CN113835264A - 曲面背光模组及其制备方法 - Google Patents
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Abstract
本发明提供一种曲面背光模组及其制备方法。所述曲面背光模组包括由反射板、导光板、光学板组、光源构成的背光单元,以及依次设于所述背光单元边缘的固定层和限位层。所述曲面背光模组的制备方法包括设置卡扣,设置复合材料片材和热固性树脂,升温并施压,冷却等步骤。本发明提供的所述曲面背光模组及其制备方法解决了现有技术的曲面背光模组的各部分之间难以充分贴合、易分离,光源的位置易偏移等技术问题。
Description
技术领域
本发明涉及液晶显示技术领域,具体涉及一种曲面背光模组及其制备方法。
背景技术
曲面背光模组是曲面液晶显示器的关键零组件之一,用于供应充足的亮度与分布均匀的光源,使曲面液晶显示器能正常显示影像。曲面背光模组的基本结构是依次设置的反射板、导光板、光学板组,以及设于所述导光板侧面的光源(LED灯条),其常用的生产工艺是采用模具加压直屏背光模组使其弯曲。但由于曲面背光模组的各部分之间存在应力差,因此存在难以充分贴合、易分离等问题。
另外,为了保证光源发出的光线全部进入导光板内,光源应当尽可能准确的沿导光板的中心线布置。但在进行压弯加工过程中,光源设置的位置极易发生偏移,会导致导光板的直曲渐变处出现暗影或亮斑,严重影响曲面背光模组的正常使用。
发明内容
为解决现有技术的曲面背光模组的各部分之间难以充分贴合、易分离,光源的位置易偏移等技术问题,本发明提供一种解决上述问题的曲面背光模组的制备方法。
一种曲面背光模组,包括依次设置的反射板、导光板、光学板组,以及设于所述导光板侧面的光源,所述反射板、所述导光板、所述光学板组、所述光源构成背光单元,所述背光单元的边缘包有一圈固定层,所述固定层外包有一圈限位层。
在本发明提供的曲面背光模组的一种较佳实施例中,所述固定层为热塑性树脂;所述限位层为热固性树脂基复合材料。
一种曲面背光模组的制备方法,包括以下步骤:
步骤一:准备所述反射板、所述导光板、所述光学板组、所述光源、卡扣、复合材料片材、热固性树脂、加工设备;
步骤二:将所述反射板、所述导光板、所述光学板组、所述光源组装为所述背光单元,在所述背光单元的边缘卡满所述卡扣;
步骤三:于所述卡扣远离所述背光单元的外壁涂抹所述热固性树脂,并铺设所述复合材料片材,重复多次至合适厚度;
步骤四:将设置了所述卡扣、所述复合材料片材、所述热固性树脂的所述背光单元置于所述加工设备内,升温并施压,使所述卡扣软化、所述热固性树脂固化、所述背光单元弯曲;
步骤五:冷却后即得所述曲面背光模组。
在本发明提供的曲面背光模组的制备方法的一种较佳实施例中,所述卡扣为“C”形结构,其开口处宽度小于等于所述背光单元的厚度,开口内底面设有与所述光源衔接的凹槽。采用热塑性树脂制造。
在本发明提供的曲面背光模组的制备方法的一种较佳实施例中,所述卡扣远离所述背光单元的外壁采用热塑性树脂制造。
在本发明提供的曲面背光模组的制备方法的一种较佳实施例中,所述热固性树脂为低温固化的热固性树脂;所述卡扣所采用的热塑性树脂的软化温度低于所述热固性树脂的固化温度。
在本发明提供的曲面背光模组的制备方法的一种较佳实施例中,所述加工设备设备包括加热腔,设于所述加热腔内的弯曲施压设备、压实施压设备,所述背光单元设于所述压实施压设备内。
所述压实施压设备包括方框形的压实工装,围绕所述背光单元的边缘设置,在所述压实工装的内壁,即所述压实工装与所述背光单元之间处设有多个膨胀包,所述膨胀包内填充热膨胀材料。
所述弯曲施压设备以与所述压实施压设备、所述背光单元垂直的角度,对所述背光单元施压,使所述背光单元弯曲。
相较于现有技术,本发明提供的所述曲面背光模组在背光单元的边缘包覆有所述固定层和所述限位层,对所述光源的位置进行固定,也对所述背光单元的各部分进行固定,解决了因曲面背光模组的各部分之间应力差导致的难以充分贴合、易分离等问题。
相较于现有技术,本发明提供的所述曲面背光模组的制备方法采用热塑性树脂、热固性树脂和热膨胀材料的配合,在合适的温度下可以一次性完成曲面背光模组的弯曲、光源的固定、所述背光单元各部分的固定三个加工,工艺简单快捷,制得的产品质量好。
