WO2020015401A1 - 导光板的制作方法和显示装置的制作方法 - Google Patents

导光板的制作方法和显示装置的制作方法 Download PDF

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Publication number
WO2020015401A1
WO2020015401A1 PCT/CN2019/082295 CN2019082295W WO2020015401A1 WO 2020015401 A1 WO2020015401 A1 WO 2020015401A1 CN 2019082295 W CN2019082295 W CN 2019082295W WO 2020015401 A1 WO2020015401 A1 WO 2020015401A1
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WIPO (PCT)
Prior art keywords
foaming agent
polymer material
guide plate
light guide
sub
Prior art date
Application number
PCT/CN2019/082295
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English (en)
French (fr)
Inventor
程加河
Original Assignee
惠科股份有限公司
重庆惠科金渝光电科技有限公司
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Publication of WO2020015401A1 publication Critical patent/WO2020015401A1/zh

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    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/0001—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems
    • G02B6/0011—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems the light guides being planar or of plate-like form
    • G02B6/0065—Manufacturing aspects; Material aspects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/0001—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems
    • G02B6/0011—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems the light guides being planar or of plate-like form
    • G02B6/0033—Means for improving the coupling-out of light from the light guide
    • G02B6/0035—Means for improving the coupling-out of light from the light guide provided on the surface of the light guide or in the bulk of it
    • G02B6/004—Scattering dots or dot-like elements, e.g. microbeads, scattering particles, nanoparticles
    • G02B6/0041—Scattering dots or dot-like elements, e.g. microbeads, scattering particles, nanoparticles provided in the bulk of the light guide

Definitions

  • the present application relates to the field of display technology, and in particular, to a method for manufacturing a light guide plate and a method for manufacturing a display device.
  • a surface light source is often formed by combining a light guide plate with an edge-type light source, and the light emitted by the edge-type light source enters the light guide plate from the light entrance surface on one side of the light guide plate, and then passes through the light guide point of the light guide plate After being emitted and diffused, the light is emitted from the light exit surface of the light guide plate to provide the display panel with light required for work.
  • the embodiments of the present application provide a method for manufacturing a light guide plate and a method for manufacturing a display device. Through the embodiments of the present application, the weight of the light guide plate and the display device can be reduced, and display uniformity can be improved.
  • a method for manufacturing a light guide plate includes: providing a polymer material; providing a foaming agent; and mixing the polymer material and the foaming agent in a preset manner and The injection mold is injected to produce a light guide plate containing air bubbles, and the air bubbles are generated by the foaming agent; wherein the polymer material is polymethyl methacrylate or polycarbonate; and the foaming agent is Nitrogen or carbon dioxide; the step of mixing the polymer material and the foaming agent in a predetermined manner and injecting them into a molding mold to prepare a light guide plate containing air bubbles, and the air bubbles are generated by the foaming agent
  • the method comprises: uniformly mixing the polymer material and the foaming agent and injecting the molding die to obtain a light guide plate including uniformly distributed bubbles, and the bubbles are generated by the foaming agent.
  • the polymer material is polymethyl methacrylate or polycarbonate.
  • the polymer material and the foaming agent are mixed in a predetermined manner and injected into a molding mold to obtain a light guide plate containing air bubbles, and the air bubbles are generated by the foaming agent.
  • the step of generating includes uniformly mixing the polymer material and the foaming agent and injecting the molding die to obtain a light guide plate containing uniformly distributed bubbles, and the bubbles are generated by the foaming agent.
  • the polymer material and the foaming agent are mixed in a predetermined manner and injected into a molding mold to obtain a light guide plate containing air bubbles, and the air bubbles are generated by the foaming agent.
  • the generated steps include: injecting the polymer material into the forming mold in a first period of time; continuing to inject the polymer material into the forming mold in a second period of time to uniformly mix the polymer material and the blowing agent The resulting mixture; and continued injecting the polymer material into the forming mold for a third period of time.
  • the time lengths of the first time and the third time are equal.
  • the polymer material and the foaming agent are mixed in a predetermined manner and injected into a molding mold to obtain a light guide plate containing air bubbles, and the air bubbles are generated by the foaming agent.
  • the generated steps include: injecting the polymer material into a first sub-mold to make a first sub-plate; and injecting a mixture obtained by uniformly mixing the polymer material and the foaming agent into a second sub-mold to produce A second sub-board containing uniformly distributed air bubbles is obtained, and the air bubbles are generated by the foaming agent; the polymer material is injected into a third sub-mold to make a third sub-board; and the first sub-board is made;
  • the daughter board, the second daughter board, and the third daughter board are aligned and superimposed and combined in a thickness direction to obtain the light guide plate; wherein the first daughter board, the second daughter board, and the first daughter board
  • the three daughter boards have the same length and the same width, and the second daughter board is located between the first daughter board
  • the thicknesses of the first and second sub-boards are different.
  • the polymer material and the foaming agent are mixed in a predetermined manner and injected into a molding mold to obtain a light guide plate containing air bubbles, and the air bubbles are generated by the foaming agent.
  • the generated steps include: injecting the polymer material into a first sub-mold to make a first sub-plate; and injecting a mixture obtained by uniformly mixing the polymer material and the foaming agent into a second sub-mold to produce A second daughter board containing uniformly distributed bubbles is obtained, and the bubbles are generated by the foaming agent; the polymer material is injected into a third daughter mold to make a third daughter board; and the polymer material A mixture obtained by uniformly mixing with the foaming agent is injected into a fourth sub-mold to obtain a fourth daughter board containing uniformly distributed bubbles, and the bubbles are generated by the foaming agent; the polymer material is injected A fifth sub-mold to make a fifth sub-board; and aligning the first sub-board, the second sub-board, the third sub
  • the polymer material and the foaming agent are mixed in a predetermined manner and injected into a molding mold to obtain a light guide plate containing air bubbles, and the air bubbles are generated by the foaming agent.
  • the generated steps include: injecting the mixture obtained by uniformly mixing the polymer material and the foaming agent in a first ratio into the forming mold in a first period of time; and continuing into the forming mold in a second period of time Injecting the mixture obtained by uniformly mixing the polymer material and the foaming agent in a second ratio; and continuously injecting the polymer material and the foaming agent in a third time period into the molding mold for a third time A mixture obtained by uniformly mixing ratios; wherein the second ratio is smaller than the first ratio and the third ratio.
  • An embodiment of the present application further provides a method for manufacturing a display device, including: providing a light guide plate, the light guide plate is made by the method for manufacturing a light guide plate according to any one of the foregoing embodiments, and the light guide plate includes: a body Air bubbles are formed in the body; a light incident surface is located at a side of the body; and a light emitting surface is located at the top of the body; a back plate is provided and the back A board is installed on a side of the bottom of the body that is far from the top, and a surface of the back plate facing the body is a smooth surface that is mirror-finished; a light emitting unit is provided, and the light emitting unit is adjacent to the light incident surface Setting; providing an optical film group, and setting the optical film group on a side of the top part away from the bottom part.
  • air bubbles are formed in the light guide plate, which can reduce the weight of the light guide plate without reducing the thickness of the light guide plate.
  • the air bubbles in the light guide plate can destroy the total reflection of the light in the light guide plate and generate fog
  • the light output effect enables more light to be emitted from the light exit surface of the light guide plate, and finally achieves the technical effect of reducing the weight of the light guide plate and improving the uniformity of the display while ensuring the thickness of the light guide plate.
  • FIG. 1 is a schematic flowchart of a method for manufacturing a light guide plate according to an embodiment of the present application
  • FIG. 2 is a schematic flowchart of a method for manufacturing a display device according to an embodiment of the present application
  • FIG. 3 is a schematic diagram of a light guide plate and a display device including the light guide plate, which are obtained by using the method provided by an embodiment of the present application;
  • FIG. 4 is a schematic diagram of a light guide plate and a display device including the light guide plate, which are obtained by using the method provided by an embodiment of the present application;
  • FIG. 5 is a schematic diagram of a light guide plate and a display device including the light guide plate obtained by using the method provided by an embodiment of the present application;
  • FIG. 6 is a schematic diagram of a light guide plate and a display device including the light guide plate prepared by using the method provided by an embodiment of the present application;
  • FIG. 7 is a schematic diagram of a light guide plate and a display device including the light guide plate prepared by using the method provided by an embodiment of the present application.
  • the display device in the embodiment of the present application may be a liquid crystal display panel, an OLED (Organic Light Emitting Diode) display device, a QLED (Quantum Dot Light Emitting Diode) display device, a curved display device, or other display device .
