JP7340067B1 - Foam diffusion plate and manufacturing method thereof - Google Patents

Abstract

An object of the present invention is to provide a high-quality foamed diffuser plate with favorable total reflection performance, good uniformity, and less unevenness, and a method for manufacturing the same. A foamed diffuser plate includes a foamed core layer. The upper and lower surfaces of the foam core layer are covered with a protective layer, and the thickness ratio of the foam core layer to the protective layers on the upper and lower surfaces is 1:7 to 9:1. The mass percentage of each raw material for the protective layer is 90-99% PS raw material, 0.01-1% stabilizer, 0.1-3% organic silicon, 0.1-3% inorganic diffusing agent, and 0.1% diffusing oil. ~3%, styrene-butadiene copolymer 0.1~2%, and magnesium silicate salt mineral 0.1~6%. The mass percentage of raw materials for the foam core layer is 95-99% GPPS raw material, 0.3-0.6% antioxidant, 0.6-1% organic silicon diffusing agent, 0.5-2% foaming agent, UV 0.3-0.6%, toughening agent 0.5-2%, stabilizer 0.3-0.6%, nucleating agent 1-5%. A plurality of cell voids are formed inside the foam core layer. [Selection diagram] Figure 1

Description

TECHNICAL FIELD The present invention relates to a light diffusion plate, and more particularly to a foam diffusion plate and a manufacturing method thereof.

A light diffuser plate causes physical phenomena of refraction, reflection and scattering when a light beam hits two media with different refractive indices on the way of propagation by chemical or physical means. ), PC (Polycarbonate), PS (Polystyrene), PP (Polypropylene), etc., an inorganic or organic light diffusing agent is added to the substrate foundation, or an artificial light diffusion agent is added through the array arrangement of the fine pattern structure on the substrate surface. The light diffusing plate is made of liquid crystal, because the light diffusing plate can adjust the light ray in a similar way, causing the light ray to be refracted, reflected and scattered in different directions to change the light path, and sufficiently scatter the incident light to achieve the optical diffusion effect. It has been widely applied in display, LED illumination and imaging display system.

In the conventional display backlight source, one surface or two surfaces of the conventional light diffuser plate are processed with a concave-convex dot or concave dot pattern to enhance the light dispersion performance of the diffuser plate, and the point light source of the LED light bar. Light rays emitted from are homogenized as they pass through the diffuser plate. However, with the continual upgrade and renewal of display panels, it has become difficult to meet the needs of manufacturers with conventional light diffuser structures. I didn't like the effect.

In view of such a situation, the present inventor has completed the present invention as a result of earnest research.
SUMMARY OF THE INVENTION A main object of the present invention is to provide a high-quality foamed diffuser panel with favorable total reflection performance, good uniformity, less unevenness, and a method for manufacturing the same.