本发明提供的所述曲面背光模组的制备方法中通过设置所述卡扣,使得在加工前的组装过程中、加工时的压弯过程中、以及加工后的使用过程中均可以稳定的固定所述光源,保证产品质量。
本发明提供的所述曲面背光模组的制备方法中通过设置所述复合材料片材和所述热固性树脂来制得所述背光单元的固定框架,相较于传统的框架固定方式,其贴合性更好、稳固性更好。并且配合软化后的所述卡扣可以实现绑定加固的效果,抗冲击性能好。
本发明提供的所述曲面背光模组的制备方法中通过采用所述热膨胀材料对所述复合材料片材和所述热固性树脂来进行压实,相较于传统的机械压实、气压压实等方案,操作更简单、设备要求低。
附图说明
图1是曲面背光模组中背光单元的结构示意图;
图2是背光单元设置了部分卡扣后的结构示意图;
图3是图2的局部放大图;
图4是背光单元设置了卡扣、复合材料片材、热固性树脂后的结构示意图;
图5是背光单元设置了卡扣、复合材料片材、热固性树脂、部分压实施压设备后的结构示意图;
图6是图5的局部放大图;
图7是图5中压实施压设备的剖视图。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅是本发明的一部分实施例,而不是全部的实施例。
实施例1:
请参阅图1,是本发明提供的曲面背光模组中背光单元1的结构示意图。包括依次设置的长方形反射板11、导光板12、光学板组13,以及设于所述导光板12一面长边侧壁的灯条14。这部分与现有技术的背光模组基本一致,便不再赘述其具体结构。
所述曲面背光模组的制备方法包括以下步骤:
步骤1:提供所述背光单元1。
提供卡扣2、碳纤维片材、环氧树脂固化剂(起始固化温度70~ 130℃)、加工设备、膨胀石墨(起始膨胀温度70~150℃)。所述加工设备包括加热腔、弯曲施压设备、压实施压设备3。
请同时参阅图2和图3,分别是在所述背光单元1的基础上设置卡扣2的结构示意图,及其局部放大图。
步骤2:沿所述背光单元1的边缘等间距的设置多个所述卡扣2。附图中仅绘制了其中位于拐角处的一小部分。
所述卡扣2为PET材质(起始软化温度70~90℃)制得的“C”形结构,开口处卡在所述背光单元1边缘。亦可采用其他软化温度近似的材料,以进一步获得散热、抗冲击等其他性能。
所述卡扣2包括两种构型,一种构型的内壁光滑,卡在所述背光单元1没有设置所述灯条14的三侧;另一种构型的内壁设有两条卡槽,卡在所述背光单元1设置所述灯条14的一侧,两条卡槽正好将所述灯条14定位在所述导光板12侧壁的中心。
请参阅图4,是在所述步骤2中结构的基础上设置所述碳纤维片材和所述环氧树脂固化剂的结构示意图。
步骤3:沿所述背光单元1的边缘包覆所述碳纤维片材并涂抹所述环氧树脂固化剂,重复多次至将所述卡扣2完全覆盖。
步骤4:在所述背光单元1、所述卡扣2、所述碳纤维片材、所述环氧树脂固化剂构成的整体外包覆隔离膜(附图中未示出)。
请参阅图5和图6,分别是在所述步骤4中结构的基础上设置所述压实施压设备3的结构示意图,及其局部放大图。
步骤5:沿所述背光单元1、所述卡扣2、所述碳纤维片材、所述环氧树脂固化剂、所述隔离膜构成的整体边缘设置所述压实施压设备3。附图中仅绘制了其中位于拐角处的一小部分。
所述压实施压设备3为方框形结构,其中宽边为整体式结构,长边为多段分体式结构。长边包括多个梯形的施压单元31,均为等腰梯形的结构,在梯形的下底面处通过转轴与另一所述施压单元31或与宽边活动连接。两条宽边在中间处断开并通过卡销连接(附图中未示出),即所述压实施压设备3为相拼接的两部分构成。
请参阅图7,是所述压实施压设备3的剖视图。
所述压实施压设备3的横截面为与所述卡扣2近似的“C”形结构,采用耐压较强的钢材制作,并在内壁焊接有一层网板32。所述网板32内侧间隙插入有固体片状的所述膨胀石墨。
步骤6:将所述背光单元1、所述卡扣2、所述碳纤维片材、所述环氧树脂固化剂、所述隔离膜、所述压实施压设备3构成的整体置于所述弯曲施压设备,所述弯曲施压设备设于所述加热腔内。
由所述弯曲施压设备对上述整体向下施压,使所述背光单元1弯曲为目标形状。弯曲过程中所述卡扣2保持对所述灯条14的固定,避免其位置产生偏移。