  • OLED Organic Light Emitting Diode
  • QLED Quadantum Dot Light Emitting Diode
  • an embodiment of the present application provides a method for manufacturing a light guide plate, which mainly includes:
  • Step S11 providing a polymer material
  • Step S13 providing a foaming agent
  • Step S15 The polymer material and the foaming agent are mixed in a predetermined manner and injected into a molding mold to obtain a light guide plate containing air bubbles, and the air bubbles are generated by the foaming agent.
  • the polymer material is, for example, a polymer material such as PMMA (Polymethylmethacrylate, polymethylmethacrylate) or transparent PC (Polycarbonate, polycarbonate).
  • the foaming agent is, for example, a foaming agent such as nitrogen or carbon dioxide.
  • step S15 includes, for example, uniformly mixing the polymer material and the foaming agent and injecting the molding die to obtain a light guide plate including uniformly distributed air bubbles, and the air bubbles are formed by Said foaming agent is produced.
  • step S15 includes, for example ,: injecting the polymer material into the molding die in a first period of time; and continuing to inject the polymer material and the polymer material into the forming mold in a second period of time.
  • the time length of the first time is, for example, equal to the time length of the third time.
  • step S15 includes, for example, injecting the polymer material into a first sub-mold to make a first sub-plate; and injecting a mixture obtained by uniformly mixing the polymer material and the foaming agent.
  • the thickness of the first sub-board and the thickness of the second sub-board are different, for example.
  • step S15 includes, for example, injecting the polymer material into a first sub-mold to make a first sub-plate; and injecting a mixture obtained by uniformly mixing the polymer material and the foaming agent.
  • the fifth daughter board is aligned and superimposed and combined in a thickness direction to obtain the light guide plate; wherein the first daughter board, the
  • the superimposed composition is, for example, sequentially connecting the contact surfaces between each two adjacent daughter boards superimposed and aligned in the thickness direction by using optical glue OCA (Optically Clear Adhesive) bonding or heat welding to obtain the light guide plate.
  • OCA Optically Clear Adhesive
  • step S15 includes, for example ,: injecting the polymer material and the foaming agent into the molding mold in a first period of time, the mixture obtained by uniformly mixing the foaming agent in a first ratio; and in a second period of time Continue to inject the polymer material and the foaming agent into the molding mixture in a second ratio; and continue to inject the polymer material and A mixture obtained by uniformly mixing the foaming agent in a third ratio; wherein the second ratio is smaller than the first ratio and the third ratio.
  • a method for manufacturing a display device mainly includes:
  • Step S21 Provide a light guide plate, which is made of the light guide plate manufacturing method according to any one of the foregoing embodiments, and the light guide plate includes: a body, air bubbles are formed in the body; The light-entering surface is located at a side of the body; and the light-exiting surface is located at the top of the body;
  • Step S23 providing a back plate, and mounting the back plate on a side of the bottom of the body that is far from the top, the surface of the back plate facing the body is a smooth surface that has been mirror-finished;
  • Step S25 providing a light emitting unit, and setting the light emitting unit adjacent to the light incident surface;
  • Step S27 Provide an optical film group, and set the optical film group on a side of the top far from the bottom.
  • step S15 includes: "mixing the polymer material and the foaming agent uniformly and injecting them into the molding mold to obtain a light guide plate containing uniformly distributed bubbles, and the bubbles are formed by
  • the “foaming agent is produced”
  • the display device 100a further includes a light source module 10a and a back plate 20a.
  • the light guide plate 30a includes a main body 31a, a light incident surface 32a on the side of the main body 31a, a light exit surface 33a on the top of the main body 32a, and a reflective surface 34a on the bottom of the main body 31a opposite to the light exit surface 33a, and reflects in one embodiment
  • the surface 34a is provided with a plurality of halftone dots or a reflective sheet is bonded to the surface.
  • the light incident surface 32a may be located on only one side of the main body 31a, or may be symmetrically distributed on opposite sides of the main body 31a, or even on the sides of the main body 31a.
  • the light source module 10a includes a light emitting unit 11a disposed adjacent to the light incident surface 32a of the light guide plate, and a circuit board 12a supporting the light emitting unit 11a.
  • the back plate 20a is disposed at the bottom of the light guide plate 30a.
  • the surface of the back plate 20a facing the light guide plate 30a is mirror-finished to reflect the light emitted from the reflective surface 34a onto the back plate 20a onto the light exit surface 33a of the light guide plate 30a.
  • Mirror treatment means that the surface is smooth, and most of the light can be specularly reflected after incident on the surface.
  • Bubbles 311a are formed in the body 31a of the light guide plate 30a.
  • the arrangement of the bubbles 311a can reduce the weight of the light guide plate 30a without reducing the thickness of the light guide plate 30a.
  • the thickness of the light guide plate 30a does not change, most of the light emitted by the light emitting unit 11a can still enter the light guide plate 30a, and the bubbles 311a are disposed in the body 31a, and the structural strength of the light guide plate 30a will not be greatly reduced.
  • the bubble 311a can destroy the total reflection of the light in the body 31a, and produce a fogged light output effect, so that more light is uniformly emitted from the light output surface 33a on the top of the light guide plate 30a.
  • the weight of the display device 100a using the light guide plate 30a is also effectively reduced.
  • the body 31a may have a plurality of uniformly distributed air bubbles 311a.
  • the diameter of the air bubbles 311a in the main body 31a ranges from 0.1 mm to 2 mm, and can be specifically set according to the thickness of the light guide plate 30a and the weight to be reduced. For example, when the thickness of the light guide plate 30a is 4mm, the diameter of the bubble 311a may be 0.5mm; when the thickness of the light guide plate 30a is 6mm, the diameter of the bubble 311a may be 0.8mm; when the thickness of the light guide plate 30a is 9mm, the diameter of the bubble 311a may be It's 1.5mm.
  • the space occupied by the bubble 311a in the body 31a greatly affects the weight of the light guide plate 30a.
  • the total volume of the bubble 311a can be relatively small; when the weight to be reduced is large, the total volume of the bubble 311a can be It is large, but in order to ensure that the light guide plate 30a has a certain strength, the total volume of the bubbles 311a should not be too large.
  • the volume ratio of the bubbles 311a to the body 31a ranges from 1: 9 to 4: 6.
  • the volume ratio of the bubbles 311a to the body 31a may be 2: 8; when a large weight reduction is required, the volume ratio of the bubbles 311a to the body 31a may be 3: 7.
  • step S15 includes: “injecting the polymer material into the molding die in a first period of time; continuing to inject the polymer material and A mixture obtained by uniformly mixing the foaming agent; and continuing to inject the polymer material into the molding die in a third period of time, where the length of the first time is equal to the length of the third time, for example,
  • the display device 100b further includes a light source module 10b and a back plate 20b.
  • the light guide plate 30b includes a main body 31b, a light incident surface 32b on the side of the main body 31b, a light exit surface 33b on the top of the main body 32b, and a reflective surface 34b on the bottom of the main body 31b and opposite to the light exit surface 33b.
  • the light incident surface 32b may be located on only one side of the main body 31b, or may be symmetrically distributed on opposite sides of the main body 31b, or even on the side surfaces around the main body 31b.
  • the light source module 10b includes a light emitting unit 11b disposed adjacent to the light incident surface 32b of the light guide plate 30b, and a circuit board 12b supporting the light emitting unit 11b.
  • the back plate 20b is disposed at the bottom of the light guide plate 30b.
  • the surface of the back plate 20b facing the light guide plate 30b is treated as a mirror to reflect the light emitted from the reflective surface 34b onto the back plate 20b onto the light exit surface 33b of the light guide plate 30b.
  • Mirror treatment means that the surface is smooth, and most of the light can be specularly reflected after incident on the surface.
  • Bubbles 311b are formed in the body 31b of the light guide plate 30b.
  • the arrangement of the bubbles 311b can reduce the weight of the light guide plate 30b without reducing the thickness of the light guide plate 30b.
  • the thickness of the light guide plate 30b is unchanged, most of the light emitted by the light emitting unit 11b can still enter the light guide plate 30b, and the air bubble 311b is disposed in the body, and the structural strength of the light guide plate 30b will not be greatly reduced.
  • the bubble 311b can destroy the total reflection of the light in the body 31b, and generate a fogged light output effect, so that more light is uniformly emitted from the light output surface 33b on the top of the light guide plate 30b.
  • the weight of the display device 100b using the light guide plate 30b is also effectively reduced.
  • the thickness of the bubble is 0.1mm to 3mm, which is determined according to the thickness of the light guide plate 30b.
