TWI541546B - Display device and method for fabricating reflective sheet for the same - Google Patents

Description

Display device and method of manufacturing the same for the display device

The present disclosure relates to a display device and a method of manufacturing the reflective sheet of the display device. Moreover, and more particularly, it relates to a display device and a method of manufacturing the reflective sheet of the display device, wherein the method of manufacturing the reflective sheet assembly is utilized separately without a separate bead coating process, the first and second skin layers of the reflective sheet It can be formed to have an embossed surface.

The liquid crystal display device displays an image by adjusting the light transmittance of the liquid crystal having dielectric anisotropy by using an electric field. The liquid crystal display device includes a liquid crystal display panel, a backlight unit, and a driving circuit unit. The liquid crystal display panel includes a thin film transistor substrate and a color filter substrate. The thin film transistor substrate and the color filter substrate are opposite to each other. Bonding, the backlight unit emits light to the liquid crystal display panel, and the driving circuit unit is configured to drive the liquid crystal display panel.

The backlight unit includes a light source to generate light, a light guide plate to guide the light to the liquid crystal display panel, and a reflective sheet formed on a lower portion of the light guide plate to reflect light to the liquid crystal display panel.

The reflective sheet is supported by a bottom of the cover. Thus, the bottom of the cover is not flat and thus its load is locally concentrated, which causes adhesion between the reflective sheet and the light guide plate. In addition, light cannot occur through the compressed portion of the light guide plate and thus the image blurring of the dark areas.

In order to prevent adhesion between the reflective sheet and the light guide plate, as shown in Fig. 1, the reflective sheet includes a bead layer formed on the upper and lower portions of the reflective sheet, respectively.

As shown in Fig. 1, the reflective sheet is formed by a process for fabricating the structure of the reflective sheet, and the reflective sheet is coated with a bead layer by a bead coating process to form the bead layer. In other words, you need to enter A separate bead coating process is used for the formation of the bead layer, and therefore, the method results in high manufacturing cost and increased manufacturing time.

Thus, the bead coating process requires process line design and engineering costs, labor, and the cost of raw materials such as resins and beads required in the coating process. These factors are the main reason behind the increase in the cost of reflectors.

Accordingly, the present invention is directed to a display device and a method of fabricating the reflective sheet of the display device that substantially obviate one or more problems due to limitations and disadvantages of the related art.

It is an object of the present invention to provide a display device and a method of manufacturing the reflective sheet of the display device, wherein the first surface layer and the second surface of the reflective sheet can be formed by separately using a method of manufacturing a reflective sheet assembly without a separate bead coating process The skin layer has an embossed surface.

Additional advantages, objects, and features of the invention will be set forth in the description in the description. The objectives and other advantages of the invention will be realized and attained by the <RTI

In order to achieve the above objects and other advantages and in accordance with the purpose of the present invention, specifically and generally described herein, a display device includes a display panel for displaying an image; a plurality of light emitting diodes (LEDs) for generating light Providing the light to the display panel; a light guide plate for guiding light to the display panel; and a reflective sheet for reflecting light directed to a cover bottom disposed under the LEDs to the light guide plate And comprising a reflective layer, a first surface layer formed on the upper portion of the reflective layer, and a second surface layer formed on the lower portion of the reflective layer, wherein the first surface is formed by a plurality of first reflective patterns The skin layer and the second skin layer are formed to have an embossed surface for preventing adhesion between the reflective layer and the light guide plate to improve light efficiency, and the reflective layer comprises a plurality of second reflection patterns, each second reflection The pattern contains a filler in an air layer.

The first reflective patterns can include organic or inorganic fillers or beads.

Each of the first reflective patterns may comprise a filler in an air layer.

The first reflective patterns can include hollow fillers, each hollow filler comprising an air layer in a filler.

The first reflective patterns may have a size of 10 μm to 80 μm.

The first reflective patterns may include at least two different materials selected from the group consisting of organic fillers, inorganic fillers, hollow fillers, and beads.

The first reflective patterns can be configured such that the organic or inorganic fillers are formed on the hollow filler or beads.

The organic or inorganic fillers may have a size of from 1 μm to 2 μm, and the beads or hollow fillers may have a size of from 10 μm to 20 μm.

In another aspect of the invention, a method of making a reflective sheet, the method comprising preparing a non-oriented film by a melt-extrusion process, the non-oriented film comprising a first skin layer and a second skin layer and a reflective layer, Each of the first skin layer and the second skin layer includes a plurality of first reflection patterns disposed between the first skin layer and the second skin layer and including a plurality of second reflection patterns, the second reflections The pattern is formed from a surfactant-coated filler; the non-oriented film is compressed by an extrusion process; and the oriented film is oriented and heat treated in the machine and transverse directions, wherein the non-oriented film is oriented The first skin layer and the second skin layer are reduced in thickness and because the first reflective patterns have an embossed surface, and the reflective layer comprises the second reflective patterns, each second reflective pattern comprising a surrounding filler An air layer.

The first reflective patterns may include organic fillers, inorganic fillers or beads.

Each of the first reflective patterns may include a filler in an air layer.

The first reflective patterns can include hollow fillers, each hollow filler comprising an air layer in a filler.

The first reflective patterns may have a size of 10 μm to 80 μm.

The first reflective patterns may include at least two different materials selected from the group consisting of organic fillers, inorganic fillers, hollow fillers, and beads.

The first reflective patterns can be configured such that the organic or inorganic fillers are formed on the beads or hollow filler.

The organic or inorganic fillers may have a size of from 1 μm to 2 μm, and the beads or hollow fillers may have a size of from 10 μm to 20 μm.

In another aspect of the invention, a display device includes a display panel for displaying an image, and a plurality of light emitting diodes (LEDs) for generating light to provide the light to the display panel; a light guide plate for guiding light to the display panel; and a reflective sheet for reflecting light directed to the cover bottom disposed under the LEDs to the light guide plate and comprising a reflective layer formed on the reflective layer a first skin layer on the upper portion and a second skin layer formed on the lower portion of the reflective layer, wherein the first skin layer and the second skin layer are formed to have an embossed surface for preventing the reflective layer from the guide layer The light plates are bonded together to increase the efficiency of light, and the reflective layer comprises a plurality of bubble layers.

