TW201610514A - Backlight module with light leakage prevention design and manufacturing method thereof - Google Patents

Abstract

A backlight module and manufacturing method thereof are provided. The backlight module includes a light module and a modulation film disposed on the light module. The light module has a bottom plate, a plurality of light sources, and at least one low reflective portion. The bottom plate has a carrier surface carrying the light sources; the carrier surface has a first reflection rate. The low reflective portion is disposed on the carrier surface and has a second reflection rate smaller than the first reflection rate. The modulation film includes a plurality of light exit holes and supporting unit through holes; at least some of the supporting unit through holes have a vertical projecting zone on the carrier surface at least partially overlapping with the low reflective portions.

Description

Backlight module with anti-light leakage design and manufacturing method thereof

The present invention relates to a backlight module for a display device and a method of fabricating the same; and more particularly to a backlight module for a display device and having a light leakage prevention design and a method of fabricating the same.

In recent years, the technology of liquid crystal display devices has gradually matured. As consumer preferences and demands increase, liquid crystal display devices are becoming thinner. In order to achieve the purpose of thinning, various components of the liquid crystal display device are required to be reduced in thickness, such as a display panel, an optical film, and a backlight module. In the backlight module, since the required light mixing space is required, the required thickness is usually large, and thus it is also the main target for thickness reduction.

Figure 1 shows a thinner direct type backlight module. As shown in FIG. 1, a plurality of light emitting diode light sources 13 are disposed on the bottom plate 10. Next, a reflective film 30 is provided above the light-emitting diode light source 13. A plurality of through holes 31 and support holes 32 are formed in the reflective film 30. The light generated by the light-emitting diode light source 13 is reflected by the back and forth between the reflective film 30 and the bottom plate 100, and is emitted by different through holes 31 to achieve the purpose of light source dispersion. Further, a diffusion plate 50 is additionally provided above the reflective film 30. The diffusion plate 50 is supported by the support member 11 disposed on the bottom plate 10 through the support hole 32, The light leaving the reflective diaphragm 30 passes through the diffuser 50 to produce a uniform backlight.

However, as the display area of the display device increases, the area of the backlight module also increases accordingly. In the above backlight module, when the area of the reflective film 30 is increased, it is necessary to consider the tension of the reflective film 30 and the change of thermal expansion and contraction, and the support member 11 is disposed at different positions, and further, the reflective film is required. The support holes 32 are embossed by a mold at different positions of 30. However, when the area of the reflective film 30 is increased, the size of the mold for imprinting is increased, and the cost of the relative mold manufacturing is also greatly increased, and when the design of the display device is changed, the backlight module also needs to be redesigned. Imprinted molds result in an increase in total production costs.

It is an object of the present invention to provide a backlight module and a manufacturing method thereof, which can reduce the cost of production.

Another object of the present invention is to provide a backlight module and a manufacturing method thereof, which can reduce the condition of light leakage.

The backlight module comprises a light source module and an optical control film. The light source module includes a carrier, a plurality of light sources and at least one low reflection portion. The carrier has a bearing surface for carrying the light source; wherein the bearing surface has a first reflectivity. The light source and the low reflection portion are disposed or formed on the bearing surface, wherein the low reflection portion has a second reflectance, and the second reflectance is smaller than the aforementioned first reflectance. The optical control film is disposed above the light source module to distribute the light generated by the light source from different positions of the optical control film. The optical control film comprises a plurality of light exit holes and a plurality of support members perforation mixed distribution, and respectively penetrates the optical control film. At least a portion of the support perforations overlap the low reflection portion at a vertical projection range of the bearing surface. The low-reflection part absorbs at least part of the optical tones that may have been self-supporting through the perforations. The light that controls the film substantially reduces the occurrence of light leakage caused by reflection from the bearing surface.

The manufacturing method of the backlight module comprises the steps of: forming a plurality of light exit holes and a plurality of support member through holes in a first region of the optical control film; forming a plurality of light exit holes in the second region of the optical control film by using the mold; A plurality of support members are perforated; a plurality of low reflection portions are formed on the bearing surface of the carrier plate, and a plurality of light sources are disposed to form the light source module, wherein the reflectivity of the low reflection portion is lower than the reflectivity of the bearing surface. Finally, the optical control film is disposed above the light source module, and the low reflection portion is opposite to the partial support member. The support member perforations opposite to the low reflection portion in the first region have a first relative position distribution with respect to the range of the first region, and the support member perforations opposite to the low reflection portion in the second region have a range relative to the second region. The relative position distribution, wherein the first relative position distribution and the second relative position distribution are not completely the same.