Thus, the gist of the present invention is as described in the following (1) to (10).
(1) A foam diffusion plate including a foam core layer,
The upper and lower surfaces of the foam core layer are covered with a protective layer, and the thickness ratio of the foam core layer and the protective layers on the upper and lower surfaces is 1:7 to 9:1,
The mass % of each raw material of the protective layer is PS raw material 90-99%, stabilizer 0.01-1%, organic silicon 0.1-3%, inorganic diffusing agent 0.1-3%, diffusion oil 0.1%. 1 to 3%, styrene-butadiene copolymer 0.1 to 2%, magnesium silicate salt mineral 0.1 to 6%,
The mass % of the raw materials of the foam core layer is 95 to 99% of GPPS raw material, 0.3 to 0.6% of antioxidant, 0.6 to 1% of organic silicon diffusing agent, 0.5 to 2% of foaming agent, 0.3-0.6% UV resistance, 0.5-2% toughener, 0.3-0.6% stabilizer, 1-5% nucleating agent,
A foam diffusion plate, wherein a plurality of voids are formed inside the foam core layer.
(2) The diffuser foam plate according to (1), wherein a pattern for enhancing light refraction and reflection performance is formed on one side of the protective layer farther from the foam core layer.
(3) a quantum dot layer is formed between the two protective layers;
The foam diffusion plate according to (1), wherein the quantum dot layer covers the surface of the foam core layer.
(4) The mass % of each raw material of the quantum dot layer is 90 to 99% of plastic raw material, 0.01 to 1% of stabilizer, 0.1 to 3% of organic silicon, 0.1 to 3% of inorganic diffusing agent, Diffusion oil 0.1-3%, styrene-butadiene copolymer 0.1-2%, magnesium silicate salt mineral 0.1-6%, quantum dot 0.01-1%,
The diffuser bubble plate according to (3), wherein the quantum dots have a particle size of 2 to 12 nm.
(5) the foam core layer further comprises quantum dots;
The mass% of the raw material of the quantum dots is 0.01 to 1%,
The diffuser bubble plate according to (1), wherein the quantum dots have a particle size of 2 to 12 nm.
(6) adding a PS heat-resistant agent to the components of the foam core layer and the protective layer;
The diffuser foam plate according to any one of (1) to (5), wherein the PS heat-resistant agent has a mass percentage of 0.1 to 3%.
(7) A method for manufacturing the foam diffusion plate according to (1),
preparing two raw materials for the protective layer and one raw material for the foam core layer having the same composition;
separately and uniformly mixing the raw material for the protective layer and the raw material for the foamed core layer;
a step of putting the mixed raw material of the protective layer and the raw material of the foamed core layer into a screw extruder and heating them to melt them;
Finally, extruding from the die head of the screw extruder to extrude the raw material of the protective layer and the raw material of the foam core layer in a flaky manner, and cover the surface of the foam core layer with the protective layer. A method for manufacturing a foam diffusion plate.
(8) the screw extruder includes three heating zones;
The first stage temperature of the heating region is 140 to 220° C.,
The second stage temperature of the heating region is 160 to 240° C.,
The method for producing a diffuser foam plate according to (7), wherein the third stage temperature of the heating region is 180 to 260°C.
(9) The method for producing a diffuser foam plate according to (7), wherein the extrusion temperature from the die head is controlled within a range of 170 to 260°C.
(10) The method for producing a diffuser foam plate according to (7), wherein the screw extruder has a plurality of raw material supply ports used to feed various kinds of different raw materials into the screw extruder.

The foam diffusion plate and the manufacturing method thereof according to the present invention use a PS raw material for the protective layers on the upper and lower surfaces of the foam core layer, add an inorganic diffusing agent, form the protective layer into a hard protective layer, and two protective layers protects the foam core layer, refracts and reflects light rays, and adds a foaming agent to the foam core layer to form a plurality of voids inside the foam core layer, and there is an air medium in the voids Therefore, when a ray of light is incident on the foam core layer, it first passes through the base material of the foam core layer and then enters the voids of the cells. high uniformity, less unevenness, high quality, low density and light weight due to voids inside the foam core layer, organic silicon diffusing agent has a diffusing effect, The nucleating agent can stabilize the cell size of the foaming agent, and the antioxidant can prevent yellowing of the foam core layer.

FIG. 1 is a structural diagram showing a foam diffusion plate according to one embodiment of the present invention. FIG. 2 is a cross-sectional view of a scanning electron microscope of a foam core layer of a foam diffusion plate according to an embodiment of the present invention. FIG. 3 is an enlarged view of a magnifying glass in which a flat surface of a foam diffusion plate according to an embodiment of the present invention is irradiated with light. FIG. 4 is a structural diagram of a test backlight source module according to an embodiment of the present invention. FIG. 5 is a diagram showing the light spread effect when the ordinary diffuser is installed in front of the backlight source. FIG. 6 is a diagram showing the light spread effect when the foam diffusion plate is installed in front of the backlight source. FIG. 7 is an explanatory diagram showing a structure in which a foam diffusion plate according to one embodiment of the present invention is installed on a quantum dot layer. FIG. 8 is an explanatory diagram showing the structure of quantum dots included in the foam core layer of the foam diffusion plate according to one embodiment of the present invention. FIG. 9 is a flow chart showing a method of manufacturing a foam diffusion plate according to one embodiment of the present invention.

Hereinafter, specific embodiments will be described in detail based on the drawings in order to make the objects, features and effects of the present invention more comprehensible.

Please refer to FIG. As shown in FIG. 1 , a foam diffuser panel according to an embodiment of the present invention includes a foam core layer 10 and protective layers 20 covering the upper and lower surfaces of the foam core layer 10 . The thickness ratio of the foam core layer 10 and the upper and lower protective layers 20 is 1:7 to 9:1.

The mass % of each raw material of the protective layer 20 is PS raw material 90-99%, stabilizer 0.01-1%, organic silicon 0.1-3%, inorganic diffusing agent 0.1-3%, diffusion oil 0.1%. 1-3%, styrene-butadiene copolymer 0.1-2%, magnesium silicate salt mineral 0.1-6%.