The first skin layer and the second skin layer can have an embossed surface and include a plurality of reflective patterns.

The reflective patterns can be the same size and comprise at least two different materials selected from the group consisting of organic fillers, inorganic fillers, and beads.

The reflective patterns can be of different sizes and comprise at least two different materials selected from the group consisting of organic fillers, inorganic fillers, and beads.

The reflective patterns can be configured such that the organic or inorganic fillers are formed on the beads.

The inorganic fillers may include calcium carbonate (CaCO ₃ ) or cerium oxide.

The organic fillers can include ruthenium.

The organic or inorganic fillers may have a size of from 1 μm to 2 μm, and the beads may have a size of from 10 μm to 20 μm.

In another aspect of the invention, a method of making a reflective sheet, the method comprising: preparing a film by a melt-extrusion process, the film comprising a first skin layer and a second skin layer and a reflective layer, the reflective layer disposed Between the first skin layer and the second skin layer; injecting CO ₂ gas into the film and forming a plurality of bubble layers in the reflective layer by a foaming process; forming an embossed surface by extruding the film The first skin layer and the second skin layer; and a reflective sheet comprising the first skin layer and the second skin layer having an embossed surface by a die cutting process.

The forming can include forming the first skin layer and the second skin layer having an embossed surface while the film passes between the upper and lower rolls each having a plurality of protrusions.

In the preparation, the first skin layer and the second skin layer may include a plurality of reflective patterns having the same size and comprising at least two different materials selected from the group consisting of organic fillers, inorganic fillers, and beads.

In the preparation, the first skin layer and the second skin layer may include a plurality of reflective patterns having different sizes and comprising at least two different materials selected from the group consisting of organic fillers, inorganic fillers, and beads.

When the first skin layer and the second skin layer comprise the reflective patterns by a melt-extrusion process, the forming may include forming the first skin layer and the second skin layer having an embossed surface by pressing the film. Each of the first skin layer and the second skin layer includes a plurality of reflective patterns that are disposed such that a soft organic or inorganic filler is formed over the beads.

The organic fillers can include ruthenium.

The inorganic fillers may include calcium carbonate (CaCO ₃ ) or cerium oxide.

The organic or inorganic fillers may have a size of from 1 μm to 2 μm, and the beads may have a size of from 10 μm to 20 μm.

The above general description and the following detailed description are intended to be illustrative and illustrative of the invention

100‧‧‧ top shell

110‧‧‧Model base

120‧‧‧LCD panel

130‧‧‧Optical film unit

130a‧‧‧Diffuser

130b‧‧‧ pictures

140‧‧‧Light guide plate

142‧‧‧ Groove section

150‧‧‧LED package

150a‧‧‧ Subject

150b‧‧‧LED

150c‧‧‧Resin materials

152‧‧‧LED reflector

154‧‧‧Light source substrate

160‧‧‧reflector

162‧‧‧ first surface

164‧‧‧ second surface

165‧‧‧First reflection pattern

166‧‧‧reflective layer

168‧‧‧second reflection pattern

168a‧‧ Air layer

168b‧‧‧Filling

172‧‧‧First reflection pattern

172a‧‧‧Filling

172b‧‧ Air layer

174‧‧‧First reflection pattern/hollow filler

174a‧‧ Air layer

174b‧‧‧Filling

176‧‧‧ bubble layer

178‧‧‧ first surface

179‧‧‧ second surface

182a‧‧·Resistance pattern

186‧‧‧reflective pattern

186a‧‧‧reflective pattern

186b‧‧‧reflective pattern

190‧‧‧ Covered

200‧‧‧ Beam

202, 204, 210‧‧‧ beams

210‧‧‧Oven (Fig. 10)

210a‧‧‧Upper roll

210b‧‧‧lower roller

212‧‧‧ Beam

214‧‧‧ Beam

286‧‧‧First reflection pattern

286a‧‧‧First reflection pattern

286b‧‧‧First reflection pattern

MD‧‧‧ machine direction

S10, S12, S14, S32, S34, S36‧‧ steps

TD‧‧‧ transverse direction

BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are set forth in the claims In the drawings: Fig. 1 is a cross-sectional view showing a process of coating a conventional reflection sheet using beads; and Fig. 2 is a cross-sectional view showing one of display devices according to the first embodiment and the second embodiment of the present invention; 3 to 3D are cross-sectional views illustrating an example of a reflection sheet of a display device according to a first embodiment of the present invention; 4 is a cross-sectional view of a reflection sheet and a light guide plate of a display device according to a first embodiment of the present invention; and FIG. 5 is a cross-sectional view for explaining light reflection of a reflection sheet of the display device according to the first embodiment of the present invention; 6 is a schematic view showing a process of fabricating a structure of a reflection sheet of a display device according to a first embodiment of the present invention; and FIG. 7 is a view for explaining a process for manufacturing a reflection sheet of a display device according to the first embodiment of the present invention. Cross-sectional view (Fig. 7(a) is a cross-sectional view of the non-oriented film according to the melt-extrusion process shown in Fig. 6, and Fig. 7(b) is a cross-sectional view of the oriented film according to the aligning process shown in Fig. 6. 8A to 8C are cross-sectional views illustrating an example of a reflection sheet of a display device according to a second embodiment of the present invention; and FIG. 9 is a view showing a reflection sheet and a light guide plate of the display device according to the second embodiment of the present invention; 1 is a schematic view illustrating a method of fabricating a structure of a reflective sheet of a display device according to a second embodiment of the present invention; and FIG. 11 is a view for explaining the manufacture of a display device according to a second embodiment of the present invention A cross-sectional view of a method of filming (Fig. 11(a) is a cross-sectional view of a film formed by the melt-extrusion process shown in Fig. 10, and Fig. 11(b) is a drawing process according to Fig. 10. Cutaway view of the film).