100‧‧‧Light source module

110‧‧‧ Carrier Board

111‧‧‧ bearing surface

113‧‧‧ Carrier board body

115‧‧‧reflector

117‧‧‧ hole

119‧‧‧ holes

130‧‧‧Light source

150‧‧‧low reflection section

151‧‧‧Sheet components

153‧‧‧Locking device

170‧‧‧ boards

300‧‧‧Optical Control Film

301‧‧‧reflecting surface

310‧‧‧Lighting hole

311‧‧‧ Block

330‧‧‧Support perforation

331‧‧‧Vertical projection range

391‧‧‧First area

392‧‧‧Second area

510‧‧‧Support

600‧‧‧Diffuser

700‧‧‧Mold

710‧‧‧ embossed surface

730‧‧‧ protrusion

1 is a schematic view of a thinned backlight module; FIG. 2 is an exploded view of an embodiment of a backlight module of the present invention; FIG. 3 is a cross-sectional view of an embodiment of a backlight module of the present invention; 5A is a cross-sectional view of another embodiment of the low reflection area; FIG. 5B is a cross-sectional view of another embodiment of the low reflection area; FIG. 6 is a cross-sectional view of another embodiment of the low reflection area; and FIG. 7 is a cross-sectional view of another embodiment of the low reflection area; 8 is a flow chart of an embodiment of a method for manufacturing a backlight module; 9A to 9D are schematic diagrams showing steps in a manufacturing process of a backlight module; and FIG. 10 is a schematic view showing a distribution of perforations of a support member corresponding to a low reflection portion in the first region and the second region.

The present invention provides a backlight module for use in a display device. In a preferred embodiment, the display device uses a liquid crystal display panel to cooperate with the backlight module to generate an image. However, in various embodiments, the display device can also cooperate with other display panels that require a backlight module.

In the embodiment shown in FIG. 2 , the backlight module includes a light source module 100 and an optical control film 300 . The light source module 100 includes a carrier 110, a plurality of light sources 130, and at least one low reflection portion 150. The carrier 110 has a bearing surface 111 for carrying the light source 130; wherein the bearing surface 111 has a first reflectivity, and the first reflectivity is higher than the reflectivity of the low reflecting portion 150. The measurement of the reflectance is preferably performed by comparing the white barium sulfate white powder with the reflectance of the white barium sulfate white powder to determine the relative reflectance value of the other material. The carrier 110 is preferably made of a metal material such as an aluminum plate; however, in various embodiments, the carrier 110 may also be made of a plastic material. The bearing surface 111 is preferably formed by the surface of the body of the carrier 110. However, when the material reflectivity of the carrier 110 itself is insufficient, other reflective materials may be added to the body of the carrier 110 to form a carrier having a first reflectivity. Face 111.

The light source 130 is disposed on the bearing surface 111, and is preferably distributed in a matrix matrix manner. In the preferred embodiment, the light source 130 is a light emitting diode; however, it is not limited thereto. The low-reflection portion 150 is formed on the bearing surface 111, and is formed by, but not limited to, applying a low-reflection material or forming a hole in the bearing surface 111 to reduce the relative position on the bearing surface 111. The low reflection portion 150 has a second reflectance, and the second reflectance is smaller than the aforementioned first reflectance.

As shown in FIG. 2 and FIG. 3 , the optical control film 300 is disposed above the light source module 100 , that is, a surface corresponding to the light emitted by the light source module 100 is disposed. The optical control film 300 is configured to distribute light generated by the light source 130 from different positions of the optical control film 300; in a preferred embodiment, the optical control film 300 has a reflective surface 301 facing one side of the light source 130, and optically regulated The film 300 itself passes through a plurality of light exit holes 310. In the embodiment shown in FIG. 2, the light exit holes 310 are preferably combined into a plurality of blocks 311 respectively corresponding to different light sources 130, and the block 311 is designed in one of the long side or the short side direction of the optical control film 300. there may be a slight discrepancy or identical, but places a fixed periodic manner arrayed in the other direction. The light generated by the light source 130 can be reflected back and forth through the reflective surface 301 and the bearing surface 111, and the optical control film 300 is passed through the optical aperture 310. Thus, the density of the optical aperture 310 on different positions on the optical control film 300 can be adjusted. The size is used to distribute the light generated by the light source 130 by varying the aperture ratio per unit area at different locations.

