种电子中或与多种电子装置关联,所述多种电子装置例如(但不限于)移动电话、无线装置、个人数据助理(PDA)、手持式或便携式计算机、GPS接收器/导航器、相机、MP4视频播放器、摄像机、游戏控制台、手表、时钟、计算器、电视监视器、平板显示器、计算机监视器、汽车显示器(例如,里程表显示器等)、导航仪、座舱控制器和/或显示器、相机视图的显示器(例如,车辆中后视相机的显示器)、电子相片、电子广告牌或指示牌、投影仪、建筑结构、包装和美学结构(例如,对于一件珠宝的图像的显示器)等。
在一些示例中,上述显示装置1可以为LCD(Liquid Crystal Display,液晶显示)显示装置。
在一些示例中,如图1所示,显示装置1包括:背光模组10,位于背光模组10出光侧的彩膜基板20,以及,位于背光模组10与彩膜基板20之间的阵列基板30。
示例性的,上述背光模组10可以作为光源,用于提供背光。例如背光模组10提供的背光可以为白光或蓝光。
例如,背光模组10的出光侧,指的是,背光模组10发出光线的一侧。
示例性的,阵列基板30可以包括多个像素驱动电路、多个像素电极,该多个像素驱动电路例如呈阵列状排布。多个像素驱动电路与多个像素电极一一对应电连接,像素驱动电路为相应的像素电极提供像素电压。
示例性的,彩膜基板20可以包括多种彩色滤光片等。例如,在背光模组10提供的背光为白光的情况下,上述彩色滤光片可以包括红色滤光片、绿色滤光片和蓝色绿光片等。例如红色滤光片仅可以使得入射光线中的红光透过,绿色滤光片仅可以使得入射光线中的绿光透过,蓝色滤光片仅可以使得入射光线中的蓝光透过。又如,在在背光模组10提供的背光为蓝光的情况下,上述彩色滤光片可以包括红色滤光片和绿色滤光片等。
示例性的,彩膜基板20还包括:公共电极。公共电极可以接收公共电压。
在一些示例中,如图1所示,显示装置1还包括:位于彩膜基板20与阵列基板30之间的液晶层40。
示例性的,液晶层40包括多个液晶分子。例如,在像素电极和公共电极之间可以形成电场,位于像素电极和公共电极之间的液晶分子可以在该电场的作用下,发生偏转。
可以理解的是,背光模组10提供背光,可以透过阵列基板30,入射至液晶层40的液晶分子。液晶分子在像素电极和公共电极之间形成的电场的作用下,发生翻转,从而改变透过液晶分子的光线的量,使得经液晶分子出射的光线达到预设亮度。上述光线穿过彩膜基板20中不同颜色的滤光片后出射。该出射的光线,包括各种颜色的光,例如红色光、绿色光、蓝色光等,各种颜色的光线相互配合,使得显示装置1实现显示。
示例性的,显示装置1中的背光模组10的类型有多种,可以根据实际情况进行设置,本公开对此不作限制。
例如,背光模组10可以为侧入式背光模组,背光模组10也可以为直下式背光模组。
为方便描述,本公开以下的实施例以背光模组10为直下式背光模组为例进行介绍。
在一些实施例中,如图2所示,背光模组10包括:发光基板100及位于发光基板100的出光侧的光学膜片200。
示例性的,光学膜片200包括:依次层叠设置在发光基板100出光侧的扩散板210、量子点膜220、扩散片230和复合膜240等。
例如,扩散板210和扩散片230用于消除灯影,并将发光基板100发出的光线进行均匀化处理,提高光线的均一性。
例如,量子点膜220用于对发光基板100发出的光进行转换。可选地,在发光基板100发出的光为蓝光的情况下,量子点膜220可以将该蓝光转换为白光,并且提高该白光的纯度。
例如,复合膜240用于提高发光基板100发出的光线的亮度。
可以理解的是,发光基板100发出的光线,入射至上述光学膜片200后射出的光线的亮度得到增强,且射出的光线纯度更高,均匀性更好。
在一些示例中,如图2所示,背光模组10还包括:设置在发光基板100(例如发光基板100的反射层130)与光学膜片200的扩散板210之间的支撑柱201。关于反射层130可以参见下文中的说明,此处不再赘述。
示例性的,支撑柱201可以通过胶水固定在发光基板100上。支撑柱201可以用于支撑光学膜片200,并使得发光基板100发出的光获得一定的混光距离,从而可以进一步地消除灯影,提高光线的均匀性。
在一些实施例中,上述发光基板100包括:衬底110,以及设置衬底110一侧的多个发光器件120、反射层130。
在一些示例中,上述衬底110可以为柔性衬底。该柔性衬底例如可以为PET(Polyethylene Terephthalate,聚对苯二甲酸乙二醇酯)衬底、PEN(Polyethylene Naphthalate Two Formic Acid Glycol Ester,聚萘二甲酸乙二醇酯)衬底或PI(Polyimide,聚酰亚胺)衬底等。
在另一些示例中,上述衬底110可以为刚性衬底。例如,该衬底的材料可以为玻璃等。上述衬底110也可以为印刷电路板(Printed Circuit Board,简称PCB)、铝基板等。
在一些示例中,上述多个发光器件120可以为LED(Light Emitting Diode,发光二极管),也可以为Mini LED或Micro LED。
示例性的,如图3所示,上述多个发光器件120可以沿第一方向X呈多列排列,沿第二方向Y呈多行排布。
例如,第一方向X与第二方向Y的夹角可以为85°、90°、95°等,本公开以第一方向X与第二方向Y的夹角为90°为例进行说明。
示例性的,发光器件120可以作为发光基板100的光源。
示例性的,发光基板100还包括:设置在衬底110上的对位标记(Mark)、基板编号(Panel ID)等。
例如,对位标记用于实现发光基板100与光学膜片200等的安装对位。基板编号用于对单个发光基板100进行标注识别。由此,对位标记和基板编号需要裸露于反射层130上,方便进行对位或识别。
在一些示例中,反射层130具有多个开口131。
示例性的,反射层130的多个开口131用于使得位于衬底110上的器件例如发光器件120(或者上文提到的对位标记、基板编号等)从反射层130的表面裸露出来,避免反射层130覆盖在发光器件120上,避免反射层130对发光器件120发出的光进行遮挡,进而避免影响发光器件120的发光效率,从而可以提高发光基板100的发光效率。
示例性的,上述多个开口131包括多个第一开口131a。一个发光器件120位于一个第一开口131a内。
示例性的,多个第一开口131a与多个发光器件120可以一一对应设置。
在一些示例中,反射层130具有一定的反射率,可以对多个发光器件120发出的光线进行反射,从而提高发光器件120的光线利用率。
示例性的,第一开口131a的面积可以大于或等于相应的发光器件120的面积,且第一开口131a的中心与相应的发光器件120的中心重合。
采用上述设置方式,可以尽可能地避免发光器件120发出的光被反射层130的边缘遮挡,进而可以提高发光基板100的发光效率。
在一种实现方式中,针对发光基板的不同尺寸规格,可以采用不同的制备方法形成发光基板。例如,对于大尺寸的发光基板,制备方法一般包括以下步骤:备料→丝网印刷工艺制备反射层→自动光学检测(Automated Optical Inspection,简称AOI)→固晶→补点→AOI→封装等。又如,对于中大尺寸的的发光基板(玻璃基板)或中小尺寸的发光基板(PCB基板),制备方法一般包括以下步骤:备料→丝网印刷工艺制备反射层→曝光→显影→AOI→固晶→封装等。上述两种制备方法均是在固晶工艺前进行反射层的制备。其中,固晶工艺中包括回流焊工艺。由于回流焊工艺的温度较高,因此,回流焊工艺会使得在先形成的反射层的材料发生氧化变黄等现象,进而会使得反射层的反射率下降,降低发光基板的发光效率,降低发光模组及显示装置的亮度。此外,上述两种制备方法中,反射层制作完成后,容易出现反射层材料沉积在与发光器件连接的焊盘上,进而容易带来发光器件的灭灯或虚焊的风险,且在固晶操作中固定单个发光器件的过程中,在先形成的反射层容易黏连发光器件,进而容易出现多个发光器件同时被固定,使得发光器件的固定位置出现误差的问题。