Hereinafter, embodiments will be described with reference to the accompanying drawings. The features and operational effects of the embodiments will be apparent from the following description of the specific embodiments. Throughout the drawings, the same reference numerals will be used to refer to the same elements. When the detailed description of the prior art causes unnecessary blurring of the subject matter of the present invention, the description thereof will be omitted.

Hereinafter, an exemplary embodiment of the present invention will be described with reference to FIGS. 2 to 11.

Fig. 2 is a cross-sectional view showing a display device in accordance with a first embodiment of the present invention.

Referring to FIG. 2, a display device according to a first embodiment of the present invention includes a display panel for displaying an image, a backlight unit for supplying light to the display panel, a mold frame 110 for accommodating the display panel, a top case 100, And a cover 190 for arranging the backlight unit, wherein the top case 100 surrounds an edge region of the display panel and is coupled to the mold frame 110.

The display panel can be, for example, a liquid crystal display panel, an organic light emitting display panel, and a liquid crystal display panel (serving as the display panel) will be described by way of example.

The liquid crystal display panel (indicated by reference numeral 120) includes a lower substrate, an upper substrate, a pixel electrode, and a common electrode, wherein the lower substrate includes a thin film transistor connected to a gate line and a A data line, the upper substrate includes a color filter to achieve color, and the pixel electrode is coupled to the thin film transistor, and the common electrode forms a vertical electric field or a horizontal electric field together with the pixel electrode.

The color filters are formed on the upper substrate to separate colors based on a black matrix. The color filters are formed based on red (R), green (G), and blue (B) to achieve red, green, and blue.

The common electrode may be formed on the back surface of the upper substrate as a transparent conductive film to form a vertical electric field together with the pixel electrode, or may be formed on the lower substrate as a transparent conductive film to form a horizontal electric field together with the pixel electrode. A reference voltage (for example, a common voltage) for driving the liquid crystal is applied to the common electrode.

The thin film transistor is formed on the lower substrate to selectively supply a data signal from the data line to the pixel electrode in response to a gate signal from the gate line. For the operation, the thin film transistor includes a gate electrode, a source electrode, a germanium electrode, an active layer overlapping the gate electrode, a gate insulating film, and an ohmic layer, wherein the gate electrode is connected to the gate line. The source electrode is connected to the data line, the germanium electrode is connected to the pixel electrode, the gate insulating film is disposed between the active layers, and the active layer forms a channel between the source electrode and the germanium electrode, the ohmic layer An ohmic contact is achieved between one of the active layers and the source electrode and between the other active layer and the germanium electrode.

The pixel electrode is independently formed in each of the plurality of pixel regions such that the pixel electrode overlaps the color filters R, G, and B, and is connected to the germanium electrode of the thin film transistor. When a data signal is supplied through the thin film transistor, the pixel electrode together with the common electrode A common voltage is applied to the common electrode to form a vertical electric field or a horizontal electric field such that liquid crystal molecules aligned in the vertical direction rotate according to dielectric anisotropy. Further, the transmittance of light passing through the pixel region is changed based on the degree of rotation of the liquid crystal molecules to achieve gray scale control.

The liquid crystal panel may be driven in a twisted nematic (TN) mode, an in-plane switching (IPS) mode, or a fringe field switching (FFS) mode. In the twisted nematic mode, the electrodes are disposed at two substrates, and the liquid crystal directors are arranged Distorted by 90 degrees, and a voltage is applied to the electrodes to drive the liquid crystal directors, in which the two electrodes are formed on a substrate and the liquid crystal director passes a horizontal electric field generated between the electrodes To control, in the fringe field switching mode, the two electrodes are formed as transparent conductive elements and the liquid crystal molecules are driven by the fringe field formed between the disposed electrodes, so that the distance between the electrodes is small. However, embodiments of the invention are not limited to the examples described above.

The top case 100 is manufactured to have a rectangular frame shape having a flat portion and a side portion bent at right angles. The top case 100 covers an edge area of the liquid crystal display panel 120 and is connected to a side of the mold frame 110. Therefore, the top case 100 protects the liquid crystal display panel 120 and the backlight unit from external impact and prevents elements of the display device disposed between the top case 100 and the cover bottom 190 from leaving the inside of the display device.

The cover bottom 190 houses and supports the backlight unit and is connected to the mold base 110.

The mold base 110 is formed of a plastic molding material or an alloy material, and an inner side wall of the mold base 110 is molded to have a stepped surface. The liquid crystal display panel 120 is disposed on the stepped surface of the mold frame 110, and its stepped surface prevents the backlight unit from moving and buffers an external impact applied to the backlight unit.

The backlight unit includes a plurality of light emitting diode (LED) packages 150 for generating light, a light guide plate 140 for guiding light to the liquid crystal display panel 120, an LED reflector 152, a reflective sheet 160, and an optical sheet unit 130. . In this way, the backlight unit can be side-light or direct-lit and provide light to the liquid crystal display panel 120 according to the orientation of the LED packages 150. In the direct type backlight unit, the LED packages 150 are disposed on the back surface of the light guide plate 140 to supply light to the liquid crystal display panel 120. In the edge type backlight unit, the LED packages 150 are disposed in the lateral direction of the light guide plate 140 to supply light to the liquid crystal display panel 120. The case where the LED packages 150 are arranged in the lateral direction of the light guide plate 140 will be described by way of example.

The LED packages 150 may be disposed on opposite sides or four sides of the light guide plate 140, respectively, in each case disposed on the light source substrate 154. Each LED package 150 includes a body 150a, an LED 150b, a lead frame (not shown), and a resin material 150c, wherein the LED 150b is disposed in a recessed portion of the body 150a, the lead frame is via a wire (not shown) Electrically connected to the LED 150b, the resin material 150c is formed to cover the LED 150b.