  • the bubble 311b provided between the reflecting surface 34b and the light emitting surface 33b should be kept at a distance from the reflecting surface 34b and the light emitting surface 33b so that The light guide plate 30b still has sufficient strength.
  • the thickness of the bubble 311b is 0.5 mm to 2 mm, for example, 1 mm.
  • step S15 includes: “injecting the polymer material into a first sub-mold to make a first sub-plate; injecting a mixture obtained by uniformly mixing the polymer material and the foaming agent into A second sub-mold to obtain a second sub-plate containing uniformly distributed bubbles, and the bubbles are generated by the foaming agent; and injecting the polymer material into a third sub-mold to make a third sub-plate ; And aligning the first sub-board, the second sub-board, and the third sub-board and stacking them in a thickness direction to obtain the light guide plate; wherein the first sub-board, the first The two daughter boards and the third daughter board have the same length and the same width, and the second daughter board is located between the first daughter board and the third daughter board.
  • the light emitting unit 11c is an LED
  • the corresponding light source module 10c is an LED light bar.
  • the back plate 20c is disposed at the bottom of the light guide plate 30c.
  • the surface of the back plate 20c facing the light guide plate 30c is mirror-finished to reflect the light emitted from the reflective surface 34c onto the back plate 20c onto the light exit surface 33c of the light guide plate 30c.
  • Mirror treatment means that the surface is smooth, and most of the light can be specularly reflected after incident on the surface.
  • the optical film group (not labeled in FIG. 5) is located above the light exit surface 33 c of the light guide plate 30 c, and includes, for example, an optical film such as a diffusion sheet.
  • Bubbles 311c are formed in the body 31c of the light guide plate 30c.
  • the arrangement of the bubbles 311c can reduce the weight of the light guide plate 30c without reducing the thickness of the light guide plate 30c.
  • the thickness of the light guide plate 30c does not change. Most of the light emitted by the light emitting unit 11c can still enter the light guide plate 30c.
  • the air bubble 311c is disposed in the body, and the structural strength of the light guide plate 30c will not be greatly reduced.
  • the bubble 311c can destroy the total reflection of the light in the body 31c, and produce a fogged light output effect, so that more light is uniformly emitted from the light output surface 33c on the top of the light guide plate 30c.
  • the weight of the display device 100c using the light guide plate 30c is also effectively reduced.
  • the bubbles 311c are located on a layer between the light emitting surface 33c and the reflecting surface 34c.
  • the plurality of bubbles 311c are located substantially on the same plane, which is parallel to the reflecting surface 34c and the light emitting surface 33c, and is close to the reflecting surface 34c away from the light emitting surface 33c.
  • the bubble 311c is disposed near the reflecting surface 34c, so that the light totally reflected in the body 31c is scattered by the bubble 311c and exits from the light emitting surface 33c when it approaches the reflecting surface 34c, thereby improving the light flux on the light emitting surface 33c.
  • the diameter of the air bubble 311c in the body 31c ranges from 0.3 mm to 1.5 mm, and can be specifically set according to the thickness of the light guide plate 30c and the weight to be reduced. For example, when the thickness of the light guide plate 30c is 5mm, the diameter of the bubble 311c may be 0.4mm; when the thickness of the light guide plate 30c is 6mm, the diameter of the bubble 311c may be 1.0mm; when the thickness of the light guide plate 30c is 10mm, the diameter of the bubble 311c may be It is 1.3mm.
  • the space occupied by the bubble 311c in the body 31c greatly affects the weight of the light guide plate 30c.
  • the total volume of the bubble 311c can be relatively small; when the weight to be reduced is large, the total volume of the bubble 311c can be It is large, but in order to ensure that the light guide plate 30c has a certain strength, the total volume of the bubble 311c should not be too large.
  • the volume ratio of the bubbles 311c to the body 31c ranges from 1: 9 to 3: 7.
  • the volume ratio of the bubble 311c to the body 31c may be 1: 9; when a large weight reduction is required, the volume ratio of the bubble 311c to the body 31c may be 2: 8.
  • step S15 includes: “injecting the polymer material into a first sub-mold to make a first sub-plate; and injecting a mixture obtained by uniformly mixing the polymer material and the foaming agent into A second sub-mold to obtain a second sub-plate containing uniformly distributed bubbles, and the bubbles are generated by the foaming agent; and injecting the polymer material into a third sub-mold to make a third sub-plate Injecting the mixture obtained by uniformly mixing the polymer material and the foaming agent into a fourth sub-mold to obtain a fourth sub-board containing uniformly distributed bubbles, and the bubbles are generated by the foaming agent; Injecting the polymer material into a fifth sub-mold to make a fifth sub-board; and injecting the first sub-board, the second sub-board, the third sub-board, the fourth sub-board, and The fifth daughter board is aligned and superimposed and combined in a thickness direction to obtain the light guide plate; wherein the first daughter board, the
  • the light guide plate 30d includes a main body 31d, a light incident surface 32d on the side of the main body 31d, a light exit surface 33d on the top of the main body 32d, and a reflective surface 34d on the bottom of the main body 31d and opposite to the light exit surface 33d.
  • the light incident surface 32d may be located on only one side of the body 31d, or may be symmetrically distributed on both sides of the body 31d, or even on the sides of the body 31d.
  • the light source module 10d includes a light emitting unit 11d disposed adjacent to the light incident surface 32d of the light guide plate 30d, and a circuit board 12d supporting the light emitting unit 11d.
  • the back plate 20d is disposed at the bottom of the light guide plate 30d.
  • the surface of the back plate 20d facing the light guide plate 30d is mirror-finished to reflect the light emitted from the reflective surface 34d onto the back plate 20d to the light exit surface 33d of the light guide plate 30d.
  • Mirror treatment means that the surface is smooth, and most of the light can be specularly reflected after incident on the surface.
  • the optical film group (not labeled in FIG. 6) is located above the light emitting surface 33 d of the light guide plate 30 d, and includes, for example, an optical film such as a diffusion sheet.
  • Bubbles 311d are formed in the body 31d of the light guide plate 30d.
  • the arrangement of the bubbles 311d can reduce the weight of the light guide plate 30d without reducing the thickness of the light guide plate 30d.
  • the thickness of the light guide plate 30d is unchanged, most of the light emitted by the light emitting unit 11d can still enter the light guide plate 30d, and the air bubble 311d is disposed in the body, and the structural strength of the light guide plate 30d will not be greatly reduced.
  • the bubble 311d can destroy the total reflection of the light in the body 31d, and produce a fogged light output effect, so that more light is uniformly emitted from the light output surface 33d on the top of the light guide plate 30d.
  • the weight of the display device 100d using the light guide plate 30d is also effectively reduced.
  • the bubble 311d is located on two layers between the light emitting surface 33d and the reflecting surface 34d.
  • the plurality of bubbles 311d are located on two mutually parallel planes.
  • the two mutually parallel planes are parallel to the reflecting surface 34d and the light emitting surface 33d.
  • the two are parallel to each other.
  • the entire plane is close to the reflecting surface 34d and away from the light emitting surface 33d.
  • the bubble 311d is disposed near the reflecting surface 34d, so that the light totally reflected in the body 31d is scattered by the bubble 311d and exits from the light emitting surface 33d when approaching the reflecting surface 34d, thereby improving the light flux on the light emitting surface 33d.
  • the diameter of the air bubble 311d in the body 31d ranges from 0.1 mm to 1.5 mm, and can be specifically set according to the thickness of the light guide plate 30d and the weight to be reduced. For example, when the thickness of the light guide plate 30d is 5mm, the diameter of the bubble 311d may be 0.5mm; when the thickness of the light guide plate 30d is 6mm, the diameter of the bubble 311d may be 1.0mm; when the thickness of the light guide plate 30d is 10mm, the diameter of the bubble 311d may be It is 1.2mm.
  • the space occupied by the bubble 311d in the body 31d greatly affects the weight of the light guide plate 30d.
  • the ratio of the volume of the bubbles 311d to the volume of the body 31d ranges from 1: 9 to 4: 6.
  • the volume ratio of the bubble 311d to the body 31d may be 1: 9; when a large weight reduction is required, the volume ratio of the bubble 311d to the body 31d may be 2: 8.
  • step S15 includes: “injecting the polymer material and the foaming agent into the molding mold into a mixture obtained by uniformly mixing the first proportion in the first time period; in the second time period Continue to inject the polymer material and the foaming agent into the molding mixture in a second ratio; and continue to inject the polymer material and A mixture obtained by uniformly mixing the foaming agent in a third ratio; wherein, when the second ratio is smaller than the first ratio and the third ratio, a light guide plate 30e and a light guide plate 30e are obtained.
