CN116647979A - 一种柔性曲面led显示屏及其加工工艺 - Google Patents
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Abstract
本发明涉及柔性曲面LED显示屏技术领域,公开了一种柔性曲面LED显示屏的加工工艺,包括以下步骤:步骤一、对显示屏基板进行预处理,采用印刷工艺制作电路图案;步骤二、LED灯珠安装:将LED灯珠粘贴在印刷的电路上,使用特殊的焊接技术将电极连接到电路,并对LED灯珠进行硅胶封装;步骤三、凸起加强并覆膜:通过添加硬化材料,即得柔性线路板,随后进行真空表面处理;步骤四、弯曲和切割:根据使用需要对柔性线路板进行弯曲、折叠、卷曲和切割。通过在柔性电路板的背光模块上贴附金属薄膜,提高光学性能,金属薄膜可以提高显示屏的反射率和透过率,增强显示效果并提高亮度,同时金属薄膜还可有效地抑制显示屏的漏光,提高对比度和显示质量。
Description
技术领域
本发明涉及柔性曲面LED显示屏技术领域,具体为一种柔性曲面LED显示屏及其加工工艺。
背景技术
LED显示屏越来越向高端方向发展,市场上显示屏产品趋于轻、薄;LED显示屏性能稳定、节能环保、亮度高、图像绚丽及使用周期长,因LED显示屏具有上述优点,其广泛应用于户外以及户内的光电显示领域,为了满足显示屏的立体感受,常将显示屏设置为曲面,其中LED显示屏由于其由多个阵列的发光单元组成使得其弯曲呈曲面时,使用效果更佳,但是现有技术中所生产的柔性曲面LED显示屏的亮度和对比度较低,并且机械强度和稳定性不高,因此我们提出了一种柔性曲面LED显示屏及其加工工艺。
发明内容
针对现有技术的不足,本发明提供了一种柔性曲面LED显示屏及其加工工艺,解决了现有技术中所生产的柔性曲面LED显示屏的亮度和对比度较低,并且机械强度和稳定性不高的问题。
为实现以上目的,本发明通过以下技术方案予以实现:一种柔性曲面LED显示屏的加工工艺,包括以下步骤:
步骤一、对显示屏基板进行预处理,采用印刷工艺制作电路图案;
步骤二、LED灯珠安装:
将LED灯珠粘贴在印刷的电路上,使用特殊的焊接技术将电极连接到电路,并对LED灯珠进行硅胶封装;
步骤三、凸起加强并覆膜:
通过添加硬化材料,即得柔性线路板,随后进行真空表面处理;
步骤四、弯曲和切割:
根据使用需要对柔性线路板进行弯曲、折叠、卷曲和切割,将其形成所需形状;
步骤五、弯曲和组装并进行测试:
将柔性线路板、外壳、玻璃层、LED芯片进行组装,即得柔性LED显示屏,随后对其进行模拟仿真验证。
优选的,所述步骤一的具体步骤如下:
S1、根据具体的应用需求,选择基板材料,并将所选的基板材料切割成合适的尺寸和形状;
S2、对焊盘进行提前处理并将其与基板连接,根据具体应用的需要,将基板上显示的颜色进行校正;
S3、通过计算机辅助设计软件或者手工绘制,设计出电路图案,将设计好的电路图案转移到铝基、铜基或者不锈钢基的压敏胶上,形成印版;
S4、在基板表面均匀涂布银浆、铜浆、金浆,依照电路图案形成指向导电线路及电极的线条;
S5、使用丝网印刷机将铝基、铜基或者不锈钢基的印版对准基板表面,将导电和连接线路打印在基板上,通过烘干或紫外光束曝光对导电浆料进行固化处理,随后进行清洗,去除不需要的残留物。
优选的,所述S2步骤中,所述焊盘进行提前处理的具体步骤如下:
S201、将焊盘表面清洁干净,除去油污和杂质,使用柔性材料填充焊盘;
S202、对S201步骤中填充后的焊盘涂敷防氧化涂料,随后通过增温机构对其进行增温,即完成预处理。
优选的,所述步骤二,所述硅胶封装的具体步骤如下:
A、硅氧烷和交联剂进行混合,并通过搅拌机进行搅拌,将基板模具放入密闭容器中,注入硅胶料,待硅胶料变硬后,将硅胶模具取出;
B、将基板放入硅胶模具中,将硅胶灌入到基板中空隙中,硅胶灌注完后,使用真空除泡机器除去任何空气泡,将硅胶模具放在恒温恒湿的环境下固化,即可。
优选的,所述A步骤中,所述交联剂为甲醛、脲醛、酚醛、环氧树脂、高密度聚乙烯、过氧化物和铁盐中的一种或者多种。