The light guide plate 140 is arranged in a direction in which light is emitted from the LED 150b and thus uniformly distributes light emitted from the LED 150b to the entire surface of the light guide plate 140, and then guides the light to the liquid crystal display panel 120. For this operation, the light guide plate 140 may be formed of a transparent and heat resistant polycarbonate or an acrylic resin which is transparent and has a high refractive index. Further, the light guide plate 140 is provided with a groove portion 142 at its lower surface, so that the efficiency of light emitted from the liquid crystal display panel 120 can be enhanced.

The optical sheet unit 130 diffuses and focuses the light emitted from the light guide plate 140, increases the brightness of the light, thereby causing an increase in luminous efficiency, and, thereafter, guiding the light to the liquid crystal display panel 120. The optical sheet unit 130 injects light emitted from the light guide plate 140 onto the liquid crystal display panel 120 after focusing, so that luminous efficiency is enhanced. For this operation, the optical sheet unit 130 includes at least two diffusion sheets 130a and a cymbal sheet 130b. The diffusion sheets 130a focus and diffuse light emitted from the light guide plate 140, and the cymbals 130b collect light emitted from the diffusion sheets 130a. The diffusion sheet 130a includes an upper diffusion sheet 130a disposed at an upper portion of the cymbal sheet 130b and a lower diffusion sheet 130a disposed at a lower portion of the cymbal sheet 130b.

The LED reflector 150 is formed of a reflective material, is connected to a portion of the mold frame 110, and between the light guide plate 140 and the LED package 150, reflects light directed to the mold frame 110 disposed on the LED packages 150 to the light guide plate 140.

The reflection sheet 160 reflects the light that is incident on the cover bottom 190 disposed under the LED 150b to the light guide plate 140. Further, the reflection sheet 160 extends to a position corresponding to the LED reflector 150 and thus reflects light directed to the cover bottom 190 disposed under the LED 150b to the light guide plate 140.

The reflective sheet 160 includes a reflective layer 166, a first surface layer 162, and a second surface layer 164. The first surface layer 162 is formed on the upper portion of the reflective layer 166, and the second surface layer 164 is disposed on the reflective layer 166. On the lower part.

As shown in FIGS. 3A to 3D, the first skin layer 162 and the second skin layer 164 include a plurality of first reflection patterns 165, and the first reflection patterns take the form of an embossed surface.

As shown in FIG. 3A, the first reflective patterns 165 may be formed of an organic filler or an inorganic filler or beads. As shown in FIG. 4, an air gap is formed between the reflective sheet 160 and the light guide plate 140 due to the first reflective pattern 165 in the first surface layer 162, and thus the reflective sheet 160 can be prevented from adhering to the light guide plate 140. Further, light incident on the reflection sheet 160 is reflected due to collision with a plurality of fillers or a plurality of beads.

As shown in FIG. 3B, the hollow filler 174 may be formed as the first reflective patterns 174. That is, each hollow filler 174 includes a filler 174b formed of an acrylic material and an air layer 174a formed in the filler 174b. The hollow filler 174 can prevent adhesion between the light guide plate 140 and the reflection sheet 160 due to the filler 174b formed of an acrylic material, and can enhance the reflectance of light due to the air layer 174a (refracted light) in each of the fillers 174b.

In particular, as shown in Fig. 5, a part of the light beam 212 incident on the reflection sheet 160 is reflected by the external collision with the respective filler 174b, and the remaining light beam 214 is refracted by the air layer 174a in the filler 174b. And the refracted beam is reflected or refracted by the second reflective pattern 168 within the reflective layer 166. Therefore, the hollow filler 174 formed in the first skin layer 162 can prevent the reflective sheet 160 from adhering to the light guide plate 140. The first reflective pattern 174 can include a hollow filler and an organic or inorganic material.

Further, as shown in FIG. 3C, the first reflective pattern 172 may include an air layer 172b and a filler 172a formed in the air layer 172b. Therefore, the surface of the light guide plate 140 and the surface of the reflection sheet 160 may be worn due to friction between the light guide plate 140 and the reflection sheet 160. However, in the present embodiment, the light guide plate 140 contacts the air layer 172b, and thus the wear of the reflection sheet 160 can be prevented, and the weight of the light guide plate 140 is also supported by the filler 172a having good rigidity, so that the light guide plate 140 can be prevented. Contact with the reflective sheet 160. By forming the first reflective pattern 172 such that the filler 172a is included in the air layer 172b, a portion of the light beam incident on the reflective sheet 160 is reflected by the collision with the filler 172a in the air layer 172b, and the remaining light beam is The equal air layer 172b is refracted, and the refracted light beam is reflected or refracted by the second reflective pattern 168 formed in the reflective layer 166. As shown in FIGS. 3B and 3C, the reflectance of light can be enhanced by forming the air layer 172b or 174a formed in the first reflective pattern 172 or 174. The first reflection patterns shown in FIGS. 3A to 3C may have a size of 10 μm to 80 μm.

Further, as shown in FIG. 3D, the first reflective pattern 286 may have an uneven surface and include a plurality of first reflective patterns 286a and 286b having different sizes. The first anti The shot patterns 286a and 286b may be formed of at least two different materials selected from the group consisting of organic fillers, inorganic fillers, beads, and hollow fillers.

Thus, as shown in FIG. 3D, in order to maintain the gap between the reflective sheet 160 and the light guide plate 140, the first reflective pattern 286 of the first skin layer 162 may include a hollow filler or beads 286a (rigid filler) and a soft organic or inorganic filler. 286b, the soft organic or inorganic fillers 286b have a relatively small size and are disposed on the hollow fillers or beads 286a, thereby preventing wear of the contact surface between the light guide plate 140 and the reflective sheet 160, and the light guide plate 140 Can be supported. Specifically, the first reflective patterns 286a and 286b included in the first skin layer 162 and the second skin layer 164 may be formed such that an organic or inorganic filler 286b having a smaller size than the hollow filler or beads 286a is disposed on the beads Above 286a. Thus, the organic or inorganic fillers 286b have a size of from 1 μm to 2 μm, and the hollow fillers or beads 286a have a size of from 10 μm to 20 μm.