  • the display device 100e further includes a light source module 10e, a back plate 20e, and an optical film group.
  • the light guide plate 30e includes a main body 31e, a light incident surface 32e on the side of the main body 31e, a light exit surface 33e on the top of the main body 32e, and a reflective surface 34e on the bottom of the main body 31e and opposite to the light exit surface 33e.
  • the light incident surface 32e may be located on only one side of the body 31e, or may be symmetrically distributed on both sides of the body 31e, or even on the sides of the body 31e.
  • the light source module 10e includes a light emitting unit 11e disposed adjacent to the light incident surface 32e of the light guide plate 30e and a circuit board 12e supporting the light emitting unit 11e.
  • the back plate 20e is disposed at the bottom of the light guide plate 30e.
  • the surface of the back plate 20e facing the light guide plate 30e is mirror-finished to reflect the light emitted from the reflective surface 34e onto the back plate 20e onto the light exit surface 33e of the light guide plate 30e.
  • Mirror treatment means that the surface is smooth, and most of the light can be specularly reflected after incident on the surface.
  • the optical film group (not labeled in FIG. 7) is located above the light emitting surface 33 e of the light guide plate 30 e, and includes, for example, an optical film such as a diffusion sheet.
  • Bubbles 311e are formed in the body 31e of the light guide plate 30e.
  • the arrangement of the bubbles 311e can reduce the weight of the light guide plate 30e without reducing the thickness of the light guide plate 30e.
  • the thickness of the light guide plate 30e does not change, most of the light emitted by the light emitting unit 11e can still enter the light guide plate 30e, and the air bubble 311e is disposed in the body, and the structural strength of the light guide plate 30e will not be greatly reduced.
  • the bubble 311e can destroy the total reflection of the light in the body 31e, and generate a fogged light output effect, so that more light is uniformly emitted from the light output surface 33e on the top of the light guide plate 30e.
  • the weight of the display device 100e using the light guide plate 30e is also effectively reduced.
  • the body 31e includes a central area and a peripheral area surrounding the central area. Especially when the thickness of the light guide plate 30e is small and the number of bubbles 311e on the body 31e will greatly reduce the strength of the light guide plate 30e, the bubbles 311e in the peripheral area can be smaller than the center. The bubbles 311e in the area are more dense, so that the central area has a higher intensity than the peripheral area.
  • the diameter of the air bubble 311e in the main body 31e ranges from 0.1 mm to 1.5 mm, and can be specifically set according to the thickness of the light guide plate 30e and the weight to be reduced. For example, when the thickness of the light guide plate 30e is 5mm, the diameter of the bubble 311e may be 0.5mm; when the thickness of the light guide plate 30e is 6mm, the diameter of the bubble 311e may be 1.0mm; when the thickness of the light guide plate 30e is 10mm, the diameter of the bubble 311e may be It is 1.2mm.
  • the space occupied by the bubble 311e in the body 31e greatly affects the weight of the light guide plate 30e.
  • the volume ratio of the bubbles 311e to the body 31e ranges from 1: 9 to 4: 6.
  • the bubble volume ratio in the central region may be 1: 9, and the bubble volume ratio in the peripheral region may be 3: 7.
  • the bubble volume ratio in the central area can be 1: 9, and the bubble volume ratio in the peripheral area can be 2: 8. It is 2: 8, and the bubble volume ratio in the peripheral area can be 3: 7.
  • the air bubble 311e is located in the body 31e, and the air bubble 311e is kept at a distance from the light incident surface 32e, and the distance dimension is 2 to 10 mm, for example, 5 mm.
  • the air bubble 311e is formed in the body 31e of the light guide plate 30e, the light guide plate 30e is lightened without reducing the thickness of the light guide plate 30e and the intensity of the light guide plate 30e. weight.
  • the resulting display device 100e having the light guide plate 30e is also made lighter.
  • the bubbles 311e can be used as a scattering structure to scatter light.