优选的,所述A步骤中,所述搅拌机的搅拌速度为8~15转/分钟,所述搅拌机的搅拌时长为10~15分钟,所述搅拌机的间歇时长为3~5分钟,所述B步骤,所述硅胶模具固化时长为1~2天。
优选的,所述S201步骤中,所述柔性材料为聚酰亚胺薄膜和聚氨酯材料。
优选的,所述步骤三中,所述真空表面处理的具体步骤如下:
①、柔性线路板放置在真空室内,使用高能粒子束沉积,并对其表面进行微小处理;
②、将所需的金属材料蒸发或溅射到基板表面,对柔性线路板的背光模块上贴附金属薄膜,然后进行退火处理。
优选的,所述②步骤中,所述金属薄膜为铝薄膜、银薄膜、铜薄膜、铂薄膜中的一种
一种柔性曲面LED显示屏,包括显示屏外壳,所述显示屏外壳的前侧固定连接有显示屏玻璃层,所述显示屏外壳的后端中部设置有多个散热孔,所述显示屏外壳的后端下侧设置有DVI插口,所述显示屏外壳的内部设置有LED显示屏面板。
本发明提供了一种柔性曲面LED显示屏及其加工工艺。具备以下有益效果:
1、本发明通过在制备工艺中添加高强度、高韧性的柔性材料,提高耐用性,高强度、高韧性的柔性材料具有很好的耐用性,使其可以经受长时间的弯曲和扭曲而不会断裂或损坏,这可以使柔性显示屏更加耐用,延长其使用寿命,同时提高弯曲性能,柔性材料可以在多种角度下弯曲,其弯曲强度比刚性材料更高,不易产生疲劳和断裂等损伤,增加了其在复杂环境下的可靠性和稳定性,相对于刚性材料,柔性材料的密度一般较低,使用时可以减轻显示屏的整体重量,有利于减小产品的体积和重量等设计要求。
2、本发明通过在柔性电路板的背光模块上贴附金属薄膜,提高其光学性能,金属薄膜可以提高显示屏的反射率和透过率,增强其显示效果并提高亮度,同时,金属薄膜还可以有效地抑制显示屏的漏光,提高对比度和显示质量;提高了抗电磁干扰,金属薄膜可以有效地屏蔽电磁干扰,减少来自其他无线电设备和电磁波辐射的影响,从而保证显示屏的稳定性和可靠性,增加了耐磨性,金属薄膜具有一定的硬度和韧性,可以增加显示屏的表面硬度和耐磨性,减少磨损和刮伤等损坏。
附图说明
图1为本发明的立体前侧示意图;
图2为本发明的立体后侧示意图;
图3为本发明的结构爆炸图。
其中,1、显示屏外壳;2、显示屏玻璃层;3、散热孔;4、DVI插口;5、LED显示屏面板。
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,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例:
本发明实施例提供一种柔性曲面LED显示屏的加工工艺,包括以下步骤:
步骤一、对显示屏基板进行预处理,清除基板表面的杂质、氧化物等物质,提高基板表面的平整度和粘附性,以便进行后续的电路图案印刷,对显示屏基板进行预处理,然后采用印刷工艺制作电路图案是制造显示屏的重要步骤之一,是实现高品质、高性能显示屏必不可少的过程,采用印刷工艺制作电路图案,在电路图案印刷过程中,需要根据实际情况选择合适的制造技术和印刷设备,以保证电路图案的清晰度和精度,同时,在印刷过程中需要严格控制印刷参数,特别是印刷压力、温度、湿度等因素,以确保印刷质量的稳定性和可靠性,具体步骤如下:
S1、根据具体的应用需求,选择基板材料,并将所选的基板材料切割成合适的尺寸和形状;
S2、对焊盘进行提前处理并将其与基板连接,根据具体应用的需要,将基板上显示的颜色进行校正,焊盘进行提前处理的具体步骤如下:
S201、将焊盘表面清洁干净,除去油污和杂质,使用柔性材料填充焊盘,柔性材料为聚酰亚胺薄膜和聚氨酯材料;
S202、对S201步骤中填充后的焊盘涂敷防氧化涂料,随后通过增温机构对其进行增温,即完成预处理;
S3、通过计算机辅助设计软件或者手工绘制,设计出电路图案,将设计好的电路图案转移到铝基、铜基或者不锈钢基的压敏胶上,形成印版;
S4、在基板表面均匀涂布银浆、铜浆、金浆,依照电路图案形成指向导电线路及电极的线条;