In the reflective layer 166, a second reflective pattern 168 including a filler 168b formed in the air layer 168a is formed to reflect incident light. Specifically, as shown in FIG. 5, a portion of the light beam 202 in the light beam 200 passing through the first reflective patterns 174 is reflected by the filler 168b of the second reflective pattern 168 of the reflective layer 166, through the first reflection of the first surface layer 162. Each of the remaining beams 204 of the beam 200 of the pattern 174 is refracted by one of the air layers of the second reflective pattern 168, and the refracted beam 204 is reflected or refracted by the air layer 168a of the other second reflective pattern 168. For this reason, reflection and refraction are repeated, thereby enhancing the reflectance of the incident light.

As described above, by forming the air layer 168a and the filler 168b in the reflective layer 166, the light beam incident on the reflective layer 166 can be repeatedly refracted by the air layer 168a, and then the refracted light is reflected and incident on The light beam of the reflective layer 166 can also be reflected by the filler 168b to enhance the reflectivity of the incident light.

Fig. 6 is a schematic view showing a process of fabricating the structure of the reflection sheet 160 of the display device according to the first embodiment of the present invention. Fig. 7 is a cross-sectional view for explaining a process for manufacturing the reflection sheet 166 of the display device according to the first embodiment of the present invention. In particular, Fig. 7(a) is a cross-sectional view of the non-oriented film according to the melt-extrusion process shown in Fig. 6, and Fig. 7(b) is an oriented film according to the aligning process shown in Fig. 6. Cutaway view.

In the process of fabricating the structure of the reflective sheet 160 of the display device according to the first embodiment of the present invention, first, a non-oriented film is prepared by a melt-extrusion process (step S10), wherein The non-oriented film is composed of a first skin layer 162 and a second skin layer 164 and a reflective layer 166. Each of the first skin layer 162 and the second skin layer 164 includes the first reflective patterns 174, and the reflective layer 166 includes the second reflective patterns. 168, the second reflective patterns 168 are formed between the first skin layer 162 and the second skin layer 164. Thus, the first reflective patterns 174 can be formed from a hollow filler 174, each hollow filler 174 including an air layer 174a in a filler 174b formed of an acrylic material, and the second reflective patterns 168 can each include a surface active Filler 168b. Further, the first reflective patterns 174 may be formed of at least one of an organic filler, an inorganic filler, beads, and a surfactant-coated filler. The non-oriented film formed by the melt-extrusion process (step S10) is shown in Fig. 7(a).

Subsequently, the non-oriented film is compressed by an extrusion process (step S12).

Then, the non-oriented film is subjected to an alignment process in a machine direction (MD) and a lateral direction (TD), and then the oriented film is heat-treated (step S14).

As shown in FIG. 7(b), when the non-oriented film (including the first skin layer 162 and the second skin layer 164 and the reflective layer 166) is subjected to an alignment process in the machine direction and the lateral direction, the first skin layer 162 and the second skin layer 164 are 164. The thickness is reduced and since the first reflective pattern 174 has an embossed surface. At the same time, the reflective layer 166 is formed to include the second reflective patterns 168, each of which has a filler 168b within the air layer 168a.

Hereinafter, a method of forming the second reflective pattern 168 in the reflective layer 166 will be described in detail. When the filler 168b included in the reflective layer 166 is oriented in the machine and transverse directions, each of the air layers 168a is formed in the filler 168b due to the surfactant coated on the outer surface of each filler 168b. Between the reflective layers 166. That is, the filler 168b does not adhere to the reflective layer 166 due to the surfactant applied to the outer surface of the filler 168b. To this end, due to the surfactant, there is no adhesion between the filler 168b and the reflective layer 166, and when the film of the reflective layer 166 is stretched in the machine and transverse directions, the air layer 168a is formed around each of the fillers 168b. At the same time, the first skin layer 162 and the second skin layer 164 are reduced in thickness by the orientation process and have an embossed surface depending on the shape of the hollow fillers 174.

As described above, the hollow fillers 174 are formed as the first reflective patterns in the first skin layer 162 and the second skin layer 164, but embodiments of the present invention are not limited thereto. For example, the first reflective pattern within the first skin layer 162 and the second skin layer 164 can be formed from at least one of an organic filler, an inorganic filler, beads, and a surfactant-coated filler.

When the first reflective pattern in the first skin layer 162 and the second skin layer 164 is formed of an organic filler, an inorganic filler or a bead, the first skin layer 162 and the second skin layer 164 have a reduced thickness due to the orientation process and have a shape according to the formation of the filler or the beads. An embossed surface, as shown in Figures 3A and 3B.

In the case where the first reflective pattern (for example, the first reflective pattern 172) in the first surface layer 162 and the second surface layer 164 is formed of a surfactant-coated filler, as shown in FIG. 3C, the first surface layer is simultaneously formed. 162 and second skin layer 164 are stretched in the machine and transverse directions. The air layer 172b is formed between the filler 172a and the first skin layer 162. The air layers 172b are formed on the filler 172a and the second skin layer 164. Between, and the first skin layer 162 and the second skin layer 164 have an embossed surface depending on the shape of the filler 172a. Thus, due to the surfactant applied to the outer surface of the filler 172a, between the filler 172a and the first skin 162 during the drawing process and between the filler 172a and the second skin 164, the air layer 172b The formation is due to the absence of adhesion between the filler 172a and the first skin 162 and between the filler 172a and the second skin 164.

Further, in the case where the first reflective pattern 286 of the first skin layer 162 and the second skin layer 164 is formed of at least two different materials selected from the group consisting of organic fillers, inorganic fillers, and beads, as shown in FIG. 3D, the soft organic Or an inorganic filler 286b is disposed over the hollow filler or beads 286a that is a rigid filler while the reflective sheet 160 is stretched in the machine and transverse directions such that the first skin layer 162 and the second skin layer 164 are due to the beads 286a and The fillers 286b have an uneven surface. The organic or inorganic filler 286b formed over the beads 286a has a size of 1 μm to 2 μm, and the beads 286a have a size of 10 μm to 20 μm.