  • the display devices 100a-100e in the foregoing embodiments also include: Structures known to those skilled in the art such as plastic frames, front frames, panels, etc. may be included.
  • the disclosed system, device, and / or method may be implemented in other ways.
  • the device embodiments described above are only schematic.
  • the division of the unit / module is only a logical function division.
  • multiple units or modules may The combination can either be integrated into another system, or some features can be ignored or not implemented.
  • the displayed or discussed mutual coupling or direct coupling or communication connection may be indirect coupling or communication connection through some interfaces, devices or units, which may be electrical, mechanical or other forms.
  • the units / modules described as separate components may or may not be physically separated, and the components displayed as units / modules may or may not be physical units, may be located in one place, or may be distributed to multiple channels. Network unit. Some or all of the units / modules may be selected according to actual needs to achieve the objective of the solution of this embodiment.

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Abstract

一种导光板的制作方法，包括：提供聚合物材料（S11）；提供发泡剂（S13）；以及将聚合物材料与发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板（S15），且气泡由发泡剂产生。还公开了一种显示装置的制作方法。

Description

导光板的制作方法和显示装置的制作方法 技术领域
本申请涉及显示技术领域，尤其涉及一种导光板的制作方法和一种显示装置的制作方法。
背景技术
目前，在显示技术领域中，常通过导光板结合侧入式光源来形成面光源，侧入式光源发出的光线从导光板一侧的入光面进入导光板，再经过导光板上导光点的发射和扩散后从导光板的出光面射出，以向显示面板提供工作所需光线。
然而，为了充分利用LED发出的光源，需要使其大部分光线射入导光板内，往往通过使制作的导光板达到一定的厚度来解决以上问题，虽然采用该种方法制作的导光板可以提高光线的入射率，但是也会导致具有该导光板的显示装置的厚度增加，不符合当前显示装置轻型化的发展趋势，且出射光线均匀性不好。
发明内容
为了解决上述问题，本申请实施例提供一种导光板的制作方法和一种显示装置的制作方法，通过本申请实施例能够减轻导光板和显示装置的重量以及提高显示均匀性。
为实现上述目的，本申请实施例提供的一种导光板的制作方法，包括：提供聚合物材料；提供发泡剂；以及将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生；其中，所述聚合物材料为聚甲基丙烯酸甲酯或聚碳酸酯；所述发泡剂为氮气或二氧化碳；所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生的步骤包括：将所述聚合物材料与所述发泡剂均匀混合并注入所述成型模具，以制得包含均匀分布的气泡的导光板，且所述气泡由所述发泡剂产生。
本申请实施例还提供的一种导光板的制作方法，包括：提供聚合物材料；提供发泡剂；以及将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生。
在其中一个实施例中，所述聚合物材料为聚甲基丙烯酸甲酯或聚碳酸酯。
在其中一个实施例中，所述发泡剂为氮气或二氧化碳。
在其中一个实施例中，所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生 的步骤包括：将所述聚合物材料与所述发泡剂均匀混合并注入所述成型模具，以制得包含均匀分布的气泡的导光板，且所述气泡由所述发泡剂产生。
在其中一个实施例中，所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生的步骤包括：在第一时间段向所述成型模具内注入所述聚合物材料；在第二时间段向所述成型模具内继续注入将所述聚合物材料和所述发泡剂均匀混合得到的混合物；以及在第三时间段向所述成型模具内继续注入所述聚合物材料。
在其中一个实施例中，所述第一时间和第三时间的时间长度相等。
在其中一个实施例中，所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生的步骤包括：将所述聚合物材料注入第一子模具，以制成第一子板；将所述聚合物材料与所述发泡剂均匀混合得到的混合物注入第二子模具，以制得包含均匀分布的气泡的第二子板，且所述气泡由所述发泡剂产生；将所述聚合物材料注入第三子模具，以制成第三子板；以及将所述第一子板、所述第二子板和所述第三子板对齐且在厚度方向上叠加合成以得到所述导光板；其中，所述第一子板、所述第二子板和所述第三子板的长度相同且宽度相同，所述第二子板位于所述第一子板和所述第三子板之间。
在其中一个实施例中，所述第一子板和第二子板的厚度不同。
在其中一个实施例中，所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生的步骤包括：将所述聚合物材料注入第一子模具，以制成第一子板；将所述聚合物材料与所述发泡剂均匀混合得到的混合物注入第二子模具，以制得包含均匀分布的气泡的第二子板，且所述气泡由所述发泡剂产生；将所述聚合物材料注入第三子模具，以制成第三子板；将所述聚合物材料与所述发泡剂均匀混合得到的混合物注入第四子模具，以制得包含均匀分布的气泡的第四子板，且所述气泡由所述发泡剂产生；将所述聚合物材料注入第五子模具，以制成第五子板；以及将所述第一子板、所述第二子板、所述第三子板、所述第四子板和所述第五子板对齐且在厚度方向上叠加合成以得到所述导光板；其中，所述第一子板、所述第二子板、所述第三子板、所述第四子板和所述第五子板的长度相同且宽度相同，所述第一子板、所述第二子板、所述第三子板、所述第四子板和所述第五子板依次相接。
在其中一个实施例中，所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生的步骤包括：在第一时间段向所述成型模具内注入所述聚合物材料和所述发泡剂以第一比例均匀混合得到的混合物；在第二时间段向所述成型模具内继续注入所述聚合物材料和所述发泡剂以第二比例均匀混合得到的混合物；以及在第三时间段向所述成型模具内继续注入所述聚合物材料和所述发泡剂以第三比 例均匀混合得到的混合物；其中，所述第二比例小于所述第一比例和所述第三比例。
本申请实施例还提供的一种显示装置的制作方法，包括：提供导光板，所述导光板由前述任意一项实施例所述的导光板的制作方法制成且所述导光板包括：本体，所述本体内形成有气泡；入光面，所述入光面位于所述本体的侧部；以及出光面，所述出光面位于所述本体的顶部；提供背板，且将所述背板安装在所述本体的底部远离所述顶部的一侧，所述背板面向所述本体的表面为经过镜面处理的光滑表面；提供发光单元，并将所述发光单元邻近所述入光面设置；提供光学膜片组，将所述光学膜片组设置在所述顶部远离所述底部的一侧。
本申请实施例通过在导光板内形成有气泡，能够在不降低导光板厚度的情况下减轻导光板的重量；此外，导光板内的气泡可以破坏导光板内光线的全反射，产生雾化的出光效果，使得更多的光线从导光板的出光面射出，最终实现了在保证导光板厚度的同时减轻导光板的重量以及提高显示均匀性的技术效果。
附图说明
此处所说明的附图用来提供对本申请实施例的进一步理解，构成本申请实施例的一部分，本申请的示意性实施例及其说明用于解释本申请，并不构成对本申请的不当限定。在附图中：
图1为本申请一实施例提供的一种导光板的制作方法的流程示意图；
图2为本申请一实施例提供的一种显示装置的制作方法的流程示意图；
图3为采用本申请一个实施例提供的方法所制得的导光板和包括该导光板的显示装置的示意图；
图4为采用本申请一个实施例提供的方法所制得的导光板和包括该导光板的显示装置的示意图；
图5为采用本申请一个实施例提供的方法所制得的导光板和包括该导光板的显示装置的示意图；
图6为采用本申请一个实施例提供的方法所制得的导光板和包括该导光板的显示装置的示意图；
图7为采用本申请一个实施例提供的方法所制得的导光板和包括该导光板的显示装置的示意图。
具体实施方式
为使本申请的目的、技术方案和优点更加清楚，下面将结合本申请具体实施例及相应的附图对本申请技术方案进行清楚、完整地描述。显然，所描述的实施例仅是本申请一部分实施例，而不是全部的实施例。基于本申请中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本申请保护的范围。
本申请实施例的显示装置可以是液晶显示面板、OLED(Organic Light  Emitting Diode，有机发光二极管)显示装置、QLED(Quantum Dot Light Emitting Diode，量子点发光二极管)显示装置、曲面显示装置或其他显示装置。