S5、使用丝网印刷机将铝基、铜基或者不锈钢基的印版对准基板表面,将导电和连接线路打印在基板上,通过烘干或紫外光束曝光对导电浆料进行固化处理,随后进行清洗,去除不需要的残留物;
步骤二、LED灯珠安装:
将LED灯珠粘贴在印刷的电路上,使用特殊的焊接技术将电极连接到电路,并对LED灯珠进行硅胶封装,使用特殊的焊接技术将LED灯珠电极连接到电路上,一般常用的焊接技术有SMT(贴片式表面贴装技术)、THT(插针式贴装技术)等,对于LED灯珠的表面贴装,SMT技术是应用最广泛的一种方法,硅胶封装的具体步骤如下:
A、将硅氧烷和交联剂进行混合,并通过搅拌机进行搅拌,将基板模具放入密闭容器中,注入硅胶料,待硅胶料变硬后,将硅胶模具取出,交联剂为酚醛、环氧树脂、高密度聚乙烯和过氧化物,搅拌机的搅拌速度为15转/分钟,搅拌机的搅拌时长为15分钟,搅拌机的间歇时长为3分钟,硅胶模具固化时长为2天;
B、将基板放入硅胶模具中,将硅胶灌入到基板中空隙中,硅胶灌注完后,使用真空除泡机器除去任何空气泡,将硅胶模具放在恒温恒湿的环境下固化,即可;
步骤三、凸起加强并覆膜:
通过添加硬化材料,即得柔性线路板,随后进行真空表面处理,在制造柔性线路板时,需要在电路板上添加硬化材料,以使其保持一定的刚性和稳定性,添加硬化材料有利于柔性线路板在弯曲或扭曲时能够保持一定的形状稳定性,并且不会因为形变而影响电路的正常工作,硬化材料的加入需要控制好其配比和混合比例,以避免硬化材料与基材不兼容或出现反应而影响线路板的质量,真空表面处理的具体步骤如下:
①、柔性线路板放置在真空室内,使用高能粒子束沉积,并对其表面进行微小处理;
②、将所需的金属材料蒸发或溅射到基板表面,对柔性线路板的背光模块上贴附金属薄膜,然后进行退火处理,金属薄膜为铝薄膜;
步骤四、弯曲和切割:
根据使用需要对柔性线路板进行弯曲、折叠、卷曲和切割,将其形成所需形状,根据需求可以利用工具、仪器或手工对柔性线路板进行加工变形,例如,对于简单的弯曲或折叠,可以使用弯折机器或其他加工设备进行加工,对于更为复杂的形状,可以使用激光切割或数控切割等技术进行精密切割,在进行柔性线路板变形加工的过程中,需要注意以下几点:在进行线路板变形时,需要精确控制变形角度和半径,避免出现过弯或过扭的情况,影响其工作性能;在进行切割等加工时,需要确保不会损伤器件或电路,特别是对于某些灵敏的元件,如表面贴装电容、电感等,需要特别谨慎处理;在变形加工前需要确保线路板表面没有油污或灰尘等物质,以保证变形后贴合性能;
步骤五、弯曲和组装并进行测试:
将柔性线路板、外壳、玻璃层、LED芯片进行组装,即得柔性LED显示屏,随后对其进行模拟仿真验证,先将柔性线路板、外壳和玻璃层按照规定的位置进行组装,然后对其进行粘合或焊接等固定操作,这些步骤需要精确控制每个构件的位置和配合度,确保组装出的显示屏能够具有高质量和稳定性,在组装好的柔性线路板上,安装LED芯片,这需要使用特殊的设备,按照设计图来将LED芯片整齐排列并进行连接,主要是焊接LED芯片电极和柔性线路板上的电路连接,在组装好柔性LED屏之后,需要进行模拟仿真验证,以测试显示效果和工作性能,常见的方法包括电气仿真、光学仿真等,通过模拟显示屏在实际工作过程中的电学、光学特性来验证它是否有高品质和性能。
参照附图1-附图3,一种柔性曲面LED显示屏,包括显示屏外壳1,显示屏外壳1的前侧固定连接有显示屏玻璃层2,显示屏外壳1的后端中部设置有多个散热孔3,有利于散发显示屏中产生的热量,提高散热性能,这可以有效地减少显示屏工作时的温度升高,保证其长时间稳定的工作状态,在显示屏外壳1后端下侧设置了DVI插口4,方便与其它设备进行连接。这种设计可以满足多种应用场景和使用需求,同时,接口的设置合理,也有利于操作的简便与可靠性,显示屏外壳1的内部设置有LED显示屏面板5。
尽管已经示出和描述了本发明的实施例,对于本领域的普通技术人员而言,可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型,本发明的范围由所附权利要求及其等同物限定。