基于此,本公开的一些实施例提供了一种发光基板100的制备方法。如图4a所示,该 制备方法包括S100~S300。
S100,如图4b所示,提供衬底110。
在一些示例中,衬底110可以为PET衬底、PI衬底、PEN衬底、玻璃衬底、PCB衬底或铝基板等。
S200,如图4c所示,在衬底110上固定多个发光器件120。
示例性的,可以采用固晶工艺在衬底110上固定多个发光器件120。
示例性的,发光器件120可以为:LED、Micro LED、Mini LED等。
例如,以发光器件120为Mini LED为例,Mini LED的结构可以包括正装结构、垂直结构或倒装结构。
示例性的,上述多个发光器件120可以较为均匀地分布在衬底110上,从而使得发光基板100的整个面发光的光线较为均匀,进而提高背光模组10及显示装置1的显示质量。
S300,如图4d所示,采用3D打印工艺,在衬底110上形成反射层130。反射层130具有多个开口131,多个开口131包括多个第一开口131a。一个发光器件120位于一个第一开口131a内。其中,如图5a所示,反射层130远离衬底110一侧的表面具有多个凸起结构132。
在一些示例中,反射层130的材料可以包括:环氧树脂、苯基硅树脂、聚四氟乙烯树脂等。
示例性的,本公开实施例可以采用3D打印设备进行3D打印工艺。3D打印设备包括具有相同功能的多个打印喷头,打印喷头上设置有打印喷阀。将反射层130的材料经过一定的预处理后放入3D打印设备中,然后通过控制打印喷阀的状态,在衬底110上根据设定的打印路径移动打印喷阀,使得反射层130的材料以点状方式从打印喷阀中喷出。该点状方式滴落的反射层材料滴落到衬底110上后粘合在一起,形成沿打印路径延OP伸的一个打印条(如图5c所示)。所有打印条的整体形成反射层130。其中,在反射层130的多个开口131对应的衬底110的区域,关闭打印喷阀,进而形成多个开口131。
示例性的,如图5a为一种反射层130的形貌特征,由于3D打印工艺中点状方式滴落而粘合形成打印条,打印条互相交叠形成反射层,使得反射层130远离衬底110的一侧的表面具有多个凸起结构132。
示例性的,图5b为反射层110的另一种形貌特征,沿衬底110的厚度方向(即图中的第三方向Z),相邻两个打印条交叠的部分还会形成一个小凸起结构135,该小凸起结构135位于相邻两个凸起结构132之间。
示例性的,3D打印的自由度高,打印喷头与待打印的衬底110之间为非接触式出胶,且打印形成的反射层130对应的尺寸精度及与开口131的尺寸精度较高,有利于提高反射层130占据的衬底110的面积比例,进而可以提高反射层130的反射率,提高发光器件120发出光线的利用率。
本公开的一些实施例中,采用上述方式进行发光基板100的制备,由于先在衬底110上将发光器件120固定,然后采用3D打印工艺形成反射层130,使得反射层130在固晶工艺(此处指的是将发光器件120固定在衬底110上的工艺)后形成,可以使得反射层材料不会沉积到与发光器件连接的焊盘上,进而可以避免在先形成反射层的情况下,容易出现的反射层材料沉积在焊盘上而带来的灭灯或虚焊的风险,从而提高发光基板100的良率,此外,还可以避免固晶工艺中的回流焊工艺使得反射层130的反射率的降低的风险,进而 可以提高反射层130的光效,提高发光基板100的发光率,进而提高背光模组10及显示装置1的显示亮度,降低背光模组10及显示装置1的功耗。
在一种实现方式中,反射层的厚度一般为55μm。在采用丝网印刷形成反射层的过程中,由于单层丝网印刷的油墨的厚度较薄,一般需要进行两次丝网印刷形成双层油墨,才能达到预设的反射层的厚度,最终形成的反射层及相应的发光器件的示意图如图6a所示,可见在发光器件的周围的反射层呈阶梯状,反射层与发光器件之间的间距较大,反射层的制作精度较低。此外,如图6b所示,在反射层的表面可见网格状的压痕。
而本公开的一些实施例中,如图11b所示,采用3D打印工艺的一次打印厚度即可达到55μm,单次打印厚度大于单次丝网印刷的厚度,因此,采用3D打印工艺可以使得反射层130一次成型,在一定程度上可以提高所制备的反射层130的精度,避免丝网印刷中的多次印刷造成的反射层尺寸误差的叠加后增大以及呈阶梯状状的形貌特征,进一步提高了形成反射层130的尺寸精度,且3D打印工艺形成的反射层130的表面不存在网格状的压痕。
在一些实施例中,如图7所示,衬底110具有沿第一方向X延伸的多个第一打印区域P1、多个第二打印区域P2及多个第三打印区域P3。多个第二打印区域P2和多个第三打印区域P3交替设置,第一打印区域P1位于任意相邻的第二打印区域P2和第三打印区域P3之间。也即,每个第二打印区域P2的相对两侧均设置有两个第一打印区域P1,每个第三打印区域P3的相对两侧均设置有两个第一打印区域P1。
示例性的,一行发光器件120位于一个第二打印区域P2内。也即,一行第二发光器件120与一个第二打印区域P2对应设置,两者一一对应设置。
示例性的,衬底110上的第一打印区域P1、第二打印区域P2及第三打印区域P3也可以均沿第二方向Y延伸,在这种情况下,可以是一列发光器件120位于一个第二打印区域P2。
为方便描述,以下均以第一打印区域P1、第二打印区域P2及第三打印区域P3沿第一方向X延伸为例进行说明。
在一些实施例中,如图8a所示,在上述制备方法的S300中,采用3D打印工艺,在衬底110上形成反射层130的过程,包括S310~S320。
S310,如图8b所示,采用直线打印工艺,在各行发光器件120相对两侧的两个第一打印区域P1形成第一反射图案,采用虚线打印工艺,在各第二打印区域P2中任意相邻两个发光器件120之间形成第二反射图案。各发光器件120周围的第一反射图案与第二反射图案围成第一开口131a。如图9所示,第一开口131a的至少一个侧壁,与衬底110之间的夹角为锐角,和/或,第一开口131a的至少一个侧壁为曲面。
示例性的,第一反射图案可以包括一个或多个打印条,由此,第一反射图案的边缘即为打印条的边缘。第二反射图案可以包括一个或多个打印条,由此,第二反射图案的边缘即为打印条的边缘。
需要说明的是,首先,直线打印工艺指的是,3D打印设备沿着设定的打印路径,完成一次的打印后,所形成的打印图案为连续的、不间断的类似直线线条形状的一个打印条,该打印条上具有第一凸起结构132a。虚线打印工艺指的是,3D打印设备沿着设定的打印路径,通过控制打印喷阀实现间歇性的打开或关闭,在完成一次的打印后,所形成的打印图案为不连续的、间断的类似虚线线条形状的一个打印条,该打印条上具有第二凸起结构 132b。一个打印条对应一个凸起结构132。
其次,如图10a所示,虚线打印工艺的打印步径d1,小于或等于直线打印工艺的打印步径d2,此处的打印步径为相邻两个打印条的中心线之间的间距,其实际为3D打印设备打印完一个打印条后沿垂直于打印路径所移动的距离,也即上文中凸起结构132沿其排布方向上的尺寸。例如直线打印工艺的打印步径的范围为0.1mm~3.0mm,虚线打印工艺的打印步径的范围为0.1mm~1.5mm。因此,虚线打印工艺的打印精度大于直线打印工艺的打印精度。