In addition, as shown in FIGS. 2 and 3, the optical control film 300 further includes a plurality of support through holes 330. The support through hole 330 also penetrates the optical control film 300, is mixed with the light exit hole 310, and is preferably disposed in a matrix arrangement. The support through-holes 330 preferably have the function of emitting light and securing the support member 510. Further, at least a portion of the support member perforations 330 are positioned the same as the support members 510, and the portions of the support member perforations 330 are periodically arranged . The support through hole 330 is preferably formed at a boundary position of the block 311 formed by the light exit hole 310. As shown in FIG. 3, at least a portion of the support perforations 330 overlap the low reflection portion 150 at a vertical projection range 331 of the bearing surface 111. In the preferred embodiment, the support perforations 330, which are not provided with the support member 510, fall within the range of the low reflection portion 150 at the vertical projection range 331 of the bearing surface 111; therefore, the area of the low reflection portion 150 needs to be larger than the support perforation 330. Area. However, in various embodiments, the vertical projection range 331 of the support perforation 330 in the bearing surface 111 also only partially overlaps the low reflection portion 150. For example, when the second reflectivity is much smaller than the first reflectance, the area of the low reflection portion 150 may be smaller than the area of the support through-hole 330, but only needs to be disposed below the support through-hole 330. As shown in FIG. 3, the low reflection portion 150 preferably does not protrude into the support through hole 330, that is, the support member through hole 330 is not substantially blocked.

In addition, the backlight module preferably includes a support member 510 and a diffusion plate 600; wherein the support member 510 is preferably formed in a column shape. As shown in FIG. 2 and FIG. 3, the support member 510 is disposed on the bearing surface 111 and protrudes upward through the support through hole 330 to support the diffusion plate 600 above the optical control film 300. In the preferred embodiment, the support member 510 and the low reflection portion 150 correspond to different support member perforations 330, respectively. For the support through hole 330 not provided with the support member 510, as shown in FIG. 4, it is preferable that the low reflection portion 150 is correspondingly disposed to absorb at least a portion of the light that may be emitted from the support member through hole 330 to the optical control film 300. In fact, the situation in which light leakage occurs due to reflection from the bearing surface 111 is substantially reduced.

In the embodiment shown in FIG. 5A, the low reflection portion 150 is a sheet-like structure and is attached to the bearing surface 111. In this embodiment, the low reflection portion 150 may be a dark or low reflective gelatinous material such as a film of rubber or polyethylene (PE). In addition, the low reflection portion 150 may also be disposed in such a manner that ink or other low reflectivity material is printed on the carrying surface 111 to form dots or films. In addition, in the embodiment shown in FIG. 5B, the low reflection portion 150 may also be a sheet member 151 that is locked on the bearing surface 111; in other words, the low reflection portion 150 may be extended from the sheet member 151 or an additional screw. A locking device 153 such as a rivet is directly attached to the bearing surface 111.

In a preferred embodiment, in order to achieve a better light leakage prevention effect, the support member perforation 330 area a, the low reflection portion 150 area A, and the second reflectance R preferably have the following relationship: (a/A)*R > 0.45 Equation 1 is as shown in the above formula. When the support perforation 330 area is fixed, the surface of the low reflection portion 150 can be adjusted. The second reflectance is accumulated to maintain a better light leakage prevention effect.

Figure 6 shows another embodiment of a backlight module. As shown in FIG. 6, the carrier 110 is composed of a carrier body 113 and a reflection sheet 115. The reflection sheet 115 is superposed on the carrier body 113, and one surface of the reflection sheet 115 facing away from the carrier body 113 is formed as the aforementioned bearing surface 111. In this embodiment, the reflectance of the carrier body 113 toward one of the faces of the reflective sheet 115 is smaller than the reflectance of the carrying surface 111 formed by the reflective sheet 115. As shown in FIG. 6, at least one hole 117 is formed in the reflection sheet 115; the hole 117 exposes the surface of the carrier body 113 having a lower reflectance below. With this arrangement, the hole 117 forms a low reflection portion 150 together with the exposed portion of the carrier body 113. Compared with the foregoing embodiment, this embodiment only needs to open the hole on the reflective sheet 115, and does not need to add the low reflection portion 150 in an additional process, which saves man-hours and cost.