The mass % of the raw materials of the foam core layer 10 is 95 to 99% of GPPS raw material, 0.3 to 0.6% of antioxidant, 0.6 to 1% of organic silicon diffusing agent, 0.5 to 2% of foaming agent, 0.3-0.6% UV resistance, 0.5-2% toughener, 0.3-0.6% stabilizer, 1-5% nucleating agent. A plurality of cell voids are formed inside the foam core layer 10 .

The protective layer 20 on the upper and lower surfaces of the foam core layer 10 adopts PS raw material and adds an inorganic diffusing agent to form the protective layer 20 into a hard protective layer 20, and the foam core layer 10 between the two protective layers 20 and may refract and reflect light rays.

Please refer to FIGS. As shown in FIGS. 2 and 3, the foaming agent is added to the foam core layer 10 to form a plurality of voids inside the foam core layer 10, and the air medium is present in the voids, so that the light rays can pass through the foam core. When entering the layer 10, first, the light passes through the base material of the foam core layer 10 and then enters into the voids of the cells, where the light ray is refracted, reflected, and emitted. Therefore, the total reflectivity of the foam core layer 10 is high. , the uniformity is preferable, and the unevenness phenomenon can be reduced, so that the quality is high. In addition, since the foam core layer 10 has voids inside, the density is low and the weight of the whole is light. The organosilicon diffusing agent has a diffusing effect, the nucleating agent can stabilize the cell size of the foaming agent, and the antioxidant can prevent the foam core layer 10 from yellowing.

The thickness ratio of the foam core layer 10 and the protective layers 20 on the upper and lower surfaces of the foam diffusion plate of this embodiment is 1:8:1. The mass % of each raw material of the protective layer 20 is PS raw material 93%, stabilizer 0.5%, organic silicon 1.5%, inorganic diffusing agent 1%, diffusing oil 1%, styrene-butadiene copolymer 1%, Magnesium silicate mineral is 2%, and the mass % of the raw materials for the foam core layer is 95% GPPS raw material, 0.5% antioxidant, 0.8% organic silicon diffusing agent, 1% foaming agent, and 0.5% UV resistance. 5%, 1% toughener, 0.2% stabilizer, 1% nucleating agent.

The thickness ratio of the protective layer and the diffusion layer of the conventional ordinary diffusion plate is 1:8:1. The mass % of each raw material of the protective layer is PS raw material 93%, stabilizer 0.5%, organic silicon 1.5%, inorganic diffusing agent 1%, diffusing oil 1%, styrene-butadiene copolymer 1%, silicone 97.8% GPPS raw material, 0.5% antioxidant, 0.5% UV resistance, 1% reinforcing agent, 0.2% stabilizer is.

Accurately assemble the manufactured foam diffusion plate and ordinary diffusion plate, place the backlight source, turn on the power, and after confirming that there is no problem by inspection, preheat for 30 minutes, and place the plate material in the middle of the backlight source. Install and position in a fixed test area under the BEF and measure with the corrected photometer. See FIG. 4 for the backlight source structure. Table 1 below shows data comparing the foam board and the ordinary board.

As can be seen from Table 1 above, the foamed plate has higher brightness and uniformity than the ordinary plate, and has a lower density than the ordinary plate, so the foamed diffusion plate is lighter.

Please refer to FIGS. FIG. 5 is a diagram showing the uniform light diffusion effect when the ordinary diffusion plate is installed in front of the backlight source, and it can be seen that the brightness in the center of the ordinary diffusion plate is higher than that in the upper and lower sides. FIG. 6 is a diagram showing the diffuse diffusion effect when the foam diffusion plate is installed in front of the backlight source. Compared with FIG. 5, the diffusion effect is better in FIG. I understand.

In the means described above, a pattern that enhances light refraction and reflection performance may be formed on the side of the protective layer 20 farther from the foam core layer 10 to uniformize light reflection and refraction.

Please refer to FIG. As shown in FIG. 7, a quantum dot layer 30 is formed between two protective layers 20 . The quantum dot layer 30 covers the surface of the foam core layer 10 . The mass % of each raw material of the quantum dot layer 30 is 90 to 99% of plastic raw material, 0.01 to 1% of stabilizer, 0.1 to 3% of organic silicon, 0.1 to 3% of inorganic diffusing agent, and 0 diffusion oil. 0.1-3% styrene-butadiene copolymer, 0.1-6% magnesium silicate salt mineral, and 0.01-1% quantum dots. The particle size of the quantum dots is 2-12 nm.