同时所述加热腔对上述整体加热,在所述卡扣2开始软化的同时所述环氧树脂固化剂开始固化,转为由所述环氧树脂固化剂和所述碳纤维片材对所述灯条14进行固定,避免其位置产生偏移。
在所述卡扣2开始软化、所述环氧树脂固化剂开始固化的同时,所述膨胀石墨也开始膨胀。压紧所述所述环氧树脂固化剂和所述碳纤维片材,使其固化后的强度更佳;同时也压迫软化后的所述卡扣2流动,填充所述背光单元1边缘与所述碳纤维片材之间的间隙。
步骤7:所述加热腔在超过所述卡扣2的起始软化温度、所述环氧树脂固化剂的起始固化温度、所述膨胀石墨的起始膨胀温度后,继续少量升温并保温,所述弯曲施压设备保压,使所述步骤6中记载的变化持续进行,至完全的软化、固化、膨胀。
步骤8:冷却,并将所述背光单元1、所述卡扣2、所述碳纤维片材、所述环氧树脂固化剂、所述隔离膜、所述压实施压设备3构成的整体取出。依次移除所述压实施压设备3、所述隔离膜,修整溢出的少量PET,获得所述曲面背光模组的成品。
所述曲面背光模组包括所述所述背光单元1,包覆于所述背光单元1的固定层(所述卡扣2软化形成),包覆于所述固定层外的限位层(固化后的所述碳纤维片材和所述环氧树脂固化剂)。
实施例2:
与实施例1的区别在于:所述卡扣2的内壁,即与所述背光单元1和所述灯条14接触的部分采用耐热材料,外壁采用与实施例1中相同的材料。在置于所述加热腔内进行加工时,仅由外壁软化并填充满所述背光单元1边缘的间隙,包括所述背光单元1与所述卡扣2没有软化的部分之间,和与所述碳纤维片材之间的间隙。
以上所述仅为本发明的实施例,并非因此限制本发明的专利范围,凡是利用本发明说明书内容所作的等效结构或等效流程变换,或直接或间接运用在其它相关的技术领域,均同理包括在本发明的专利保护范围之内。
Claims (10)
1.一种曲面背光模组,包括依次设置的反射板、导光板、光学板组,以及设于所述导光板侧面的光源,其特征在于:所述反射板、所述导光板、所述光学板组、所述光源构成背光单元,所述背光单元的边缘包有一圈固定层,所述固定层外包有一圈限位层。
2.根据权利要求1所述的曲面背光模组,其特征在于:所述固定层为热塑性树脂;所述限位层为热固性树脂基复合材料。
3.一种权利要求1或2所述的曲面背光模组的制备方法,其特征在于,包括以下步骤:
步骤一:准备所述反射板、所述导光板、所述光学板组、所述光源、卡扣、复合材料片材、热固性树脂、加工设备;
步骤二:将所述反射板、所述导光板、所述光学板组、所述光源组装为所述背光单元,在所述背光单元的边缘卡满所述卡扣;
步骤三:于所述卡扣远离所述背光单元的外壁涂抹所述热固性树脂,并铺设所述复合材料片材,重复多次至合适厚度;
步骤四:将设置了所述卡扣、所述复合材料片材、所述热固性树脂的所述背光单元置于所述加工设备内,升温并施压,使所述卡扣软化、所述热固性树脂固化、所述背光单元弯曲;
步骤五:冷却后即得所述曲面背光模组。
4.根据权利要求3所述的曲面背光模组的制备方法,其特征在于:所述卡扣为“C”形结构,其开口处宽度小于等于所述背光单元的厚度,开口内底面设有与所述光源衔接的凹槽。
5.根据权利要求4所述的曲面背光模组的制备方法,其特征在于:所述卡扣采用热塑性树脂制造。
6.根据权利要求4所述的曲面背光模组的制备方法,其特征在于:所述卡扣远离所述背光单元的外壁采用热塑性树脂制造。
7.根据权利要求5或6所述的曲面背光模组的制备方法,其特征在于:所述热固性树脂为低温固化的热固性树脂;所述卡扣所采用的热塑性树脂的软化温度低于所述热固性树脂的固化温度。
8.根据权利要求3所述的曲面背光模组的制备方法,其特征在于:所述加工设备设备包括加热腔,设于所述加热腔内的弯曲施压设备、压实施压设备,所述背光单元设于所述压实施压设备内。
9.根据权利要求8所述的曲面背光模组的制备方法,其特征在于:所述压实施压设备包括方框形的压实工装,围绕所述背光单元的边缘设置,在所述压实工装的内壁,即所述压实工装与所述背光单元之间处设有多个膨胀包,所述膨胀包内填充热膨胀材料。
10.根据权利要求9所述的曲面背光模组的制备方法,其特征在于:所述弯曲施压设备以与所述压实施压设备、所述背光单元垂直的角度,对所述背光单元施压,使所述背光单元弯曲。
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