As described above, according to the process for manufacturing the reflective sheet according to the present embodiment, by using a process of separately fabricating the structure of the reflective sheet, since the bead, the organic filler, the inorganic filler, the hollow filler, or the surfactant-coated filler is included, The first skin layer 162 and the second skin layer 164 can be formed to have an embossed surface.

Conventionally, in addition to the process of fabricating a reflective sheet assembly, a bead layer is formed on each of the first skin layer and the second skin layer by a different method of coating the reflective sheet with beads. However, in accordance with the method of manufacturing the reflective sheet according to the present embodiment, the first surface layer 162 and the second surface layer 164 may be formed to include beads, an organic filler, an inorganic filler, a hollow filler, or a coating only by a process of fabricating the structure of the reflective sheet. A filler having a surfactant can also be formed to have an embossed surface.

8A to 8C are cross-sectional views illustrating an example of a reflection sheet 160 of the display device according to the second embodiment of the present invention.

The elements of the display device according to the second embodiment of the present invention are identical to the elements of the display device according to the first embodiment of the present invention, and thus, the elements other than the reflective sheet are omitted, except that the display device includes different reflective sheets. A detailed description.

The reflective sheet 160 according to the second embodiment of the present invention includes a reflective layer 166, a first surface layer 178 formed on an upper portion of the reflective layer 166, and a second surface layer 179 formed on a lower portion of the reflective layer 166.

The first skin layer 178 and the second skin layer 179 can be formed to have an embossed surface as shown in Figure 8A. Specifically, due to friction between the light guide plate 140 and the reflective sheet 160, the pattern and surface of the light guide plate 140 and the surface of the reflective sheet 160 may be worn. However, in the present embodiment, the first skin layer 178 and the second skin layer 179 are formed of a soft material and have an embossed surface, and thus, abrasion of the light guide plate 140 and the reflection sheet 160 can be prevented. Further, when the first skin layer 178 and the second skin layer 179 have an embossed surface, light is reflected and diffused due to the embossed surface thereof, thereby enhancing the reflectance of light.

As shown in FIG. 8B, the first skin layer 178 and the second skin layer 179 may have an embossed surface and include a plurality of reflective patterns 182a having the same size. Thus, the reflective patterns 182a may be formed of at least two different materials selected from the group consisting of organic fillers, inorganic fillers, and beads. The inorganic fillers may be formed of calcium carbonate (CaCO ₃ ), cerium oxide, or the like, and the organic fillers may be formed of cerium. The organic filler or inorganic filler may have a size of from 20 μm to 50 μm.

Thus, in order to prevent abrasion between the light guide plate 140 and the reflection sheet 160, the reflection patterns 182a may be formed of an organic or inorganic filler having high elasticity and being soft, thereby reducing friction between the light guide plate 140 and the reflection sheet 160. Further, the reflective patterns 182a are formed using a filler having a relatively high rigidity such as beads to support the weight of the light guide plate 140 and prevent contact between the light guide plate 140 and the reflective sheet 160.

In another embodiment, as shown in FIG. 8C, the first skin layer 178 and the second skin layer and 179 may have an uneven surface and include a plurality of reflective patterns 186a and 186b having different sizes. The reflective patterns 186a and 186b may be formed of at least two different materials selected from the group consisting of organic fillers, inorganic fillers, and beads.

Thus, as shown in FIG. 8C, each of the first reflective patterns of the first skin layer 178 includes beads 186a and a filler 186b to maintain a gap between the reflective sheet 160 and the light guide plate 140, wherein the beads 186a are rigid fillers, An iso-filler 186b is formed over the bead 186a and is formed of a soft organic or inorganic material having a relatively small size. For this reason, the wear resistance of the contact surface between the light guide plate 140 and the reflection sheet 160 can be improved and the weight of the light guide plate 140 can be supported. As described above, the first reflective pattern included in the first skin layer 178 can be formed such that the organic or inorganic fillers 186b are smaller than the beads 186a and disposed over the beads 186a. Thus, the organic or inorganic fillers 286b have a size of from 1 μm to 2 μm, and the beads 286a have a size of from 10 μm to 20 μm.

Further, as shown in FIGS. 8B and 8C, when each of the first skin layer 178 and the second skin layer 179 has an embossed surface and includes the filler 186b or the beads 186a, the light is embossed by the surface and the The filler 186b or the beads 186a are reflected and diffused so that the reflective sheet 160 can have improved light reflectivity.

Reflective layer 166 includes a plurality of bubble layers 176 and thus reflects incident light. In particular, since the bubble layers 176 are included in the reflective layer 166, light incident on the reflective layer 166 is refracted by one of the bubble layers 176, and the refracted light is again refracted by the other of the bubble layers 176. . In this way, the light that is refracted and then refracted is reflected. To this end, the bubble layers 176 increase the reflectivity of the light. The bubble layers 176 have an elliptical shape having a long axis in a horizontal direction.

Fig. 10 is a schematic view showing a method of fabricating a structure of a reflection sheet of a display device according to a second embodiment of the present invention. Figure 11 is a cross-sectional view for explaining a method of manufacturing a reflection sheet according to a second embodiment of the present invention. In particular, Fig. 11(a) is a cross-sectional view of a film formed according to the melt-extrusion process shown in Fig. 10, and Fig. 11(b) is a film formed by the extrusion process shown in Fig. 10. Cutaway view.

In the reflection sheet according to the second embodiment of the present invention, the first skin layer 178 and the second skin layer 179 may have an embossed surface, or may have an embossed surface and further include a plurality of reflection patterns. A method of manufacturing a reflective sheet including a first skin layer 178 having an embossed surface and a second skin layer 179 will now be described.