The quantum dot material has the characteristics of wide excitation spectrum, narrow emission spectrum, high color purity, and favorable photostability, which can enhance the optical performance of the diffuser plate. can be combined to improve the optical effect of the quantum dot plate, optically convert the spectral bandwidth of the light in the original backlight, reduce the emission peak width of the three primary colors, and improve the display color gamut. While it can, more importantly, it can also increase the utilization rate of the light-transmitting color filters of the backlight module after light conversion to increase the brightness.

Please refer to FIG. As shown in FIG. 8, the foam core layer 10 may further include quantum dots. The mass % of the quantum dot raw material is 0.01 to 1%, and the particle size of the quantum dots is 2 to 12 nm. Compared with the quantum dot layer 30 described above, in the embodiment of FIG. 8, the quantum dots are directly mixed into the raw material of the foam core layer 10, the quantum dots are directly embedded in the foam core layer 10, and the entire thickness of the foam diffusion plate is The above-mentioned quantum dot layer 30 allows the foam core layer 10 to cover the quantum dot layer 30 correspondingly. It can be used and processed.

A PS heat-resistant agent may be added to the components of the foam core layer 10 and the protective layer 20 . The mass% of the PS heat-resistant agent is 0.1 to 3%, and the addition of the PS heat-resistant agent enhances the heat-resistant performance of the foam diffusion plate body, and when the LED lamp irradiates during use, the temperature becomes too high. See Table 2 below for the effect after increasing the amount of the PS heat-resistant agent to prevent deformation of the foam diffusion plate.

As can be seen from Table 2 above, after adding the PS heat-resistant agent, the heat-resistant performance of the foam diffusion plate is obviously higher than that of the foam diffusion plate without the PS heat-resistant agent.

See FIG. As shown in FIG. 9, the above-described method for manufacturing a foam diffusion plate includes the following steps (a) to (d).
(a) Prepare two raw materials for the protective layer and one raw material for the foamed core layer having the same component.
(b) Separately and uniformly mix the raw material for the protective layer and the raw material for the foamed core layer.
(c) The raw material for the protective layer and the raw material for the foamed core layer, which have already been mixed, are put into a screw extruder and heated to melt.
(d) Finally extruding from the die head of the screw extruder, extruding the raw material of the protective layer and the raw material of the foam core layer in a flake manner, and covering the surface of the foam core layer with the protective layer;

Through the above processing steps, the protective layer and the foamed core layer are jointly extruded and adhesively fixed, and the surface of the foamed core layer is covered with the protective layer, which facilitates processing.

The screw extruder includes three heating zones. The first-stage temperature of the heating zone is 140-220°C, the second-stage temperature of the heating zone is 160-240°C, and the third-stage temperature of the heating zone is 180-260°C. The raw materials of the protective layer and the foam core layer are sufficiently heated and mixed to form a molten state, and the temperature extruded from the die head is controlled in the range of 170 to 260 ° C. The flow through the die head is smooth because it is still maintained in a molten state.

In addition, the screw extruder has a plurality of raw material feed ports used to feed different kinds of raw materials into the screw extruder, so that the many different raw materials are separately injected and extruded at the same time to extrude the multilayer board. may be manufactured. The quantum dot layers increased as described above may achieve the purpose of synchronous extrusion by synchronously increasing the raw materials of a set of quantum dot layers to form a four-layer foam diffusion plate.

The co-extrusion method described above is more convenient and faster than the conventional adhesive fixing method, and gas is generated during the heating process of the foaming agent, forming a cavity in the foam layer and integrally molding the foam layer and the protective layer. As a result, it is possible to omit the subsequent process of manual assembly, and it is possible to prevent the adhesive from aging after long-term use, and to solve the problem of not being able to adhere and fix between layers. may be produced by a smart method by extruding by a co-extrusion method to precisely control the thickness between each layer.