此外,以打印喷阀完成一次打印形成一个打印条为例,相邻两个打印条的叠加宽度为单条打印条的宽度d3与打印步径之间的差值。图10b为一个打印条的宽度示意图。反射层130中除边缘部分,相邻两个打印条中未重叠的部分形成了反射层130的第一部分133,相邻两个打印条重叠的边界线部分组成了反射层130的第二部分134。
示例性的,如图10a所示,第二部分134为反射层130中厚度最小的部分。反射层130中,第一部分133和第二部分134交替分布。
在一些示例中,第一部分133的厚度,与第二部分134的厚度的差值,小于或等于20μm。
示例性的,第一部分133的不同区域的厚度不同,此处第一部分133的厚度指的是第一部分133的最大厚度。
例如,第一部分133的厚度,与第二部分134的厚度的差值,可以为20μm、18μm、15μm、10μm、8μm或6μm。
以反射层130的平均厚度为55μm为例,采用上述设置方式,第一部分133的最大厚度约为65μm,第二部分134的厚度约为45μm,从而可以使得反射层130的不同区域对应的厚度波动较小,进而可以满足反射层130的反射率要求,保证发光基板100的光效。
在另一些示例中,第一部分133的厚度与第二部分134的厚度的差值,小于或等于反射层130的厚度的20%。
示例性的,第一部分133的厚度与第二部分134的厚度的差值,可以为反射层130的厚度的20%、18%、15%、10%或8%。
采用上述设置方式,使得反射层130的不同区域对应的厚度差异较小,可以满足反射层130的反射率要求,进而不影响发光基板100的光效。
示例性的,如图8b所示,打印方向OP为第一方向X,在靠近一行发光器件120的一侧,形成的第一反射图案为连续的、不间断的直线形图案。在第二打印区域P2,采用虚线打印工艺,设置3D打印设备的打印喷阀在与发光器件120对应的位置关闭,而在其余位置打开打印喷阀,由此,沿第一方向X,第二反射图案中间没有连接,第二打印区域P2内的第二反射图案的整体如同不连续、间断的虚线状。
示例性的,在各行发光器件120相对两侧的两个第一打印区域P1形成第一反射图案,是对第一开口131a在第二方向Y上的尺寸进行限位,且第一反射图案的一部分边缘构成第一开口131a的相对两个侧壁,第二反射图案是对第一开口131a在第一方向X上的尺寸进行限位,且第二反射图案的一部分边缘构成第一开口131a的两个侧壁。
示例性的,在上述步骤S310中,在各行发光器件120相对两侧的两个第一打印区域P1形成第一反射图案的过程,也可以采用虚线打印工艺形成第一反射图案。由于虚线打印工艺的精度高于直线打印工艺的打印精度,这样可以提高各发光器件120周围的第一反射 图案与第二反射图案所围成第一开口131a的精确度,进而可以提高反射层130的制作精度。
示例性的,由于采用3D打印工艺,其打印所形成的反射层130的尺寸及第一开口131a的尺寸较为精准,由此可以控制打印参数使得反射层130的边缘与发光器件120之间的间距较小,因而可以使得反射层130所覆盖的衬底110的面积比例较大,进而可以使得发光基板100的光效较高。
示例性的,由于3D打印的点状滴落方式,第一反射图案的边缘和第二反射图案的边缘在俯视图(如图8b所示)中均呈曲线形,由此,由第一反射图案的一部分边缘和第二反射图案的一部分边缘围成的第一开口131a的侧壁的俯视图也呈曲线形。此外,第一反射图案的边缘和第二反射图案的边缘在剖视图(如图9所示)呈曲面状,由此,由第一反射图案的一部分边缘和第二反射图案的一部分边缘围成的第一开口131a的一个侧壁或多个侧壁均为曲面。
示例性,如图9所示,第一开口131a的一个侧壁与衬底110的夹角为锐角。或,第一开口131a的两个或更多个侧壁与衬底110的夹角均为锐角。
示例性的,上述第一开口131a的侧壁与衬底110的夹角可以为30°、50°、60°、65°或70°。
示例性的,第一开口131a在俯视图中的形状可以为矩形,也可以为圆形等,以图3中所示的第一开口131a的俯视图中的形状为矩形为例,则第一开口131a具有四个侧壁,第一开口131a的一个或多个侧壁与衬底110之间的夹角均为锐角,也就是说围成第一开口131a的一个或多个侧壁是向第一开口131a的中心方向凸出的。其中,上述矩形或圆形,例如为不规则的矩形或不规则的圆形。
示例性的,上述第一开口131a的侧壁与衬底110的夹角的大小与反射层130的材料性质相关。采用不同的反射层材料所形成的反射层130中第一开口131a的侧壁与衬底110的夹角可以不同。
S320,如图8c所示,采用直线打印工艺,在第三打印区域P3形成多个第三反射图案。
示例性的,第三打印区域P3内没有需要裸露于反射层130上的器件,由此,可以采用直线打印工艺形成多个第三反射图案。
由于直线打印工艺的打印步径d2大于或等于虚线打印工艺的打印步径d1,由此,采用上述设置方式,可以提高第三打印区域P3的打印速率,进而提高反射层130的打印效率。
在一种实现方式中,采用丝网印刷形成发光基板的反射层,由于丝网印刷工艺的限制,形成反射层的开口的侧壁与相应的发光器件之间的间距为0.5mm左右,即使在后续增加补点工艺,使得反射层的开口的侧壁与相应的发光器件之间的间距缩小至0.3mm左右,这样发光器件与相应的开口的侧壁之间依然存在空隙,且该空隙的尺寸较大,从而使得发光器件发出的部分光线会进入上述空隙内,进而使得反射层的反射率下降,使得背光模组及显示装置的显示亮度下降,增加背光模组及显示装置的功耗。
基于此,本公开的一些示例中,采用3D打印工艺形成反射层130,使得发光器件120与相应的第一开口131a的侧壁的间距范围为,0.05mm~0.3mm。
示例性的,发光器件120与相应的第一开口131a的侧壁的间距可以为,0.30mm、0.23mm、0.18mm、0.12mm或0.05mm。
采用上述设置方式,可以使得发光器件120与相应的第一开口131a的侧壁的空隙较小,进而可以缓解由于发光器件120发出的光入射至发光器件120与第一开口131a之间的空隙而造成光线的损失,进而可以提高反射层130的反射率,增大发光基板100的光效,进而可以降低背光模组10及显示装置1的功耗。
示例性的,本公开的上述一些实施例所制备形成的反射层130的边缘,也会呈现3D打印工艺特有的形貌。
例如,如图11a所示,反射层130在衬底110上的正投影的一个边包括多个曲线段。或者,反射层130在衬底110上的正投影的多个边均包括多个曲线段。
示例性的,上述多个曲线段中的一个曲线段可以朝向衬底110的边缘方向凸出。上述多个曲线段可以均朝向衬底110的边缘方向凸出。
图11a中的两条虚线两侧表示反射层130中靠近边缘的部分的示意图,该图未示意反射层130中的开口130。图11b所示为图11a所对应的反射层130的实物的局部图。
在一些实施例中,在上述S300的采用3D打印工艺,在衬底110上形成反射层130之前,发光基板100的制备方法还包括S210a。
S210a,如图12a所示,在衬底110上固定多个驱动芯片140。该多个驱动芯片140沿第一方向X呈多列排列,沿第二方向Y呈多行排布。一行驱动芯片140位于一个第二打印区域P2。
需要说明的是,为方便表示出后续的制备方法细节,在图12a中仅示意出了一个驱动芯片140。