如图1所示，本申请实施例提供一种导光板的制作方法，主要包括：
步骤S11:提供聚合物材料；
步骤S13:提供发泡剂；以及
步骤S15:将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生。
其中，所述聚合物材料例如为PMMA(Polymethylmethacrylate，聚甲基丙烯酸甲酯)或透明PC(Polycarbonate，聚碳酸酯)等聚合物材料。所述发泡剂例如为氮气或二氧化碳等发泡剂。
在一些实施例中，步骤S15例如包括：将所述聚合物材料与所述发泡剂均匀混合并注入所述成型模具，以制得包含均匀分布的气泡的导光板，且所述气泡由所述发泡剂产生。
在另一些实施例中，步骤S15例如包括：在第一时间段向所述成型模具内注入所述聚合物材料；在第二时间段向所述成型模具内继续注入将所述聚合物材料和所述发泡剂均匀混合得到的混合物；以及在第三时间段向所述成型模具内继续注入所述聚合物材料。具体地，所述第一时间的时间长度例如等于第三时间的时间长度。
在其他一些实施例中，步骤S15例如包括：将所述聚合物材料注入第一子模具，以制成第一子板；将所述聚合物材料与所述发泡剂均匀混合得到的混合物注入第二子模具，以制得包含均匀分布的气泡的第二子板，且所述气泡由所述发泡剂产生；将所述聚合物材料注入第三子模具，以制成第三子板；以及将所述第一子板、所述第二子板和所述第三子板对齐且在厚度方向上叠加合成以得到所述导光板；其中，所述第一子板、所述第二子板和所述第三子板的长度相同且宽度相同，所述第二子板位于所述第一子板和所述第三子板之间。具体地，所述第一子板的厚度和第二子板的厚度例如不同。
在又一些实施例中，步骤S15例如包括：将所述聚合物材料注入第一子模具，以制成第一子板；将所述聚合物材料与所述发泡剂均匀混合得到的混合物注入第二子模具，以制得包含均匀分布的气泡的第二子板，且所述气泡由所述发泡剂产生；将所述聚合物材料注入第三子模具，以制成第三子板；将所述聚合物材料与所述发泡剂均匀混合得到的混合物注入第四子模具，以制得包含均匀分布的气泡的第四子板，且所述气泡由所述发泡剂产生；将所述聚合物材料注入第五子模具，以制成第五子板；以及将所述第一子板、所述第二子板、所述第三子板、所述第四子板和所述第五子板对齐且在厚度方向上叠加合成以得到所述导光板；其中，所述第一子板、所述第二子板、所述第三子板、所述第四子板和所述第五子板的长度相同且宽度相同，所述第一子板、所述第二子板、所述第三子板、所述第四子板和所述第五子板依次相接。
所述叠加合成例如是依次对在厚度方向上叠加对齐的每两个相邻子板之间的接触面采用光学胶OCA(Optically Clear Adhesive)粘合或者加热熔接等方 式连接以得到所述导光板。在此值得一提的是，本申请实施例不限于此，只要能够保证好的光透过率及连接强度的叠加合成方式都在本申请保护范围内。
在另外一些实施例中，步骤S15例如包括：在第一时间段向所述成型模具内注入所述聚合物材料和所述发泡剂以第一比例均匀混合得到的混合物；在第二时间段向所述成型模具内继续注入所述聚合物材料和所述发泡剂以第二比例均匀混合得到的混合物；以及在第三时间段向所述成型模具内继续注入所述聚合物材料和所述发泡剂以第三比例均匀混合得到的混合物；其中，所述第二比例小于所述第一比例和所述第三比例。
如图2所示，为本申请实施例提供的一种显示装置的制作方法，主要包括：
步骤S21:提供导光板，所述导光板由前述任意一项实施例所述的导光板的制作方法制成且所述导光板包括：本体，所述本体内形成有气泡；入光面，所述入光面位于所述本体的侧部；以及出光面，所述出光面位于所述本体的顶部；
步骤S23:提供背板，且将所述背板安装在所述本体的底部远离所述顶部的一侧，所述背板面向所述本体的表面为经过镜面处理的光滑表面；
步骤S25:提供发光单元，并将所述发光单元邻近所述入光面设置；
步骤S27:提供光学膜片组，将所述光学膜片组设置在所述顶部远离所述底部的一侧。
下面以附图2-7为例来详细介绍采用本申请前述实施例所提供的导光板的制作方法和显示装置的制作方法所制得的导光板和显示装置。
如图3所示，当步骤S15包括：“将所述聚合物材料与所述发泡剂均匀混合并注入所述成型模具，以制得包含均匀分布的气泡的导光板，且所述气泡由所述发泡剂产生”时，所制得的一种导光板30a和包含导光板30a的显示装置100a的一个实施例的示例。显示装置100a还包括光源模块10a和背板20a。
导光板30a包括本体31a、位于本体31a侧部的入光面32a、位于本体32a顶部的出光面33a和位于本体31a底部且与出光面33a相对设置的反射面34a，且在一个实施例中反射面34a设置有多个网点或者贴合有反射片。入光面32a可以只位于本体31a的一侧，也可以对称分布于本体31a的相对两侧，甚至可以是本体31a的四周的侧面上。光源模块10a包括邻近导光板入光面32a设置的发光单元11a和支撑该发光单元11a的电路板12a。背板20a设置于导光板30a的底部，背板20a朝向导光板30a的表面为镜面处理，以将自反射面34a射到背板20a上的光线反射到导光板30a的出光面33a上。镜面处理是指该表面光滑，光线入射到该表面后大都能够发生镜面反射。
导光板30a的本体31a内形成有气泡311a，气泡311a的设置能够在不降低导光板30a厚度的情况下，减轻导光板30a的重量。导光板30a的厚度不变，发光单元11a发出的大部分光线依然能够射入导光板30a，气泡311a设置在本体31a内，也不会很大地降低导光板30a的结构强度。此外，气泡311a可以破坏本体31a内光线的全反射，产生雾化的出光效果，使得更多的光线从导光板30a的顶部的出光面33a均匀射出。使用该导光板30a的显示装置100a的重量也被有效降低。
本体31a内可以具有多个均匀分布的气泡311a。本体31a内的气泡311a的直径范围为0.1mm至2mm，具体可以依据导光板30a的厚度和需要减小的重量设定。例如，在导光板30a的厚度为4mm时，气泡311a的直径可以是0.5mm；导光板30a厚度为6mm时，气泡311a的直径可以是0.8mm；导光板30a厚度9mm时，气泡311a的直径可以是1.5mm。
气泡311a在本体31a内占据的空间很大地影响导光板30a的自重，当需要降低的重量较小时，气泡311a的总体积可以比较小；当需要降低的重量较大时，气泡311a的总体积可以较大，但为了保证导光板30a具有一定的强度，气泡311a的总体积不宜过大。本实施例中，气泡311a与本体31a的体积之比范围为1:9至4:6。例如，当需要小幅减重时，气泡311a与本体31a的体积之比可以为2:8；当需要大幅减重时，气泡311a与本体31a的体积之比可以为3:7。
如图4所示，当步骤S15包括：“在第一时间段向所述成型模具内注入所述聚合物材料；在第二时间段向所述成型模具内继续注入将所述聚合物材料和所述发泡剂均匀混合得到的混合物；以及在第三时间段向所述成型模具内继续注入所述聚合物材料，所述第一时间的时间长度例如等于第三时间的时间长度”时，所制得的一种导光板30b和包含导光板30b的显示装置100b的一个实施例的示例。显示装置100b还包括光源模块10b和背板20b。
导光板30b包括本体31b、位于本体31b侧部的入光面32b、位于本体32b顶部的出光面33b和位于本体31b底部且与出光面33b相对设置的反射面34b。入光面32b可以只位于本体31b的一侧，也可以对称分布于本体31b的相对两侧，甚至可以是本体31b的四周的侧面上。光源模块10b包括邻近导光板30b的入光面32b设置的发光单元11b和支撑该发光单元11b的电路板12b。背板20b设置于导光板30b的底部，背板20b朝向导光板30b的表面为镜面处理，以将自反射面34b射到背板20b上的光线反射到导光板30b的出光面33b上。镜面处理是指该表面光滑，光线入射到该表面后大都能够发生镜面反射。
导光板30b的本体31b内形成有气泡311b，气泡311b的设置能够在不降低导光板30b厚度的情况下，减轻导光板30b的重量。导光板30b的厚度不变，发光单元11b发出的大部分光线依然能够射入导光板30b，气泡311b设置在本体内，也不会很大地降低导光板30b的结构强度。此外，气泡311b可以破坏本体31b内光线的全反射，产生雾化的出光效果，使得更多的光线从导光板30b的顶部的出光面33b均匀射出。使用该导光板30b的显示装置100b的重量也被有效降低。
本体31b内可以具有一个气泡311b，即导光板30b形成中空结构。在垂直于反射面34b或出光面33b的方向上，该气泡311b可以近似呈圆形或矩形，设置于本体31b内的中心处。例如，导光板30b的长度为400mm，宽度为300mm，如果气泡311b呈圆形，则该圆形直径可以为50mm至100mm，例如80mm；如果气泡311b呈矩形，则该矩形气泡311b的长度可以为80mm，宽度为60mm。
气泡311b的中心线可以居中设置于反射面34b和出光面33b之间，也可 以向反射面34b方向偏置。
气泡的厚度为0.1mm至3mm，具体依据导光板30b的厚度决定，且设置于反射面34b与出光面33b之间的气泡311b，其与反射面34b和出光面33b的应当保持距离，以使其导光板30b仍然具有足够的强度。导光板30b的厚度为4mm时，气泡311b的厚度为0.5mm至2mm，例如1mm。
如图5所示，当步骤S15包括：“将所述聚合物材料注入第一子模具，以制成第一子板；将所述聚合物材料与所述发泡剂均匀混合得到的混合物注入第二子模具，以制得包含均匀分布的气泡的第二子板，且所述气泡由所述发泡剂产生；将所述聚合物材料注入第三子模具，以制成第三子板；以及将所述第一子板、所述第二子板和所述第三子板对齐且在厚度方向上叠加合成以得到所述导光板；其中，所述第一子板、所述第二子板和所述第三子板的长度相同且宽度相同，所述第二子板位于所述第一子板和所述第三子板之间。所述第一子板的厚度例如和第二子板的厚度不同时”，所制得的一种导光板30c和包含导光板30c的显示装置100c的一个实施例的示例。显示装置100c还包括光源模块10c、背板20c和光学膜片组。
导光板30c包括本体31c、位于本体31c侧部的入光面32c、位于本体32c顶部的出光面33c和位于本体31c底部且与出光面33c相对设置的反射面34c。入光面32c可以只位于本体31c的一侧，也可以对称分布于本体31c的两侧，甚至可以是本体31c的四周的侧面上。光源模块10c包括邻近导光板30c的入光面32c设置的发光单元11c和支撑该发光单元11c的电路板12c，在一个实施例中发光单元11c为LED，相对应的光源模块10c为LED灯条。背板20c设置于导光板30c的底部，背板20c朝向导光板30c的表面为镜面处理，以将自反射面34c射到背板20c上的光线反射到导光板30c的出光面33c上。镜面处理是指该表面光滑，光线入射到该表面后大都能够发生镜面反射。此外，光学膜片组(图5中未标示)位于导光板30c的出光面33c的上方，其例如包括扩散片等光学膜片。