As can be seen from the above, the foamed diffusion plate and the method for manufacturing the foamed diffusion plate according to the present invention use a PS material for the protective layers 20 on the upper and lower surfaces of the foamed core layer 10, add an inorganic diffusion agent, and form the protective layer 20 with a hard material. is formed on the protective layer 20 to protect the foamed core layer 10 between the two protective layers 20, refract and reflect light rays, and add a foaming agent to the foamed core layer 10 so that the inside of the foamed core layer 10 is formed by A plurality of bubble voids are formed, and since there is an air medium in the bubble voids, when the light beam enters the foam core layer 10, it first passes through the base material of the foam core layer 10 and then enters the foam voids. Since the light rays are emitted after being refracted and reflected, the total reflection of the foam core layer 10 is high, the uniformity is high, and the unevenness is small, so the quality is high. Low density and light weight. In addition, the organic silicon diffusing agent has a diffusing effect, the nucleating agent has an effect of stabilizing the cell size of the foaming agent, and the antioxidant prevents the foam core layer 10 from yellowing. can also be prevented.

While the preferred embodiments of the invention have been disclosed above, as can be appreciated by those skilled in the art, they are not intended to limit the invention in any way. Various changes and modifications may be made without departing from the spirit and scope of the invention. Therefore, the claims of the present invention should be interpreted broadly to include such changes and modifications.

10 foam core layer 20 protective layer 30 quantum dot layer

Claims (8)

A foam diffusion plate including a foam core layer,
The upper and lower surfaces of the foam core layer are covered with a protective layer, and the thickness ratio of the foam core layer and the protective layers on the upper and lower surfaces is 1:7 to 9:1,
The mass % of each raw material of the protective layer is PS raw material 90-99%, stabilizer 0.01-1%, organic silicon 0.1-3%, inorganic diffusing agent 0.1-3%, diffusion oil 0.1%. 1 to 3%, styrene-butadiene copolymer 0.1 to 2%, magnesium silicate salt mineral 0.1 to 6%,
The mass % of the raw materials of the foam core layer is GPPS raw material 95%, antioxidant 0.3-0.6%, organic silicon diffusion agent 0.6-1%, foaming agent 0.5-2%, UV resistance 0 .3-0.6%, 0.5-2% toughening agent, 0.3-0.6% stabilizer, 1% nucleating agent,
A plurality of bubble voids are formed inside the foam core layer,
A foam diffusion plate, wherein a quantum dot layer is formed between the two protection layers on the upper and lower surfaces, and the quantum dot layer covers the surface of the foam core layer. 2. The diffuser foam panel of claim 1, wherein a pattern for enhancing light refraction and reflection performance is formed on one side of the protective layer farther from the foam core layer. The mass % of each raw material of the quantum dot layer is 90 to 99% of plastic raw material, 0.01 to 1% of stabilizer, 0.1 to 3% of organic silicon, 0.1 to 3% of inorganic diffusing agent, and 0 of diffusion oil. .1-3%, styrene-butadiene copolymer 0.1-2%, magnesium silicate salt mineral 0.1-6%, quantum dots 0.01-1%,
2. The diffuser bubble plate of claim 1, wherein the quantum dots have a particle size of 2 to 12 nm. The foam core layer further comprises quantum dots,
The mass% of the raw material of the quantum dots is 0.01 to 1%,
2. The diffuser bubble plate of claim 1, wherein the quantum dots have a particle size of 2 to 12 nm. A method for manufacturing a foam diffusion plate according to claim 1, comprising:
preparing two raw materials for the protective layer and one raw material for the foam core layer having the same composition;
separately and uniformly mixing the raw material for the protective layer and the raw material for the foamed core layer;
a step of putting the mixed raw material of the protective layer and the raw material of the foamed core layer into a screw extruder and heating them to melt them;
Finally, extruding from the die head of the screw extruder to extrude the raw material of the protective layer and the raw material of the foam core layer in a flaky manner, and cover the surface of the foam core layer with the protective layer. A method for manufacturing a foam diffusion plate. The raw material for the protective layer and the raw material for the foamed core layer are heated and mixed by stepwise heating in three heating regions included in the screw extruder to form a molten state,
The first stage temperature of the heating region is 140 to 220° C.,
The second stage temperature of the heating region is 160 to 240° C.,
6. The method of claim 5, wherein the third stage temperature of the heating area is 180-260.degree. 6. The method of manufacturing a diffuser foam plate according to claim 5, wherein the extrusion temperature from the die head is controlled within a range of 170-260.degree. 6. The method of manufacturing a diffuser foam panel according to claim 5, wherein the raw material for the protective layer and the raw material for the foamed core layer are separately fed into a plurality of raw material supply ports of the screw extruder and extruded.