示例性的,多个驱动芯片140与多个发光器件120位于衬底110的同一侧。
在一些示例中,一个驱动芯片140与至少一个发光器件120电连接,且驱动芯片140被配置为,驱动至少一个发光器件120发光。
示例性的,一个驱动芯片140可以与一个发光器件120电连接,且驱动该发光器件120发光。
示例性的,如图13所示,一个驱动芯片140可以与四个发光器件120电连接,且驱动该四个发光器件120发光。
示例性的,一个驱动芯片140可以与九个发光器件120电连接,且驱动该九个发光器件120发光。
示例性的,以一个驱动芯片140驱动四个发光器件120为例进行说明。
驱动芯片140与其所驱动的四个发光器件120之间的相对位置关系有多种,可以根据实际需要进行设置。
示例性的,如图13所示,由一个驱动芯片140所驱动的四个发光器件可以排布为两行两列,该驱动芯片140可以位于任一列发光器件120的正对下方(如图13中(a)所示),该驱动芯片140可以也可以位于两列发光器件120的之间(如图13中(b)所示)。或者,四个发光器件120错位排布,驱动芯片140随机排布在四个发光器件120之间的位置(如图13中(c)所示)。
下面以由一个驱动芯片140所驱动的四个发光器件排布为两行两列,且该驱动芯片位于任一列发光器件120的正对下方为例,进行说明。
在一些示例中,反射层130的多个开口131还包括多个第二开口131b。
在一些示例中,上述S300中,采用3D打印工艺,在衬底110上形成反射层130的步 骤,还包括S330a。
S330a,如图12b所示,采用直线打印工艺,在各行驱动芯片140相对两侧的两个第一打印区域P1形成第一反射图案,采用虚线打印工艺,在各第二打印区域中任意相邻两个驱动芯片140之间形成第二反射图案。各驱动芯片140周围的第一反射图案与第二反射图案围成第二开口131b。第二开口131b的至少一个侧壁,与衬底110之间的夹角为锐角,和/或,第二开口131b的至少一个壁面为曲面。
需要说明的是,为方便表示出后续的制备方法细节,在图12b中仅示意出了一个驱动芯片140。
在一些示例中,多个驱动芯片140与多个第二开口131b一一对应,且一个驱动芯片140位于一个第二开口131b内。
示例性的,第一开口131a的尺寸与发光器件120的尺寸有关,第二开口131b的尺寸与驱动芯片140的尺寸有关。在一个驱动芯片140的尺寸大于一个发光器件120的尺寸的情况下,第二开口131b在衬底110上的正投影面积,可以大于第一开口131a在衬底110上的正投影面积。
例如,驱动芯片140与相应的第二开口131b的侧壁的间距范围为0.05mm~0.3mm。
示例性的,由于第一开口131的侧壁与第二开口131b的侧壁均由第一反射图案的一部分边缘和第二反射图案的一部分组成,第一开口131和第二开口131b的结构特征可以相同。具体地,可参考前文中关于第一开口131a的结构特征的描述,此处不再赘述。
示例性的,在上述步骤S330a中,在各行驱动芯片140相对两侧的两个第一打印区域P1形成第一反射图案的过程,也可以采用虚线打印工艺,由于虚线打印工艺的打印精度高于直线打印工艺的打印精度,这样可以提高各驱动芯片140周围的第一反射图案与第二反射图案围成第二开口131b的精确度。
示例性的,多个驱动芯片140与反射层130上的第二开口131b的对应关系有多种,可以根据实际需要进行反射层140的制作。
例如,上述实施例中的多个驱动芯片140是与多个第二开口131b一一对应,一个驱动芯片140位于一个第二开口131b内,也就是多个驱动芯片140裸露于反射层130上。
又如,而在下文的另一些实施例中,多个驱动芯片140中的至少一个驱动芯片140在衬底110上的正投影,位于反射层130在衬底110上的正投影范围内。也就是说,至少一个驱动芯片140被反射层130覆盖,其对应的位置处没有第二开口131b。这样,可以减少反射层130上的第二开口131b的数量,进而可以简化反射层130的制备工艺。
在另一些实施例中,上述S300中,采用3D打印工艺,在衬底110上形成反射层130的步骤之前,还包括S210b。
S210b,如图14a所示,在衬底110上固定多个驱动芯片140。多个驱动芯片140沿第一方向X呈多列排列,沿第二方向Y呈多行排布。至少一个驱动芯片140位于多个第三打印区域P3。
示例性的,多个驱动芯片140与多个发光器件120位于衬底110的同一侧。
示例性的,一个驱动芯片140与至少一个发光器件120电连接,且驱动芯片140被配置为,驱动至少一个发光器件120发光。
例如,一个驱动芯片140可以与四个发光器件120电连接,且驱动该发光器件120发光。
示例性的,反射层130的多个开口131还包括多个第二开口131b。
在一些示例中,上述S300中,采用3D打印工艺,在衬底110上形成反射层130的步骤,还包括S330b。
S330b,如图14b所示,采用直线打印工艺,在至少一个驱动芯片140所在的第三打印区域P3形成多个第三反射图案。至少一个驱动芯片140在衬底110上的正投影,位于多个第三反射图案在衬底110上的正投影范围之内。
示例性的,如图14b所示,一个或多个驱动芯片140被多个第三反射图案组成的图案覆盖,使得该一个或多个驱动芯片140在反射层130上未裸露。
示例性的,衬底110上的所有驱动芯片140在衬底110上的正投影,均位于多个第三反射图案在衬底110上的正投影范围之内。
采用上述设置方式,不仅可以简化反射层130的制备工艺,降低打印胶阀的打印路径的设计难度,缩短3D打印形成反射层130的时间,还可以增大反射层130在衬底110所在平面上所占据的面积比例,进而可以增大反射率,提高发光器件120的光效。此外,上述设置方式,还可以提高上述至少一个驱动芯片140的封装效果,可以进一步避免水汽入侵至驱动芯片140内而导致的驱动芯片140腐蚀或漏电等不良现象。
需要说明的是,上述3D打印工艺中,直线打印工艺的打印步径大于或等于虚线打印工艺的打印步径,使得虚线打印工艺的打印速度低于直线打印的打印速度,因此,采用虚线打印工艺的时间,对整体打印时间有较大的影响。而虚线打印工艺主要用于限定开口131的尺寸。由此,采用虚线打印工艺的面积越小,整体的打印时间则相对越短,打印效率会得到提高。因此,在发光基板100上的所有驱动芯片140均被反射层130覆盖的方案(即上文中提到的衬底110上的所有驱动芯片140在衬底110上的正投影,均位于多个第三反射图案在衬底110上的正投影范围之内)中反射层130的打印时间,远小于多个驱动芯片140与多个第二开口131b一一对应的方案中反射层130的打印时间,使得虚线打印工艺的时间缩短一半左右,打印效率大约可提升50%。
示例性的,由于采用3D打印形成反射层130,上述至少一个驱动芯片140的侧面或顶面与反射层130的相对形貌特征有多种情况,具体地,上述形貌特征与反射层130的材料及3D打印具体工艺参数等相关。下面介绍几种情况,但本公开的实施例并不局限于以下几种情况。
在一些示例中,如图15a所示,反射层130中与上述至少一个驱动芯片140的顶面接触的部分的厚度,小于或等于反射层130中与衬底110接触的部分的厚度。
例如,反射层130中与上述至少一个驱动芯片140的顶面接触的部分的厚度,等于反射层130中与衬底110接触的部分的厚度。
又如,反射层130中与上述至少一个驱动芯片140的顶面接触的部分的厚度,小于反射层130中与衬底110接触的部分的厚度。