In another embodiment shown in FIG. 7, a circuit board 170 is disposed under the carrier 110. Circuit board 170 can be a system board, a power board, or other board for different purposes. The circuit board 170 preferably has a lacquer surface on one side facing the carrier plate 110, and its reflectivity is also lower than the first reflectance of the carrier surface 111. As shown in FIG. 7, at least one hole 119 is formed in the carrier 110; the hole 119 exposes the lacquer surface of the circuit board 170 having a lower reflectivity below. With this arrangement, the holes 119, together with the portion of the exposed circuit board 170, form a low reflection portion 150. Compared with the foregoing embodiment, this embodiment only needs to open the hole in the carrier plate 110, and does not need to add the low reflection portion 150 in an additional process, which saves man-hours and cost. In addition, in different embodiments, the hole 119 may be simply formed on the carrier 110 to form the low reflection portion 150 under the condition that the circuit board 170 is not disposed below, and no light reflection material may be applied after the light is incident on the hole 119. Reflection, so it can also achieve the effect of absorbing light.

FIG. 8 is a flow chart showing an embodiment of a method of manufacturing a backlight module. As shown in Figure 8, The manufacturing method of the backlight module includes the step 810: forming a plurality of light exit holes and a plurality of support member through holes in the first region on the optical control film. Referring to FIG. 9A at the same time, the mold 700 has an embossed surface 710 thereon, and the embossed surface 710 has a plurality of protrusions 730 thereon. When the embossed surface 710 is pressed against the optical control film 300, the protrusion 730 forms a light hole 310 and a support through hole 330 at different positions on the optical control film 300, respectively. Due to cost considerations, the area of the embossed surface 710 is preferably less than 1/2 of the area of the optical conditioning film 300, so embossing is required in different regions of the optical conditioning film 300, such as the first region 391.

Next, in step 830, a plurality of light exit holes and a plurality of support member perforations are formed in the second region of the optical control film by the mold. Referring to FIG. 9B at the same time, the mold 700 is moved over the second region 392 for imprinting. Since the mold 700 is used repeatedly for the first region 391 or the second region 392, the protrusions 730 on the embossed surface 710 are also the same, and the illuminating holes 310 and the support holes 330 are equally distributed. .

Referring to FIG. 9C at the same time, in step 850, a plurality of low reflection portions 150 are formed on the bearing surface 111 of the carrier 110 and a plurality of light sources 130 are disposed to form a light source module, wherein the low reflection portion 150 has low reflectance. The reflectivity of the bearing surface 111. As shown in the foregoing embodiment, the low reflection portion 150 is preferably formed in a sheet shape and attached to the bearing surface 111, but may be formed by locking a member or penetrating a hole or the like. In addition, in the preferred embodiment, a plurality of support members 510 are also disposed on the bearing surface 111 to be mixed with the low reflection portion 150.

Referring to FIG. 9D at the same time, in step 870, the optical control film 300 is disposed above the light source module, and the low reflection portion 150 is opposed to the partial support through hole 330. The first region 391 and the second region 392 are respectively located above different positions of the bearing surface 111; since the supporting forces in different regions need to be different, the supporting members provided on the portion of the bearing surface 111 corresponding to the first region 391 The distribution position of the support member 510 disposed on the portion of the bearing surface 111 corresponding to the second region 392 is not the same, that is, the portions may be identical or all different. On the other hand, below the support through-holes 330 through which the support member 510 passes, there is a corresponding low-reflection portion 150. As shown in FIG. 10, the support perforation 330 in the first region 391 opposite to the low reflection portion 150 has a first relative positional distribution with respect to the range of the first region 391, and the second region 392 is opposite to the low reflection portion 150. The support perforations 330 have a second relative positional distribution relative to the extent of the second region 392. As mentioned before, the first relative position distribution and the second relative position distribution will not be exactly the same; that is, they may be partially identical or all different. With this arrangement, the embossing can be performed using a mold having a small embossed surface 710, and the light leakage can be reduced.

As described above, the present invention can form the light hole 310 and the support through hole 330 at different positions on the optical control film 300 by continuously punching the optical control film by using a small mold. The support member 510 is disposed corresponding to the support member through hole 330, and the lower portion of the support member through hole 330 that is not passed through the support member 510 corresponds to the low reflection portion 150, so that the problem of light leakage can be effectively avoided.

The present invention has been described by the above-described related embodiments, but the above embodiments are merely examples for implementing the present invention. It must be noted that the disclosed embodiments do not limit the scope of the invention. On the contrary, modifications and equivalents of the spirit and scope of the invention are included in the scope of the invention.

