WO2020057298A1 - Led display screen - Google Patents

Led display screen Download PDF

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Publication number
WO2020057298A1
WO2020057298A1 PCT/CN2019/100488 CN2019100488W WO2020057298A1 WO 2020057298 A1 WO2020057298 A1 WO 2020057298A1 CN 2019100488 W CN2019100488 W CN 2019100488W WO 2020057298 A1 WO2020057298 A1 WO 2020057298A1
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Prior art keywords
led
diffusion film
display screen
led display
screen according
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PCT/CN2019/100488
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French (fr)
Chinese (zh)
Inventor
胡飞
王霖
李士杰
李屹
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深圳光峰科技股份有限公司
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Publication of WO2020057298A1 publication Critical patent/WO2020057298A1/en

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    • GPHYSICS
    • G09EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
    • G09FDISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
    • G09F9/00Indicating arrangements for variable information in which the information is built-up on a support by selection or combination of individual elements
    • G09F9/30Indicating arrangements for variable information in which the information is built-up on a support by selection or combination of individual elements in which the desired character or characters are formed by combining individual elements
    • G09F9/33Indicating arrangements for variable information in which the information is built-up on a support by selection or combination of individual elements in which the desired character or characters are formed by combining individual elements being semiconductor devices, e.g. diodes