在采用直线工艺,在至少一个驱动芯片140所在的第三打印区域P3形成多个第三反射图案的过程中,由于该至少一个驱动芯片140相对于在衬底110的其他区域来说,是凸出于衬底110上的,使得打印至上述驱动芯片140顶部的反射层140材料会缓慢流动至靠近驱动芯片140侧面的位置,进而使得上述驱动芯片140顶部的反射层略小于反射层140中与衬底110接触部分的厚度。
在一些示例中,如图15a及图15b所示,至少一个驱动芯片140的侧面,与反射层130 之间具有间隙。
示例性的,在3D打印过程中,由于打印喷阀距离衬底110及上述至少一个驱动芯片140的顶面及侧面等预打印表面存在一定的距离,在打印喷阀打出的反射层材料接触上述预打印表面的过程中,会有部分气体未及时溢出,进而使得至少一个驱动芯片140的侧面,与反射层130之间存在间隙。
在一些示例中,如图15c所示,反射层130在至少一个驱动芯片140的侧面处断开。
示例性的,反射层130中与至少一个驱动芯片140的侧面处接触的部分,与反射层130中与至少一个驱动芯片140的顶面处接触的部分,没有相连接。
需要说明的是,对于一个长方形形状的发光基板100来说,3D打印的打印路径沿该长方形的长边方向或该长方形的短边方向,也在一定程度上影响着反射层130的打印效率,具体地,可以根据实际情况进行择优选择打印路径,进而可以提高反射层130的打印效率。
示例性的,3D打印设备的打印喷头的数量可以是1个或者多个(此处,3D打印设备的打印喷头与打印喷阀为一一对应设置,一个打印喷头对应一个打印喷阀,因此打印喷头的数量即为打印喷阀的数量),为了满足生产效率,一般打印喷头为多头设计,打印喷头的数量需要与发光基板100中开口131的行数或列数进行匹配设计。比如在发光基板100中开口131行列数为96行*48列的情况下,虚线打印工艺的打印喷头数量可以选择1个、2个、4个、8个、12个、24个或48个等。选择的打印喷头的数量一般可以被开口的行数或列数整除。而直线打印工艺中与开口131的行列数无关。
在一些示例中,在上述3D打印工艺中,直线打印工艺的打印方向与虚线工艺的打印方向,相同或相互垂直。
示例性的,如图12b所示,直线打印工艺的打印方向为第一方向X,虚线工艺的打印方向也为第一方向X,两者方向相同。
示例性的,如图16所示,直线打印工艺的打印方向为第一方向X,虚线工艺的打印方向为第二方向Y,两者方向相互垂直。
示例性的,上述发光基板100的制备方法还包括S400。
S400,对发光器件120进行封装。
示例性的,如图22a~图22c所示,可以采用封装胶形成封装层160,对发光器件120进行封装,从而可以避免水汽入侵至发光器件120的内部,避免影响发光器件120的发光。
示例性的,在对发光器件120进行封装的过程中,也可以对驱动芯片140进行封装。由此,可以避免水汽入侵至驱动芯片140造成驱动芯片140的腐蚀或漏电问题,从而可以提高驱动芯片140的良率。
下面,本公开对一种发光基板100的反射层130的打印时间的计算方法进行举例说明。
需要说明的是,下面的示例中,为提高第一开口131a及第二开口131b的精确度,与第二打印区域P2相邻的第一打印区域P1均采用的是虚线打印工艺。
具体地,该发光基板100中,包括两列发光器件120,两列驱动芯片140,3D打印设备的打印喷阀的数量为1列。对一列发光器件120对应的第二打印区域及第一打印区域进行打印形成第一开口131a,打印喷头所使用的时间为第一工作时间为T1。在一列驱动芯片140分别位于对应的第二开口131b的情况下,打印一列驱动芯片140对应的第二打印区域及第一打印区域并围成的第二开口131b的过程,打印喷头所使用的时间为第二工作时间为T2。
示例性的,在上述两列驱动芯片140均位于第三打印区域P3的情况下,虚线打印工艺的打印时间T为2T1。
示例性的,在上述一列驱动芯片140位于第三打印区域P3,另一列驱动芯片位于第二打印区域P2的情况下,虚线打印工艺的打印时间T为2T1+T2。
示例性的,在上述两列驱动芯片140均位于第二打印区域P2的情况下,虚线打印工艺的打印时间T为2T1+2T2。
由于T1、T2均大于0,则2T1+2T2>2T1+T2>2T1。
由此可知,在驱动芯片140均位于第三打印区域P3的情况下,虚线打印工艺的打印时间最短,有利于提高3D打印工艺形成反射层130的效率。
此外,如图17a所示,在发光基板100的尺寸为802mm*341mm,发光器件120为48行,驱动芯片为24行,虚线打印工艺的打印喷头的数量为24个,发光器件120的尺寸为0.15mm*0.51mm,驱动芯片140的尺寸为0.41mm*0.41mm,虚线打印的打印速度为100mm/s,无效行程500mm,虚线打印工艺的打印步径为0.3mm,循环换行的时间为0.1s,打印方向OP为第一方向X的情况下,可以得到,打印喷头的一次打印时间为13s(具体由(800+500)/100计算得到),一行发光器件120需要循环打印4次,一行驱动芯片140需要循环打印5次,打印一列发光器件120所对应的第一开口131a的过程,打印喷头的第一工作时间T1为52.3s(具体由(4*13+0.1*3)计算得到),打印一行驱动芯片140所对应的第二开口131b的过程,打印喷头的第二工作时间T2为65.4s(具体由(5*13+0.1*4)计算得到)。
示例性的,在上述24行驱动芯片140均位于第三打印区域P3的情况下,虚线打印工艺的打印时间T为2T1,计算可得为104.6s。
示例性的,在上述一行驱动芯片140位于第三打印区域P3,另一行驱动芯片位于第二打印区域P2的情况下,虚线打印工艺的打印时间T为2T1+T2,计算可得为170s。
示例性的,在上述24行驱动芯片140均位于第二打印区域P2的情况下,虚线打印工艺的打印时间T为2T1+2T2,计算可得为235.4s。
由此可知,驱动芯片140均位于第二打印区域P2的情况下虚线打印工艺的打印时间为,在驱动芯片140均位于第三打印区域P3的情况下虚线打印工艺的打印时间的二倍多,可见,选择合适的打印路径及打印方式,可以极大地提高3D打印工艺形成反射层130的效率。
本公开的一些实施例还提供一种发光基板100,该发光基板100例如可以为采用上述任一实施例所述的制备方法所制成的发光基板。
下面对上述发光基板100的结构进行介绍。
在一些实施例中,如图3所示,上述发光基板100,包括:衬底110,以及设置衬底110一侧的多个发光器件120、反射层130。
示例性的,衬底110可以为玻璃衬底、PCB衬底等。
示例性的,上述多个发光器件120的结构特征,可参考本文中上述一些实施例中的描述,此处不再赘述。
在一些示例中,反射层130具有多个开口131,多个开口131包括多个第一开口131a;一个发光器件120位于一个第一开口131a内。
示例性的,第一开口131a与发光器件120对应设置。
示例性的,发光器件120位于相应的第一开口131a的中心位置。
在一些示例中,反射层130远离衬底110一侧的表面具有多个凸起结构132。
示例性的,由于反射层130可以采用上述任一实施例中的3D打印工艺形成,反射层130的一侧表面具有多个凸起结构132。
本公开的一些实施例所提供的发光基板100所能实现的有益效果,与上述一些实施例中提供的发光基板100的制备方法所能实现的有益效果相同,此处不再赘述。