100‧‧‧Light source module

110‧‧‧ Carrier Board

111‧‧‧ bearing surface

130‧‧‧Light source

150‧‧‧low reflection section

300‧‧‧Optical Control Film

310‧‧‧Lighting hole

311‧‧‧ Block

330‧‧‧Support perforation

310‧‧‧Lighting surface

510‧‧‧Support

600‧‧‧Diffuser

Claims (19)

A backlight module includes: a light source module, comprising: a carrier board having a bearing surface; wherein the bearing mask has a first reflectivity; a plurality of light sources respectively disposed on the bearing surface; and at least one low The reflective portion is formed on the bearing surface and has a second reflectivity, wherein the second reflectivity is smaller than the first reflectivity; an optical control film is disposed above the light source module, and the light source is generated The optical control film comprises: a plurality of light-emitting holes respectively penetrating through the optical control film; and a plurality of support members perforated, respectively penetrating the optical control film and being mixed with the light-emitting holes; Wherein at least a portion of the support member is perforated in the vertical projection range of the bearing surface and overlaps the low reflection portion. The backlight module of claim 1, wherein the low reflection portion does not protrude into the support through hole. The backlight module of claim 1, wherein the low reflection portion is attached to the bearing surface in a sheet shape. The backlight module of claim 1, wherein the low reflection portion is printed on the bearing surface with a low reflectivity material. The backlight module of claim 1, wherein the low reflection portion comprises a sheet member locked to the bearing surface. The backlight module of claim 1, wherein the vertical projection range of the support member perforated in the bearing surface falls within the range of the low reflection portion. The backlight module of claim 1, wherein the ratio of the area of the support perforation to the area of the low reflection portion multiplied by the second reflectance is greater than 0.45. The backlight module of claim 1, wherein the carrier comprises: a carrier body; and a reflective sheet disposed on the carrier body; wherein the reflective sheet faces the one side of the carrier body to form the carrier The surface of the reflective sheet is formed with at least one hole, the hole exposing a portion of the carrier body, and the hole and the exposed portion of the carrier body together form the low reflection portion. The backlight module of claim 1, further comprising at least one support member disposed on the bearing surface and extending upward through the support through hole; wherein the support member and the low reflection portion Do not correspond to different support perforations. A backlight module includes: a light source module, comprising: a carrier board having a bearing surface; wherein the bearing mask has a first reflectivity; a plurality of light sources respectively disposed on the bearing surface; and at least one low The reflective portion is formed on the bearing surface and has a second reflectivity; wherein the second reflectivity is smaller than the first reflectivity; an optical control film is disposed above the light source module, and the light source is generated The optical control film comprises: a plurality of light-emitting holes respectively penetrating through the optical control film; and a plurality of support members perforated, respectively penetrating the optical control film and being mixed with the light-emitting holes; Wherein, the low reflection portion is correspondingly provided with the support member being perforated, and substantially reduces the amount of light generated by the light source reflected by the bearing surface and penetrating through the support member. The backlight module of claim 10, wherein the low reflection portion does not protrude into the support through hole. The backlight module of claim 10, wherein the low reflection portion is formed in a sheet shape and attached to the bearing surface. The backlight module of claim 10, wherein the low reflection portion comprises a sheet member locked to the bearing surface. The backlight module of claim 10, wherein the low reflection portion is printed on the carrying surface with a low reflectivity material. The backlight module of claim 10, wherein the vertical projection range of the support member perforated in the bearing surface falls within the range of the low reflection portion. The backlight module of claim 10, wherein the ratio of the area of the support perforation to the area of the low reflection portion multiplied by the second reflectance is greater than 0.45. The backlight module of claim 10, wherein the carrier comprises: a carrier body; and a reflective sheet disposed on the carrier body; wherein the reflective sheet faces the one side of the carrier body to form the carrier The surface of the reflective sheet is formed with at least one hole, the hole exposing a portion of the carrier body, and the hole and the exposed portion of the carrier body together form the low reflection portion. The backlight module of claim 10, further comprising at least one support member disposed on the bearing surface and extending upward through the through hole of the support member; wherein the support member and the low reflection portion Do not correspond to different support perforations. A method for manufacturing a backlight module, comprising the steps of: (a) forming a plurality of light exit holes and a plurality of support member through holes in a first region of an optical control film by a mold; (b) using the mold for the optical control a second area on the film forms a plurality of light exit holes and a plurality of support member perforations; (c) forming a plurality of low reflection portions on a bearing surface of one of the carrier plates and arranging a plurality of light sources to form a light source module, wherein The low reflection portion has a lower reflectivity than the carrier And (d) arranging the optical control film over the light source module, and the low reflection portion is opposite to a portion of the support member; wherein the first region is opposite to the low reflection portion The support member has a first relative position distribution with respect to the range of the first region, and the second region has a second relative position distribution with respect to the range of the second region in the second region opposite to the low reflection portion; The first relative position distribution is not exactly the same as the second relative position distribution.