In the method of manufacturing a reflective sheet according to a second embodiment of the present invention, a film is formed by a melt-extrusion process, the film including a reflective layer 166, a first surface layer 178 formed on an upper portion of the reflective layer 166, and A second skin layer 179 is formed on the lower portion of the reflective layer 166. Thus, the first skin layer 178 and the second skin layer 179 can each be formed as a flat film, as shown in FIG. 11(a), or can include a plurality of reflective patterns. Subsequently, CO ₂ gas is injected into the reflective layer 166 of the film formed by the melt-extrusion process.

Thereafter, the film in which the CO ₂ gas is injected is subjected to a foaming process to form the bubble layer 176 in the reflective layer 166 (step S32). Specifically, the film in which the CO ₂ gas is injected is placed in the oven 210, and the CO ₂ gas placed in the non-oriented film in the oven 210 is replaced by air, and as a result, foaming occurs. Therefore, the bubble layers 176 are formed in the reflective layer 166.

Next, the first skin layer 178 and the second skin layer 179 of the film are formed by an extrusion process to have an embossed surface (step S34). Specifically, as shown in Fig. 11(b), the first skin layer 178 is formed to have an embossed surface while the upper roller 210a having a plurality of protrusions passes through the first skin layer 178. At the same time, the second skin 179 is formed to have an embossed surface while the lower roll 210b having a plurality of protrusions passes through the second skin 179.

Finally, a reflective sheet including the first skin layer 178 and the second skin layer 179 each having an embossed surface is cut by a die cutting process (step S36).

As a method of manufacturing the reflection sheet according to the second embodiment of the present invention, a method of manufacturing a reflection sheet including the first skin layer 178 and the second skin layer 179 having an embossed surface while also including a plurality of reflection patterns will now be described.

In the method of manufacturing a reflective sheet according to a second embodiment of the present invention, a film is produced by a melt-extrusion process, the film comprising a first skin layer 178 and a second skin layer 179 and a reflective layer 166, wherein the first skin layer 178 and second skin layer 179 each include the reflective patterns 166 disposed between the first skin layer 178 and the second skin layer 179. Thus, the reflective patterns can be of the same size and formed from at least two different materials selected from the group consisting of organic fillers, inorganic fillers, and beads. In another embodiment, the reflective patterns can be of different sizes and formed from at least two different materials selected from the group consisting of organic fillers, inorganic fillers, and beads. The organic or inorganic fillers have high elasticity and are formed of a soft material, and the beads have higher rigidity than the organic or inorganic fillers and thus support the weight of the light guide plate 140, thereby maintaining the light guide plate 140 and the reflection sheet 160 Clearance. For example, the inorganic fillers may be formed of calcium carbonate (CaCO ₃ ), cerium oxide, or the like, and the organic fillers may be formed of cerium. The organic filler or inorganic filler may have a size of from 20 μm to 50 μm.

Subsequently, the film in which the CO ₂ gas is injected is subjected to a foaming process to form the bubble layer 176 in the reflective layer 166 (step S32). Film injecting the CO ₂ gas 210 is placed in an oven and placed in a CO ₂ gas within the oven 210 in the non-oriented film is replaced by air, the result, foaming occurs. Therefore, the bubble layers 176 are formed in the reflective layer 166 (step S32).

Thereafter, the first skin layer 178 and the second skin layer 179 including the reflective patterns of the film are formed by an extrusion process to have an embossed surface (step S34). Specifically, as shown in Fig. 11(b), the first skin layer 178 is formed to have an embossed surface while the upper roller 210a having a plurality of protrusions passes through the first skin layer 178. At the same time, the second skin 179 is formed to have an embossed surface while the lower roll 210b having a plurality of protrusions passes through the second skin 179. Therefore, the first skin layer 178 and the second skin layer 179 each having the embossed surface as shown in FIG. 8B and including the reflective patterns 182a having the same size can be obtained, or each of them can be obtained as shown in FIG. 8C. The embossed pattern includes a plurality of first skin layers 178 and second skin layers 179 having differently sized reflective patterns 186.

Finally, a reflective sheet including the first skin layer 178 and the second skin layer 179 including the reflective patterns 182a or 186 is cut by a die cutting process (step S36).

As described above, according to the method of manufacturing the reflective sheet according to the second embodiment of the present invention, the first skin layer 178 and the second skin layer 179 may be formed to have an embossed surface or may include a filler or a bead.

Conventionally, in addition to the process of fabricating a reflective sheet assembly, a bead layer is formed on each of the first skin layer and the second skin layer by different processes of coating the reflective sheet with beads. However, according to the process for manufacturing the reflective sheet according to the second embodiment of the present invention, the reflective sheet fabric manufacturing process is separately used without using the separate bead coating process, and the first skin layer 178 and the second skin layer 179 may be formed to have an embossing The surface also includes a plurality of fillers or beads.

It is apparent from the above that, according to the display device and the method of manufacturing the reflective sheet, according to the present invention, a reflective sheet comprising a first surface layer and a second surface layer can be formed by the orientation step of the reflective sheet assembly manufacturing process. The first skin layer and the second skin layer have an embossed surface due to the plurality of reflective patterns. To this end, the reflective sheet assembly manufacturing process is utilized only without the need for a separate bead coating process, and a reflective sheet comprising a first skin layer and a second skin layer having an embossed surface in accordance with the shape of the plurality of reflective patterns can be formed.

According to the display device and the method of manufacturing the reflective sheet, the reflective sheet comprising the first skin layer and the second skin layer having an embossed surface can be formed by the pressing step of the reflective sheet assembly manufacturing method. To this end, a reflective sheet comprising a first skin layer having an embossed surface and a second skin layer can be formed using only the sheet structure manufacturing process without a separate bead coating process.

As described above, by forming the reflective sheet including the first surface layer and the second surface layer having an embossed surface by using only the reflective sheet fabric manufacturing process, the cost required for the bead coating process can be reduced, such as manufacturing equipment cost and labor. Cost, raw material cost, etc.

In addition, since the first surface layer and the second surface layer of the display device are formed by the plurality of first reflection patterns to have an embossed surface, adhesion between the light guide plate and the reflection sheet can be prevented and the reflection efficiency of light can be enhanced. Further, a plurality of second reflective patterns may be formed in a reflective layer, each of the second reflective patterns having a filler in an air layer, thereby enhancing light reflection efficiency.