在一些实施例中,如图18a所示,反射层130包括多个第一部分133和多个第二部分134,第一部分133为反射层130中与凸起结构132相对应的部分,第二部分134为反射层130中位于相邻两个凸起结构132之间的部分。
示例性的,第二部分134为反射层130中厚度最小的部分。反射层130中,第一部分133和第二部分134交替分布。
在一些示例中,第一部分133的厚度,与第二部分134的厚度的差值,小于或等于20μm。
示例性的,第一部分133的不同区域的厚度不同,此处第一部分133的厚度指的是第一部分133的最大厚度或平均厚度。
例如,第一部分133的厚度,与第二部分134的厚度的差值,可以为20μm、18μm、15μm、10μm、8μm或6μm。
以反射层130的平均厚度为55μm为例,采用上述设置方式,第一部分133的最大厚度约为65μm,第二部分134的厚度约为45μm,反射层130的不同区域对应的厚度波动较小,可以满足反射层130的反射率要求,进而保证发光基板100的光效。
在另一些示例中,第一部分133的厚度与第二部分134的厚度的差值,小于或等于反射层130的厚度的20%。
此处,反射层的厚度例如指的是,反射层的整体平均厚度。
示例性的,第一部分133的厚度与第二部分134的厚度的差值,可以为反射层130的厚度的20%、18%、15%、10%或8%。
采用上述设置方式,使得反射层130的不同区域对应的厚度差异较小,可以满足反射层130的反射率要求,进而避免影响发光基板100的光效。
在又一些示例中,第一部分133的厚度,与第二部分134的厚度的差值,小于或等于20μm。且所述第一部分的厚度与所述第二部分的厚度的差值,小于或等于所述反射层的厚度的20%。
采用上述设置方式,可以进一步保证反射层130的不同区域对应的厚度差异较小,进而可以满足反射层130的反射率要求,避免影响发光基板100的光效。
在一些示例中,如图19所示,开口131的至少一个侧壁呈曲面状。
例如,开口131的一个侧壁或多个侧壁均呈曲面状。
示例性的,由于开口131是由第一反射图案的一部分边缘及第二反射图案的一部分边缘围绕而成,使得开口131的至少一个侧壁呈曲面状。
采用上述设置方式,在发光器件120发出的光线入射至第一开口131a的侧壁的情况下,在该侧壁处发生反射并大致朝着发光基板100的出光方向出射,进而避免光线的损失,提高发光基板100的光效。
在一些实施例中,如图19所示,发光器件120与相应的第一开口131a的侧壁的间距 范围为,0.05mm~0.3mm。
示例性的,发光器件120与相应的第一开口131a的侧壁的间距可以为,0.3mm、0.22mm、0.17mm、0.08mm或0.05mm。
采用上述设置方式,可以使得发光器件120与相应的第一开口131a的侧壁的间距较小,进而可以缓解由于发光器件120发出的光入射至发光器件与第一开口之间的区域而造成光线的损伤,进而可以提高反射层130的反射率,增大发光基板100的光效,进而可以降低背光模组10及显示装置1的功耗。
在一些实施例中,如图19所示,第一开口131a的至少一个侧壁,与衬底110之间的夹角α为锐角。
示例性,第一开口131a的一个侧壁与衬底110的夹角为锐角。或,第一开口131a的两个或更多个侧壁与衬底110的夹角均为锐角。
示例性的,第一开口131a在俯视图中的形状可以为矩形,也可以为圆形等,以图3中所示的第一开口131a的俯视图中的形状为矩形为例,则第一开口131a具有四个侧壁,第一开口131a的一个或多个侧壁与衬底110之间的夹角均为锐角,也就是说围成第一开口131a的一个或多个侧壁是向开口中心凸出的。
采用上述设置方式,在发光器件120发出的光线入射至第一开口131a的侧壁的情况下,在该侧壁处发生反射并大致朝着发光基板100的出光方向出射,进而避免光线的损失,提高发光基板100的光效。
在一些实施例中,如图18a所示,上述凸起结构132远离衬底110的一侧的表面呈弧面状。
示例性的,上述弧面状,沿远离衬底110的方向向外凸出。
采用上述设置方式,可以提高从反射层130出射的光线的均一性。
需要说明的是,凸起结构132的延伸方向及排布方式,主要由3D打印工艺的打印路径决定。
示例性的,在3D打印工艺的打印路径的打印方向OP为第一方向X的情况下,多个凸起结构132沿第一方向X延伸,沿第二方向Y呈多行排布。
示例性的,如图18a及图18b所示,在3D打印工艺的打印路径的打印方向OP为第二方向Y的情况下,多个凸起结构132沿第二方向Y延伸,沿第一方向X呈多列排布。
在一些示例中,如图18a所示,多个凸起结构132包括:多个第一凸起结构132a和多个第二凸起结构132b。
示例性的,多个第一凸起结构132a和多个第二凸起结构132b的延伸及排布方式有多种。
例如,如图18a所示,多个第一凸起结构132a和多个第二凸起结构132b的延伸方向可以相同。多个第一凸起结构132a可以沿第二方向Y延伸,多个第一凸起结构132a沿第一方向X呈多列排布,第二凸起结构132b也可以沿第二方向Y延伸,且多个第二凸起结构132b沿第一方向X呈多列排布。
例如,多个第一凸起结构132a和多个第二凸起结构132b的延伸方向可以不同。多个第一凸起结构132a可以沿第一方向X延伸,多个第一凸起结构132a沿第二方向Y呈多行排布,第二凸起结构132b可以沿第二方向Y延伸,且多个第二凸起结构132b沿第一方向X呈多列排布。
在一些示例中,第一凸起结构132a在沿多个第一凸起132a的排布方向上的尺寸M1,大于或等于,第二凸起结构132b在沿多个第二凸起132b的排布方向上的尺寸M2。
示例性的,如图20所示,以第一凸起结构132a和第二凸起结构132b的延伸方向均为第一方向X为例,则第一凸起结构132a和第二凸起结构132b均沿第二方向Y排布,第一凸起结构132a沿第二方向Y的尺寸M1,大于或等于第二凸起结构132b沿第二方向Y的尺寸M2。
在进行3D打印工艺形成反射层130的过程中,3D打印设备每打印一个打印条可以形成一个凸起结构132,第一凸起结构132a沿其排布方向的尺寸较大,由此,可以减少打印条的数量,进而可以提高3D打印的效率。且由于第二凸起132b沿其排布方向的尺寸较小,进而在反射层130的边缘或开口131的周围可以打印形成第二凸起结构132b,进而可以精准控制所形成反射层130的尺寸精度,进而可以提高采用3D打印工艺形成反射层130的精度。
此外,也可以使得打印形成的多个第一凸起结构131a的数量大于多个第二凸起结构132b的数量,由此,可以使得进一步地减少打印条的数量,进而可以提高采用3D打印工艺形成反射层130的效率。
在一些示例中,如图20所示,反射层130在衬底110上的正投影的至少一个边包括多个曲线段,至少一个曲线段朝向衬底110的边缘方向凸出。
图20中的两条虚线两侧表示反射层130中靠近边缘的部分的示意图,该图未示意反射层130中的开口130。
示例性的,反射层130在衬底110上的正投影的一个边包括多个曲线段。或者,反射层130在衬底110上的正投影的多个边均包括多个曲线段。
示例性的,上述多个曲线段中的一个曲线段可以朝向衬底110的边缘方向凸出。上述多个曲线段可以均朝向衬底110的边缘方向凸出。
采用上述设置方式,在发光器件120发出的光线入射反射层130的边缘的情况下,在该边缘处发生反射并大致朝着发光基板100的出光方向出射,进而避免光线的损失,提高发光基板100的光效。