导光板30c的本体31c内形成有气泡311c，气泡311c的设置能够在不降低导光板30c厚度的情况下，减轻导光板30c的重量。导光板30c的厚度不变，发光单元11c发出的大部分光线依然能够射入导光板30c，气泡311c设置在本体内，也不会很大地降低导光板30c的结构强度。此外，气泡311c可以破坏本体31c内光线的全反射，产生雾化的出光效果，使得更多的光线从导光板30c的顶部的出光面33c均匀射出。使用该导光板30c的显示装置100c的重量也被有效降低。
气泡311c位于出光面33c和反射面34c之间的一层上，多个气泡311c大致位于同一平面上，该平面与反射面34c和出光面33c平行，且靠近反射面34c远离出光面33c。气泡311c靠近反射面34c设置，使得本体31c内全反射的光线在接近反射面34c时被气泡311c散射而从出光面33c射出，提高出光面33c上的光通量。
本体31c内的气泡311c的直径范围为0.3mm至1.5mm，具体可以依据导 光板30c的厚度和需要减小的重量设定。例如，在导光板30c的厚度为5mm时，气泡311c的直径可以是0.4mm；导光板30c厚度为6mm时，气泡311c的直径可以是1.0mm；导光板30c厚度10mm时，气泡311c的直径可以是1.3mm。
气泡311c在本体31c内占据的空间很大地影响导光板30c的自重，当需要降低的重量较小时，气泡311c的总体积可以比较小；当需要降低的重量较大时，气泡311c的总体积可以较大，但为了保证导光板30c具有一定的强度，气泡311c的总体积不宜过大。本实施例中，气泡311c与本体31c的体积之比范围为1:9至3:7。例如，当需要小幅减重时，气泡311c与本体31c的体积之比可以为1:9；当需要大幅减重时，气泡311c与本体31c的体积之比可以为2:8。
如图6所示，当步骤S15包括：“将所述聚合物材料注入第一子模具，以制成第一子板；将所述聚合物材料与所述发泡剂均匀混合得到的混合物注入第二子模具，以制得包含均匀分布的气泡的第二子板，且所述气泡由所述发泡剂产生；将所述聚合物材料注入第三子模具，以制成第三子板；将所述聚合物材料与所述发泡剂均匀混合得到的混合物注入第四子模具，以制得包含均匀分布的气泡的第四子板，且所述气泡由所述发泡剂产生；将所述聚合物材料注入第五子模具，以制成第五子板；以及将所述第一子板、所述第二子板、所述第三子板、所述第四子板和所述第五子板对齐且在厚度方向上叠加合成以得到所述导光板；其中，所述第一子板、所述第二子板、所述第三子板、所述第四子板和所述第五子板的长度相同且宽度相同，所述第一子板、所述第二子板、所述第三子板、所述第四子板和所述第五子板依次相接”时，所制得的一种导光板30d和包含导光板30d的显示装置100d的一个实施例的示例。显示装置100d还包括光源模块10d、背板20d和光学膜片组。
导光板30d包括本体31d、位于本体31d侧部的入光面32d、位于本体32d顶部的出光面33d和位于本体31d底部且与出光面33d相对设置的反射面34d。入光面32d可以只位于本体31d的一侧，也可以对称分布于本体31d的两侧，甚至可以是本体31d的四周的侧面上。光源模块10d包括邻近导光板30d的入光面32d设置的发光单元11d和支撑该发光单元11d的电路板12d。背板20d设置于导光板30d的底部，背板20d朝向导光板30d的表面为镜面处理，以将自反射面34d射到背板20d上的光线反射到导光板30d的出光面33d上。镜面处理是指该表面光滑，光线入射到该表面后大都能够发生镜面反射。此外，光学膜片组(图6中未标示)位于导光板30d的出光面33d的上方，其例如包括扩散片等光学膜片。
导光板30d的本体31d内形成有气泡311d，气泡311d的设置能够在不降低导光板30d厚度的情况下，减轻导光板30d的重量。导光板30d的厚度不变，发光单元11d发出的大部分光线依然能够射入导光板30d，气泡311d设置在本体内，也不会很大地降低导光板30d的结构强度。此外，气泡311d可以破坏本体31d内光线的全反射，产生雾化的出光效果，使得更多的光线从导光板30d的顶部的出光面33d均匀射出。使用该导光板30d的显示装置100d的重 量也被有效降低。
气泡311d位于出光面33d和反射面34d之间的两层上，多个气泡311d分别位于两个相互平行的平面上，两相互平行的平面与反射面34d和出光面33d平行，且两相互平行的平面整体靠近反射面34d远离出光面33d。气泡311d靠近反射面34d设置，使得本体31d内全反射的光线在接近反射面34d时被气泡311d散射而从出光面33d射出，提高出光面33d上的光通量。
本体31d内的气泡311d的直径范围为0.1mm至1.5mm，具体可以依据导光板30d的厚度和需要减小的重量设定。例如，在导光板30d的厚度为5mm时，气泡311d的直径可以是0.5mm；导光板30d厚度为6mm时，气泡311d的直径可以是1.0mm；导光板30d厚度10mm时，气泡311d的直径可以是1.2mm。
气泡311d在本体31d内占据的空间很大地影响导光板30d的自重，当需要降低的重量较小时，气泡311d的总体积可以比较小；当需要降低的重量较大时，气泡311d的总体积可以较大，但为了保证导光板30d具有一定的强度，气泡311d的总体积不宜过大。本实施例中，气泡311d与本体31d的体积之比范围为1:9至4:6。例如，当需要小幅减重时，气泡311d与本体31d的体积之比可以为1:9；当需要大幅减重时，气泡311d与本体31d的体积之比可以为2:8。
如图7所示，当步骤S15包括：“在第一时间段向所述成型模具内注入所述聚合物材料和所述发泡剂以第一比例均匀混合得到的混合物；在第二时间段向所述成型模具内继续注入所述聚合物材料和所述发泡剂以第二比例均匀混合得到的混合物；以及在第三时间段向所述成型模具内继续注入所述聚合物材料和所述发泡剂以第三比例均匀混合得到的混合物；其中，所述第二比例小于所述第一比例和所述第三比例”时，所制得的一种导光板30e和包含导光板30e的显示装置100e的一个实施例的示例。显示装置100e还包括光源模块10e、背板20e和光学膜片组。
导光板30e包括本体31e、位于本体31e侧部的入光面32e、位于本体32e顶部的出光面33e和位于本体31e底部且与出光面33e相对设置的反射面34e。入光面32e可以只位于本体31e的一侧，也可以对称分布于本体31e的两侧，甚至可以是本体31e的四周的侧面上。光源模块10e包括邻近导光板30e的入光面32e设置的发光单元11e和支撑该发光单元11e的电路板12e。背板20e设置于导光板30e的底部，背板20e朝向导光板30e的表面为镜面处理，以将自反射面34e射到背板20e上的光线反射到导光板30e的出光面33e上。镜面处理是指该表面光滑，光线入射到该表面后大都能够发生镜面反射。此外，光学膜片组(图7中未标示)位于导光板30e的出光面33e的上方，其例如包括扩散片等光学膜片。
导光板30e的本体31e内形成有气泡311e，气泡311e的设置能够在不降低导光板30e厚度的情况下，减轻导光板30e的重量。导光板30e的厚度不变，发光单元11e发出的大部分光线依然能够射入导光板30e，气泡311e设置在本 体内，也不会很大地降低导光板30e的结构强度。此外，气泡311e可以破坏本体31e内光线的全反射，产生雾化的出光效果，使得更多的光线从导光板30e的顶部的出光面33e均匀射出。使用该导光板30e的显示装置100e的重量也被有效降低。
本体31e包括中心区域和围绕中心区域的外围区域，特别在导光板30e的厚度尺寸较小，本体31e上的气泡311e数量会较大地降低导光板30e的强度时，外围区域的气泡311e可以比中心区域的气泡311e更加密集，使中心区域比外围区域具有更高的强度。
本体31e内的气泡311e的直径范围为0.1mm至1.5mm，具体可以依据导光板30e的厚度和需要减小的重量设定。例如，在导光板30e的厚度为5mm时，气泡311e的直径可以是0.5mm；导光板30e厚度为6mm时，气泡311e的直径可以是1.0mm；导光板30e厚度10mm时，气泡311e的直径可以是1.2mm。
气泡311e在本体31e内占据的空间很大地影响导光板30e的自重，当需要降低的重量较小时，气泡311e的总体积可以比较小；当需要降低的重量较大时，气泡311e的总体积可以较大，但为了保证导光板30e具有一定的强度，气泡311e的总体积不宜过大。本实施例中，气泡311e与本体31e的体积之比范围为1:9至4:6。具体的，中心区域的气泡体积占比可以为1:9，外围区域的气泡体积占比可以为3:7。例如，当需要小幅减重时，中心区域的气泡体积占比可以为1:9，外围区域的气泡体积占比可以为2:8；当需要大幅减重时，中心区域的气泡体积占比可以为2:8，外围区域的气泡体积占比可以为3:7。
气泡311e位于本体31e内，气泡311e与入光面32e保持间距，间距尺寸为2至10mm，例如5mm。
本申请的实施例中，由于在制得的导光板30e的本体31e内形成有气泡311e，在不降低导光板30e厚度和不大幅度降低导光板30e强度的情况下，减轻了导光板30e的重量。使得制得的具有该导光板30e的显示装置100e也更加轻型化。而且气泡311e可以作为散射结构对光线进行散射。
最后值得一提的是，前述实施例中的显示装置100a-100e除了包括前述的光源模块10a-10e、背板20a-20e、侧入式导光板30a-30e甚至光学膜片组之外，还可以包括本领域技术人员熟知的结构例如胶框、前框、面板等。
在本申请所提供的几个实施例中，应该理解到，所揭露的系统，装置和/或方法，可以通过其它的方式实现。例如，以上所描述的装置实施例仅仅是示意性的，例如，所述单元/模块的划分，仅仅为一种逻辑功能划分，实际实现时可以有另外的划分方式，例如多路单元或模块可以结合或者可以集成到另一个系统，或一些特征可以忽略，或不执行。另一点，所显示或讨论的相互之间的耦合或直接耦合或通信连接可以是通过一些接口，装置或单元的间接耦合或通信连接，可以是电性，机械或其它的形式。