Furthermore, the first skin layer and the second skin layer of the display device can be formed to have an embossed surface, and thus the adhesion between the light guide plate and the reflection sheet can be prevented and the reflection efficiency of light can be enhanced. Further, a plurality of bubble layers are formed in the reflective layer, so that the reflection efficiency of light can be improved.

Various modifications and alterations of the present invention are apparent to those skilled in the art without departing from the scope of the invention. Accordingly, the present invention is intended to cover the modifications and modifications of the invention

The present application claims the benefit of the Korean Patent Application No. 10-2012-0146893 filed on Dec. 14, 2012, and the Korean Patent Application No. 10-2013-0094372 filed on August 8, 2013, the entire disclosure of which is The references are incorporated herein.

162‧‧‧ first surface

164‧‧‧ second surface

166‧‧‧reflective layer

168‧‧‧second reflection pattern

168a‧‧ Air layer

168b‧‧‧Filling

174‧‧‧First reflection pattern

174a‧‧ Air layer

174b‧‧‧Filling

Claims (13)

A display device includes: a display panel for displaying an image; a plurality of light emitting diodes (LEDs) for generating light to provide the light to the display panel; and a light guide plate for guiding the light to The display panel; and a reflective sheet that reflects light directed to a cover bottom disposed under the LEDs to the light guide plate and includes a reflective layer, a first surface layer formed on an upper portion of the reflective layer And a second skin layer formed on a lower portion of the reflective layer, wherein the first skin layer and the second skin layer are formed to have an embossed surface due to the plurality of first reflective patterns to prevent the reflective layer from Bonding between the light guide plates to improve light efficiency, and the reflective layer includes a plurality of second reflective patterns, each of the second reflective patterns comprising a filler in an air layer, wherein the first reflective patterns are configured A soft filler having a smaller size than the rigid filler is disposed on the rigid filler, and wherein the rigid filler is a hollow filler or a bead, and the soft filler is an organic filler or an inorganic filler. The display device according to claim 1, wherein the organic or inorganic filler has a size of from 1 μm to 2 μm, and the beads or hollow fillers have a size of from 10 μm to 20 μm. A method of manufacturing a reflective sheet, the method comprising: preparing a non-oriented film by a melt-extrusion process, the non-oriented film comprising a first skin layer and a second skin layer and a reflective layer, the first skin layer and the second layer Each of the surface layers includes a plurality of first reflective patterns disposed between the first surface layer and the second surface layer and including a plurality of second reflective patterns coated with a surfactant Filler formation; Compressing the non-oriented film by an extrusion process; and orienting and thermally treating the oriented film in the machine and transverse directions, wherein the first skin layer and the second skin layer are oriented when the non-oriented film is oriented Reducing and having an embossed surface due to the first reflective patterns, and the reflective layer includes the second reflective patterns, each of the second reflective patterns comprising an air layer surrounding a filler, wherein the first reflections A soft filler having a pattern configured to be smaller than a rigid filler is disposed on the rigid filler, and wherein the rigid filler is a hollow filler or a bead, and the soft filler is an organic filler or an inorganic filler. The method of producing a reflective sheet according to claim 3, wherein the organic or inorganic filler has a size of from 1 μm to 2 μm, and the beads or hollow filler have a size of from 10 μm to 20 μm. A display device includes: a display panel for displaying an image; a plurality of light emitting diodes (LEDs) for generating light to provide the light to the display panel; and a light guide plate for guiding the light to The display panel; and a reflective sheet that reflects light directed to a cover bottom disposed under the LEDs to the light guide plate and includes a reflective layer, a first surface layer formed on an upper portion of the reflective layer And a second skin layer formed on the lower portion of the reflective layer, wherein the first skin layer and the second skin layer are formed to have an embossed surface for preventing adhesion between the reflective layer and the light guide plate The efficiency of light, wherein the reflective layer comprises a plurality of bubble layers, wherein the first skin layer and the second skin layer comprise a plurality of reflective patterns, wherein the reflective patterns are configured to be smaller than a rigid filler. Above the rigid fillers, and wherein the rigid fillers are beads, and the soft fillers are organic or inorganic fillers. The display device according to claim 5, wherein the inorganic filler comprises calcium carbonate (CaCO ₃ ) or cerium oxide. The display device according to claim 5, wherein the organic filler comprises ruthenium. The display device according to claim 5, wherein the organic or inorganic filler has a size of from 1 μm to 2 μm, and the beads have a size of from 10 μm to 20 μm. A method of manufacturing a reflective sheet, the method comprising: preparing a film by a melt-extrusion process, the film comprising a first skin layer and a second skin layer and a reflective layer, the reflective layer being disposed on the first skin layer and the Between the second skin layers; injecting CO ₂ gas into the film and forming a plurality of bubble layers in the reflective layer by a foaming process; forming the first skin layer having an embossed surface and the first by pressing the film a second skin layer; and the use of a die cutting process to cut the reflective sheet comprising the first skin layer and the second skin layer having an embossed surface, wherein the first skin layer and the second skin layer comprise a plurality of reflective patterns, wherein The reflective pattern is configured such that a soft filler having a smaller size than the rigid filler is disposed on the rigid filler, and wherein the rigid filler is a bead, and the soft filler is an organic filler or an inorganic filler. The method of producing a reflective sheet according to claim 9, wherein the forming comprises forming the first surface having an embossed surface when the film passes between the upper roller and the lower roller each having a plurality of protrusions a surface layer and the second surface layer. A method of manufacturing a reflective sheet according to claim 10, wherein the organic The filler contains ruthenium. The method of producing a reflective sheet according to claim 10, wherein the inorganic filler comprises calcium carbonate (CaCO ₃ ) or cerium oxide. The method of producing a reflective sheet according to claim 10, wherein the organic or inorganic filler has a size of from 1 μm to 2 μm, and the beads have a size of from 10 μm to 20 μm.