在一些示例中,如图19所示,反射层130中,靠近衬底110的边缘的至少一个侧面与衬底110的夹角β为锐角。
例如,反射层130中,靠近衬底110的边缘的一个侧面与衬底110的夹角为锐角。
又如,反射层130中,靠近衬底110的边缘的多个侧面与衬底110的夹角均为锐角。
例如,反射层130中,靠近衬底110的边缘的至少一个侧面与衬底110的夹角为30°、50°、60°、70°或80°。
示例性的,反射层130中,靠近衬底110的边缘的侧面与衬底110的夹角β,与第一开口131a的侧壁与衬底110的夹角α可以相同,也可以不同。
采用上述设置方式,在发光器件120发出的光线入射反射层130的侧面的情况下,在该侧面处发生反射并大致朝着发光基板100的出光方向出射,进而避免光线的损失,提高发光基板100的光效。
在一些实施例中,如图17a所示,发光基板100还包括:设置在衬底110一侧、且与多个发光器件120位于衬底110同一侧的多个驱动芯片140。
在一些示例中,一个驱动芯片140与至少一个发光器件120电连接,且驱动芯片140 被配置为,驱动至少一个发光器件120发光。
示例性的,一个驱动芯片140可以与一个发光器件120电连接,且驱动该发光器件120发光。
示例性的,一个驱动芯片140可以与四个发光器件120电连接,且驱动该四个发光器件120发光。
示例性的,一个驱动芯片140可以与九个发光器件120电连接,且驱动该九个发光器件120发光。
示例性的,以一个驱动芯片140驱动四个发光器件120为例进行说明。
驱动芯片140与其所驱动的四个发光器件120之间的相对位置关系有多种,可以参考本公开上文的一些实施例中的说明,此处不再赘述。
在一些示例中,如图17a所示,多个开口131还包括多个第二开口131b。一个驱动芯片140位于一个第二开口131b内。
示例性的,一个驱动芯片140与一个第二开口131b对应设置,且驱动芯片140位于相应的第二开口131b的中心。
示例性的,如图19所示,驱动芯片140与相应的第二开口131b的侧壁的间距范围为0.05mm~0.30mm。
例如,驱动芯片140与相应的第二开口131b的侧壁的间距可以为0.05mm、0.12mm、0.18mm、0.23mm或0.30mm。
采用上述设置方式,可以使得驱动芯片140与相应的第二开口131b之间的间距较小,进而可以使得反射层130在衬底110上占据的面积比例较大,进而可以提高反射层130的反射率,进一步提高发光基板100的发光效率。
在一些示例中,如图21a所示,至少一个驱动芯片140在衬底110上的正投影,位于反射层130在衬底110上的正投影范围之内。
图21b为图21a所对应的发光基板100的实物局部图。
示例性的,一个驱动芯片140在衬底110上的正投影,位于反射层130在衬底110上的正投影范围之内,也就是说,一个驱动芯片140被反射层130覆盖,其余的多个驱动芯片140均位于第二开口131b中。
示例性的,一行驱动芯片140在衬底110上的正投影,位于反射层130在衬底110上的正投影范围之内,也就是说,一行驱动芯片140被反射层130覆盖,其余的多个驱动芯片140均位于第二开口131b中。
采用上述设置方式,可以减少反射层130上的第二开口131b的数量,进而可以简化反射层130的制备工艺。此外,反射层130还可以对驱动芯片140起到一定的保护作用,避免外界水汽入侵驱动芯片140,进而可以避免使得驱动芯片140失效。
在一些实施例中,如图22a所示,反射层130中与上述至少一个驱动芯片140的顶面接触的部分的厚度,小于或等于反射层130中与衬底110接触的部分的厚度。
例如,反射层130中与上述至少一个驱动芯片140的顶面接触的部分的厚度,等于反射层130中与衬底110接触的部分的厚度。
又如,反射层130中与上述至少一个驱动芯片140的顶面接触的部分的厚度,小于反射层130中与衬底110接触的部分的厚度。
在采用直线工艺,在至少一个驱动芯片140所在的第三打印区域P3形成多个第三反 射图案的过程中,由于该至少一个驱动芯片140相对于在衬底110的其他区域来说,是凸出于衬底110上的,使得打印至上述驱动芯片140顶部的反射层140材料会缓慢流动至靠近驱动芯片140侧面的位置,进而使得上述驱动芯片140顶部的反射层略小于反射层140中与衬底110接触部分的厚度。
在一些示例中,如图22a及图22b所示,至少一个驱动芯片140的侧面,与反射层130之间具有间隙。
示例性的,在3D打印过程中,由于打印喷头距离衬底110及上述至少一个驱动芯片140的顶面及侧面等预打印表面存在一定的距离,在打印喷头打出的反射层材料接触上述预打印表面的过程中,会有部分气体未及时溢出,进而使得至少一个驱动芯片140的侧面,与反射层130之间存在间隙。
在一些示例中,如图22c所示,反射层130在至少一个驱动芯片140的侧面处断开。
示例性的,反射层130中与至少一个驱动芯片140的侧面处接触的部分,与反射层130中与至少一个驱动芯片140的顶面处接触的部分,没有相连接。
在一些示例中,如图23a所示,多个驱动芯片140在衬底110上的正投影,位于反射层130在衬底110上的正投影范围之内。
图23b为图23a所对应的发光基板100的实物局部图。
采用上述设置方式,可以减少反射层130上的开口131的数量,进而可以简化反射层130的制备工艺。此外,反射层130还可以对驱动芯片140起到一定的保护作用,避免外界水汽入侵驱动芯片140而导致的驱动芯片140腐蚀或漏电等不良现象。
在一些示例中,如图23a所示,发光基板100还包括:绑定结构150。其中,绑定结构150例如与驱动芯片140电连接。
示例性的,绑定结构150位于发光基板100靠近边缘的一侧。绑定结构150用于传输不同类型的工作信号至驱动芯片140,驱动芯片140可以根据该不同类型的工作信号生成驱动信号,并将该驱动信号传输至相应的发光器件120。
示例性的,绑定结构150所在的区域,未被反射层130覆盖。
示例性的,上述绑定结构150可以采用COF(Chip On Film,覆晶薄膜)实现与PCB或FPC(Flexible Printed Circuit,柔性电路板)的绑定。
以上所述,仅为本公开的具体实施方式,但本公开的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本公开揭露的技术范围内,想到变化或替换,都应涵盖在本公开的保护范围之内。因此,本公开的保护范围应以所述权利要求的保护范围为准。
Claims (22)
- 一种发光基板,包括:衬底,以及设置所述衬底一侧的多个发光器件、反射层;所述反射层具有多个开口,所述多个开口包括多个第一开口;一个发光器件位于一个第一开口内;其中,所述反射层远离所述衬底一侧的表面具有多个凸起结构。
- 根据权利要求1所述的发光基板,其中,所述反射层包括多个第一部分和多个第二部分,第一部分为所述反射层中与凸起结构相对应的部分,第二部分为所述反射层中位于相邻两个凸起结构之间的部分;所述第一部分的厚度,与所述第二部分的厚度的差值,小于或等于20μm;和/或,所述第一部分的厚度与所述第二部分的厚度的差值,小于或等于所述反射层的厚度的20%。
- 根据权利要求1或2所述的发光基板,其中,所述发光器件与相应的所述第一开口的侧壁的间距范围为0.05mm~0.3mm。
- 根据权利要求1~3中任一项所述的发光基板,其中,所述第一开口的至少一个侧壁与所述衬底之间的夹角为锐角。