所述作为分离部件说明的单元/模块可以是或者也可以不是物理上分开的，作为单元/模块显示的部件可以是或者也可以不是物理单元，即可以位于 一个地方，或者也可以分布到多路网络单元上。可以根据实际的需要选择其中的部分或者全部单元/模块来实现本实施例方案的目的。
最后应说明的是：以上实施例仅用以说明本申请的技术方案，而非对其限制；尽管参照前述实施例对本申请进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本申请各实施例技术方案的精神和范围。

Claims (20)

  1. 一种导光板的制作方法，包括：
    提供聚合物材料；
    提供发泡剂；以及
    将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生；
    其中，所述聚合物材料为聚甲基丙烯酸甲酯或聚碳酸酯；
    所述发泡剂为氮气或二氧化碳；
    所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生的步骤包括：将所述聚合物材料与所述发泡剂均匀混合并注入所述成型模具，以制得包含均匀分布的气泡的导光板，且所述气泡由所述发泡剂产生。
  2. 一种导光板的制作方法，包括：
    提供聚合物材料；
    提供发泡剂；以及
    将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生。
  3. 如权利要求2所述的导光板的制作方法，其中，所述聚合物材料为聚甲基丙烯酸甲酯或聚碳酸酯。
  4. 如权利要求2所述的导光板的制作方法，其中，所述发泡剂为氮气或二氧化碳。
  5. 如权利要求2所述的导光板的制作方法，其中，所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生的步骤包括：
    将所述聚合物材料与所述发泡剂均匀混合并注入所述成型模具，以制得包含均匀分布的气泡的导光板，且所述气泡由所述发泡剂产生。
  6. 如权利要求2所述的导光板的制作方法，其中，所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生的步骤包括：
    在第一时间段向所述成型模具内注入所述聚合物材料；
    在第二时间段向所述成型模具内继续注入将所述聚合物材料和所述发泡剂均匀混合得到的混合物；以及
    在第三时间段向所述成型模具内继续注入所述聚合物材料。
  7. 如权利要求6所述的导光板的制作方法，其中，所述第一时间和第三时间的时间长度相等。
  8. 如权利要求2所述的导光板的制作方法，其中，所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生的步骤包括：
    将所述聚合物材料注入第一子模具，以制成第一子板；
    将所述聚合物材料与所述发泡剂均匀混合得到的混合物注入第二子模具，以制得包含均匀分布的气泡的第二子板，且所述气泡由所述发泡剂产生；
    将所述聚合物材料注入第三子模具，以制成第三子板；以及
    将所述第一子板、所述第二子板和所述第三子板对齐且在厚度方向上叠加合成以得到所述导光板；
    其中，所述第一子板、所述第二子板和所述第三子板的长度相同且宽度相同，所述第二子板位于所述第一子板和所述第三子板之间。
  9. 如权利要求8所述的导光板的制作方法，其中，所述第一子板和第二子板的厚度不同。
  10. 如权利要求2所述的导光板的制作方法，其中，所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生的步骤包括：
    将所述聚合物材料注入第一子模具，以制成第一子板；
    将所述聚合物材料与所述发泡剂均匀混合得到的混合物注入第二子模具，以制得包含均匀分布的气泡的第二子板，且所述气泡由所述发泡剂产生；
    将所述聚合物材料注入第三子模具，以制成第三子板；
    将所述聚合物材料与所述发泡剂均匀混合得到的混合物注入第四子模具，以制得包含均匀分布的气泡的第四子板，且所述气泡由所述发泡剂产生；
    将所述聚合物材料注入第五子模具，以制成第五子板；以及
    将所述第一子板、所述第二子板、所述第三子板、所述第四子板和所述第五子板对齐且在厚度方向上叠加合成以得到所述导光板；
    其中，所述第一子板、所述第二子板、所述第三子板、所述第四子板和所述第五子板的长度相同且宽度相同，所述第一子板、所述第二子板、所述第三子板、所述第四子板和所述第五子板依次相接。
  11. 如权利要求2所述的导光板的制作方法，其中，所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板， 且所述气泡由所述发泡剂产生的步骤包括：
    在第一时间段向所述成型模具内注入所述聚合物材料和所述发泡剂以第一比例均匀混合得到的混合物；
    在第二时间段向所述成型模具内继续注入所述聚合物材料和所述发泡剂以第二比例均匀混合得到的混合物；以及
    在第三时间段向所述成型模具内继续注入所述聚合物材料和所述发泡剂以第三比例均匀混合得到的混合物；
    其中，所述第二比例小于所述第一比例和所述第三比例。
  12. 一种显示装置的制作方法，包括：
    提供导光板，所述导光板的提供方法包括：提供聚合物材料；提供发泡剂；以及将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生；且所述导光板包括：本体，所述本体内形成有所述气泡；入光面，所述入光面位于所述本体的侧部；以及出光面，所述出光面位于所述本体的顶部；
    提供背板，且将所述背板安装在所述本体的底部远离所述顶部的一侧，所述背板面向所述本体的表面为经过镜面处理的光滑表面；
    提供发光单元，并将所述发光单元邻近所述入光面设置；
    提供光学膜片组，将所述光学膜片组设置在所述顶部远离所述底部的一侧。
  13. 如权利要求12所述的显示装置的制作方法，其中，所述聚合物材料为聚甲基丙烯酸甲酯或聚碳酸酯。
  14. 如权利要求12所述的显示装置的制作方法，其中，所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生的步骤包括：
    将所述聚合物材料与所述发泡剂均匀混合并注入所述成型模具，以制得包含均匀分布的气泡的导光板，且所述气泡由所述发泡剂产生。
  15. 如权利要求12所述的显示装置的制作方法，其中，所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生的步骤包括：
    在第一时间段向所述成型模具内注入所述聚合物材料；
    在第二时间段向所述成型模具内继续注入将所述聚合物材料和所述发泡剂均匀混合得到的混合物；以及
    在第三时间段向所述成型模具内继续注入所述聚合物材料。
  16. 如权利要求15所述的显示装置的制作方法，其中，所述第一时间和第三时间的时间长度相等。
  17. 如权利要求12所述的显示装置的制作方法，其中，所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生的步骤包括：
    将所述聚合物材料注入第一子模具，以制成第一子板；
    将所述聚合物材料与所述发泡剂均匀混合得到的混合物注入第二子模具，以制得包含均匀分布的气泡的第二子板，且所述气泡由所述发泡剂产生；
    将所述聚合物材料注入第三子模具，以制成第三子板；以及
    将所述第一子板、所述第二子板和所述第三子板对齐且在厚度方向上叠加合成以得到所述导光板；
    其中，所述第一子板、所述第二子板和所述第三子板的长度相同且宽度相同，所述第二子板位于所述第一子板和所述第三子板之间。
  18. 如权利要求17所述的显示装置的制作方法，其中，所述第一子板和第二子板的厚度不同。
  19. 如权利要求12所述的显示装置的制作方法，其中，所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生的步骤包括：
    将所述聚合物材料注入第一子模具，以制成第一子板；
    将所述聚合物材料与所述发泡剂均匀混合得到的混合物注入第二子模具，以制得包含均匀分布的气泡的第二子板，且所述气泡由所述发泡剂产生；
    将所述聚合物材料注入第三子模具，以制成第三子板；
    将所述聚合物材料与所述发泡剂均匀混合得到的混合物注入第四子模具，以制得包含均匀分布的气泡的第四子板，且所述气泡由所述发泡剂产生；
    将所述聚合物材料注入第五子模具，以制成第五子板；以及
    将所述第一子板、所述第二子板、所述第三子板、所述第四子板和所述第五子板对齐且在厚度方向上叠加合成以得到所述导光板；
    其中，所述第一子板、所述第二子板、所述第三子板、所述第四子板和所述第五子板的长度相同且宽度相同，所述第一子板、所述第二子板、所述第三子板、所述第四子板和所述第五子板依次相接。
  20. 如权利要求12所述的显示装置的制作方法，其中，所述将所述聚合物材料与所述发泡剂以预设方式混合并注入成型模具，以制得包含气泡的导光板，且所述气泡由所述发泡剂产生的步骤包括：
    在第一时间段向所述成型模具内注入所述聚合物材料和所述发泡剂以第一比例均匀混合得到的混合物；
    在第二时间段向所述成型模具内继续注入所述聚合物材料和所述发泡剂以第二比例均匀混合得到的混合物；以及
    在第三时间段向所述成型模具内继续注入所述聚合物材料和所述发泡剂以第三比例均匀混合得到的混合物；
    其中，所述第二比例小于所述第一比例和所述第三比例。
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CN101117014A (zh) * 2006-07-31 2008-02-06 三星电子株式会社 光学板模具及其制造方法和光学板及其制造方法
CN205299407U (zh) * 2016-01-18 2016-06-08 潍坊星美电子科技有限公司 Led透镜高混光导光板
CN108267810A (zh) * 2018-03-02 2018-07-10 深圳创维－Rgb电子有限公司 一种导光板、背光模组及显示设备
CN108873152A (zh) * 2018-07-17 2018-11-23 惠科股份有限公司 导光板的制作方法和显示装置的制作方法

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