Claims (10)
1.一种柔性曲面LED显示屏的加工工艺,其特征在于,包括以下步骤:
步骤一、对显示屏基板进行预处理,采用印刷工艺制作电路图案;
步骤二、LED灯珠安装:
将LED灯珠粘贴在印刷的电路上,使用特殊的焊接技术将电极连接到电路,并对LED灯珠进行硅胶封装;
步骤三、凸起加强并覆膜:
通过添加硬化材料,即得柔性线路板,随后进行真空表面处理;
步骤四、弯曲和切割:
根据使用需要对柔性线路板进行弯曲、折叠、卷曲和切割,将其形成所需形状;
步骤五、弯曲和组装并进行测试:
将柔性线路板、外壳、玻璃层、LED芯片进行组装,即得柔性LED显示屏,随后对其进行模拟仿真验证。
2.根据权利要求1所述的一种柔性曲面LED显示屏的加工工艺,其特征在于,所述步骤一的具体步骤如下:
S1、根据具体的应用需求,选择基板材料,并将所选的基板材料切割成合适的尺寸和形状;
S2、对焊盘进行提前处理并将其与基板连接,根据具体应用的需要,将基板上显示的颜色进行校正;
S3、通过计算机辅助设计软件或者手工绘制,设计出电路图案,将设计好的电路图案转移到铝基、铜基或者不锈钢基的压敏胶上,形成印版;
S4、在基板表面均匀涂布银浆、铜浆、金浆,依照电路图案形成指向导电线路及电极的线条;
S5、使用丝网印刷机将铝基、铜基或者不锈钢基的印版对准基板表面,将导电和连接线路打印在基板上,通过烘干或紫外光束曝光对导电浆料进行固化处理,随后进行清洗,去除不需要的残留物。
3.根据权利要求2所述的一种柔性曲面LED显示屏的加工工艺,其特征在于,所述S2步骤中,所述焊盘进行提前处理的具体步骤如下:
S201、将焊盘表面清洁干净,除去油污和杂质,使用柔性材料填充焊盘;
S202、对S2-1步骤中填充后的焊盘涂敷防氧化涂料,随后通过增温机构对其进行增温,即完成预处理。
4.根据权利要求1所述的一种柔性曲面LED显示屏的加工工艺,其特征在于,所述步骤二,所述硅胶封装的具体步骤如下:
A、将硅氧烷和交联剂进行混合,并通过搅拌机进行搅拌,将基板模具放入密闭容器中,注入硅胶料,待硅胶料变硬后,将硅胶模具取出;
B、将基板放入硅胶模具中,将硅胶灌入到基板中空隙中,硅胶灌注完后,使用真空除泡机器除去任何空气泡,将硅胶模具放在恒温恒湿的环境下固化,即可。
5.根据权利要求4所述的一种柔性曲面LED显示屏的加工工艺,其特征在于,所述A步骤中,所述交联剂为甲醛、脲醛、酚醛、环氧树脂、高密度聚乙烯、过氧化物和铁盐中的一种或者多种。
6.根据权利要求4所述的一种柔性曲面LED显示屏的加工工艺,其特征在于,所述A步骤中,所述搅拌机的搅拌速度为8~15转/分钟,所述搅拌机的搅拌时长为10~15分钟,所述搅拌机的间歇时长为3~5分钟,所述B步骤,所述硅胶模具固化时长为1~2天。
7.根据权利要求3所述的一种柔性曲面LED显示屏的加工工艺,其特征在于,所述S201步骤中,所述柔性材料为聚酰亚胺薄膜和聚氨酯材料。
8.根据权利要求1所述的一种柔性曲面LED显示屏的加工工艺,其特征在于,所述步骤三中,所述真空表面处理的具体步骤如下:
①、柔性线路板放置在真空室内,使用高能粒子束沉积,并对其表面进行微小处理;
②、将所需的金属材料蒸发或溅射到基板表面,对柔性线路板的背光模块上贴附金属薄膜,然后进行退火处理。
9.根据权利要求8所述的一种柔性曲面LED显示屏的加工工艺,其特征在于,所述②步骤中,所述金属薄膜为铝薄膜、银薄膜、铜薄膜、铂薄膜中的一种。
10.一种柔性曲面LED显示屏,其特征在于,使用权利要求书1-9任一项所述的一种柔性曲面LED显示屏的加工工艺,包括显示屏外壳(1),所述显示屏外壳(1)的前侧固定连接有显示屏玻璃层(2),所述显示屏外壳(1)的后端中部设置有多个散热孔(3),所述显示屏外壳(1)的后端下侧设置有DVI插口(4),所述显示屏外壳(1)的内部设置有LED显示屏面板(5)。
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