- 根据权利要求1~4中任一项所述的发光基板,其中,所述第一开口的至少一个侧壁呈曲面状。
- 根据权利要求1~5中任一项所述的发光基板,其中,凸起结构远离所述衬底的一侧表面呈弧面状。
- 根据权利要求1~6中任一项所述的发光基板,其中,所述多个凸起结构包括多个第一凸起结构及多个第二凸起结构;所述多个第一凸起结构沿第一方向延伸,所述多个第一凸起结构沿第二方向呈多行排布;所述多个第二凸起结构沿第一方向延伸,所述多个第二凸起结构沿第二方向呈多行排布,或,所述多个第二凸起结构沿第二方向延伸,所述多个第二凸起结构沿第一方向呈多列排布;所述第一方向和所述第二方向相交。
- 根据权利要求7所述的发光基板,所述第一凸起结构在所述多个第一凸起的排布方向上的尺寸,大于或等于,所述第二凸起结构在所述多个第二凸起的排布方向上的尺寸。
- 根据权利要求1~8中任一项所述的发光基板,其中,所述反射层在所述衬底上的正投影的至少一条边包括多个曲线段,至少一个曲线段朝向所述衬底的边缘方向凸出。
- 根据权利要求1~9中任一项所述的发光基板,其中,所述反射层中,靠近所述衬底的边缘的至少一个侧面与所述衬底的夹角为锐角。
- 根据权利要求1~10中任一项所述的发光基板,还包括:设置在所述衬底一侧、且与所述多个发光器件位于所述衬底同一侧的多个驱动芯片;一个驱动芯片与至少一个发光器件电连接,所述驱动芯片被配置为,驱动所述至少一个发光器件发光;所述多个开口还包括多个第二开口;一个驱动芯片位于一个第二开口内。
- 根据权利要求1~10中任一项所述的发光基板,还包括:设置在所述衬底一侧、且与所述多个发光器件位于所述衬底同一侧的多个驱动芯片;一个驱动芯片与至少一个发光 器件电连接,且所述驱动芯片被配置为,驱动所述至少一个发光器件发光;至少一个驱动芯片在所述衬底上的正投影,位于所述反射层在所述衬底上的正投影范围之内。
- 根据权利要求12所述的发光基板,其中,所述反射层中与所述驱动芯片的顶面接触的部分的厚度,小于或等于所述反射层中与所述衬底接触的部分的厚度。
- 根据权利要求12或13所述的发光基板,其中,所述驱动芯片的至少一个侧面,与所述反射层之间具有间隙。
- 根据权利要求12~14中任一项所述的发光基板,其中,所述反射层在所述驱动芯片的至少一个侧面处断开。
- 一种发光基板的制备方法,包括:提供衬底;在所述衬底上固定多个发光器件;采用3D打印工艺,在所述衬底上形成反射层;所述反射层具有多个开口,所述多个开口包括多个第一开口;一个发光器件位于一个第一开口内;其中,所述反射层远离所述衬底一侧的表面具有多个凸起结构。
- 根据权利要求16所述的制备方法,其中,所述多个发光器件沿第一方向呈多列排列,沿第二方向呈多行排布;所述衬底具有沿所述第一方向延伸的多个第一打印区域、多个第二打印区域及多个第三打印区域;所述多个第二打印区域和所述多个第三打印区域交替设置,第一打印区域位于任意相邻的第二打印区域和第三打印区域之间;一行发光器件位于一个第二打印区域内;所述采用3D打印工艺,在所述衬底上形成反射层,包括:采用直线打印工艺,在各行发光器件相对两侧的两个第一打印区域形成第一反射图案,采用虚线打印工艺,在各第二打印区域中任意相邻两个发光器件之间形成第二反射图案;各发光器件周围的第一反射图案与第二反射图案围成所述第一开口;所述第一开口的至少一个侧壁,与所述衬底之间的夹角为锐角,和/或,所述第一开口的至少一个侧壁为曲面;采用直线打印工艺,在所述第三打印区域形成第三反射图案。
- 根据权利要求17所述的制备方法,其中,在所述采用3D打印工艺,在所述衬底上形成反射层之前,所述制备方法还包括:在所述衬底上固定多个驱动芯片;所述多个驱动芯片沿第一方向呈多列排列,沿第二方向呈多行排布;一行驱动芯片位于一个第二打印区域;所述多个开口还包括多个第二开口;所述采用3D打印工艺,在所述衬底上形成反射层,还包括:采用直线打印工艺,在各行驱动芯片相对两侧的两个第一打印区域形成第一反射图案,采用虚线打印工艺,在各第二打印区域中任意相邻两个驱动芯片之间形成第二反射图案;各驱动芯片周围的第一反射图案与第二反射图案围成第二开口;所述第二开口的至少一个侧壁,与所述衬底之间的夹角为锐角,和/或,所述第二开口的至少一个壁面为曲面。
- 根据权利要求17所述的制备方法,其中,在所述采用3D打印工艺,在所述衬底上形成反射层之前,所述制备方法还包括:在所述衬底上固定多个驱动芯片;所述多个驱动芯片沿第一方向呈多列排列,沿第二 方向呈多行排布;至少一个驱动芯片位于所述多个第三打印区域;所述采用3D打印工艺,在所述衬底上形成反射层,还包括:采用直线打印工艺,在所述至少一个驱动芯片所在的第三打印区域形成多个第三反射图案;所述至少一个驱动芯片在所述衬底上的正投影,位于所述多个第三反射图案在所述衬底上的正投影范围之内。
- 根据权利要求17~19中任一项所述的制备方法,其中,所述直线打印工艺的打印方向与所述虚线工艺的打印方向,相同或相互垂直。
- 一种背光模组,包括:如权利要求1~15中任一项所述的发光基板,以及位于所述发光基板的出光侧的光学膜片。
- 一种显示装置,包括:如权利要求21所述的背光模组;位于所述背光模组出光侧的彩膜基板;以及,位于所述背光模组与所述彩膜基板之间的阵列基板。
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CN215986820U (zh) * | 2021-06-22 | 2022-03-08 | 惠州视维新技术有限公司 | 背光模组 |
CN114527603A (zh) * | 2022-03-14 | 2022-05-24 | 武汉华星光电技术有限公司 | 背光模组和显示面板 |
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JP2006066282A (ja) * | 2004-08-27 | 2006-03-09 | Sharp Corp | バックライトユニット及びこれを用いた液晶表示装置 |
US20150160402A1 (en) * | 2013-04-07 | 2015-06-11 | Boe Technology Group Co., Ltd. | Light guiding plate and method for manufacturing the same and backlight source and display device comprising the same |
CN111061091A (zh) * | 2019-12-31 | 2020-04-24 | 厦门天马微电子有限公司 | 一种光学模组及显示装置 |
CN113126363A (zh) * | 2019-12-31 | 2021-07-16 | 海信视像科技股份有限公司 | 一种显示装置 |
CN113064301A (zh) * | 2021-03-15 | 2021-07-02 | 海信视像科技股份有限公司 | 一种显示装置 |
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CN114153095A (zh) * | 2021-12-02 | 2022-03-08 | 上海中航光电子有限公司 | 一种背光模组及其制备方法、显示装置 |
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