Definitions

  • the invention relates to the technical field of LED displays, and in particular to an LED display screen.
  • Traditional film projection equipment uses a combination of a projector and a projection screen. Due to the design defect of the lens in the projector and the reflective characteristics of the LED display screen, the traditional projection projection equipment using this method has the disadvantages of poor picture uniformity, low brightness, poor picture contrast and high energy consumption.
  • LED display screens using LED chips generally use one pixel for one LED chip to display.
  • three pixels, red, green, and blue, are used to form a pixel. .
  • the size of the LED display screen is usually in the range of 10 meters ⁇ 5 meters to 20 meters ⁇ 10 meters or larger.
  • the pitch p of the LED chips included in it is adjusted accordingly.
  • the width of the LED display screen is 10 meters, the distance between adjacent LED chips is 2.5 mm, and when the width of the LED display screen is 20 meters, the distance between adjacent LEDs is 5 mm.
  • the ratio of the pitch of the LED chip to the size of the LED chip is usually greater than 5: 1, which makes the pixel filling rate of the LED chip not high, which causes the problem that the picture on the LED display screen is not soft due to the strong graininess.
  • the pixel filling rate of LED chips can be increased by increasing the number of LED chips included in the LED display screen, thereby improving the softness, this method will significantly increase the number of chips and drive power consumption, which will result in projection costs and projections. Increased power consumption.
  • the present invention discloses an LED display screen, which is composed of an LED array layer and an optical diffusion film, which can be used without significantly increasing cost and power consumption.
  • the pixel filling rate of the LED chip is significantly improved, so that a softer picture is displayed on the LED display screen.
  • an LED display screen which includes: an LED array layer composed of a plurality of LED chips and used to emit light; and an optical diffusion film disposed on the LED array layer to emit light Side, wherein the light emitted from the LED array layer is diffused to the audience side through the optical diffusion film.
  • the LED display screen according to the present invention can effectively increase the application range of the screen using the LED chip and the optical diffusion film, improve the display effect of the LED display screen, and improve the visual enjoyment and experience of the audience.
  • the LED display screen in the present invention is not only applicable to movie screens, but also to large outdoor advertising screens.
  • FIG. 1 is a corresponding display manner of pixels and LED chips in a conventional LED display screen.
  • FIG. 2a shows the light distribution of a single LED chip in a cross-sectional view of an LED display screen in the present invention.
  • FIG. 2b shows the light distribution of a single LED chip in the front view of the LED display screen in the present invention.
  • FIG. 3 is a cross-sectional view of the structure of an LED display screen in the present invention.
  • Figures 4a-4d illustrate the effect of the pitch p of the LED chip and the distance h between the optical diffusion film and the LED array layer on the area of overlapping crosstalk.
  • FIG. 5 is a schematic diagram of an angle ⁇ between an emitted light and a normal line after passing through the optical diffusion film.
  • FIG. 6 is a relationship curve between the intensity I ( ⁇ ) of the incident parallel light and the angle ⁇ after being diffused by the optical diffusion film in parallel .
  • 7a-7d are brightness distribution diagrams of adjacent LED chips under different diffusion angles.
  • Fig. 8a is a circular light distribution when the optical diffusion film is an isotropic diffusion film.
  • Fig. 8b is an elliptical light distribution when the optical diffusion film is an anisotropic diffusion film.
  • FIG. 9 is a schematic diagram of splicing optical films to form an LED display screen in a longitudinal adjacency manner.
  • FIG. 10 is a schematic diagram of splicing optical films to form an LED display screen in a lateral adjacency manner.
  • FIG. 11 is a splicing method of splicing two adjacent optical film materials together using adhesive tape.
  • FIG. 12 is a splicing method of splicing two adjacent optical film materials together using thermal welding or ultrasonic welding.
  • FIG. 13a is a splicing method for aligning the seam of the thin film material with the seam of the LED module.
  • FIG. 13b is a splicing method in which the seam of the thin film material is not aligned with the seam of the LED module.
  • FIG. 14 is a mechanical protrusion positioning structure used in the LED display screen of the present invention.
  • FIG. 2a-2b show the light distribution of a single LED chip in the LED display screen of the present invention, wherein FIG. 2a is a cross-sectional view of the light distribution of the single LED chip, and FIG. 2b is a top view of the light distribution of the single LED chip.
  • the up-down direction in FIG. 2a is the direction perpendicular to the LED display screen, and the upper side is the audience side.
  • Fig. 2b is a top view as viewed from the audience side.
  • h is the distance between the optical diffusion film (not shown in Fig. 2a) and the LED chip in a direction perpendicular to the surface of the LED display screen
  • D is the spot diameter of the single LED chip on the optical diffusion film.
  • ⁇ stop is the light emitting angle of the light emitted by the single LED chip.
  • p is the distance between adjacent LED chips in the LED array layer
  • the diameter D of the light spot can be defined by the corresponding light emission angle ⁇ stop .
  • the illumination distribution E ( ⁇ stop ) of the light spot on the surface of the optical diffusion film can be calculated according to the following formula (1)
  • the value of a is increased, the corresponding spot diameter D is reduced.
  • the spot diameter D defined by the light angle ⁇ stop can be used as the distance p between the LED chips.
  • the light distribution of a single LED chip can be approximated as a Lambertian distribution, and its light intensity I ( ⁇ stop ) can be calculated according to the following formula (4)
  • ⁇ stop is the light emitting angle of the light emitted by a single LED chip
  • I is the intensity of the light emitted when ⁇ stop is 0.
  • FIG. 3 is a cross-sectional view of the structure of an LED display screen in the present invention. The position and size of the light spot formed by the LED in the LED display screen are also explained.
  • the LED display screen in the present invention includes an LED array layer and an optical diffusion film.
  • the optical diffusion film is placed at a position closer to the viewer side than the LED array layer according to a certain distance h, that is, it is disposed on the light emitting side of the LED array layer. Thereby, the light emitted from the LED array layer is scattered to the viewer side by the optical diffusion film.
  • FIG. 3 illustrates by way of example that the LED array layer includes three LED chips, namely LED1, LED2, and LED3, those skilled in the art should understand that the LED array layer may include any number of LED chips as required.
  • the light spots formed by the chips LED1, LED2, and LED3 are respectively the light spot light intensity 1 (or the spatial distribution of light spot illumination 1), the light spot light intensity 2 (or the spatial distribution of light spot illumination 2), and the light spot light intensity 3 (Or spatial distribution of spot illumination 3).
  • the pixel fill ratio of an LED chip is defined as the ratio of the light emitting area and the pixel area of the LED chip.
  • the pixel fill ratio can be defined as the ratio of the spot area to the pixel area:
  • the horizontal direction indicates the position of the light spot
  • the vertical direction indicates the spatial distribution of the light intensity or the light intensity of the light spot.
  • the positions of an optical diffusion film (referred to as an optical diffusion film 1) indicated by a solid line and an optical diffusion film (referred to as an optical diffusion film 2) indicated by a broken line are shown in FIG. 3.
  • an optical diffusion film referred to as an optical diffusion film 1
  • an optical diffusion film 2 indicated by a broken line
  • FIG. 3 shows that when the diffusion film is set to a certain distance, the light spots formed by adjacent LED chips overlap on the diffusion film, which can fill the black areas between adjacent LED chips, improve the pixel filling rate, and eliminate the screen. Graininess, but when h is reduced, the light spots formed on the optical diffusion film 2 become smaller, and the black area between adjacent LED chips cannot be completely filled, and the graininess cannot be eliminated.
  • the LED display screen in the present invention can effectively shield the gaps between the LED chips through the optical diffusion film, thereby improving the pixel filling rate of the LED chip, and making the pixel filling rate of the LED chip reach 70% or more.
  • the distance p between adjacent LED chips and the distance h between the optical diffusion film and the LED array layer are made The relationship satisfies the following conditions: h ⁇ p ⁇ 5h, preferably 2h ⁇ p ⁇ 4h.
  • Figures 4a-4d illustrate the effect of the pitch p of the LED chip and the distance h between the optical diffusion film and the LED array layer on the area of overlapping crosstalk. It can be seen in conjunction with Figs. 4a-4d that as the ratio between p and h gradually becomes smaller, the area between overlapping crosstalk becomes smaller. After repeated studies by the inventor of the present invention, it is found that the relationship between the distance p between adjacent LED chips and the distance h between the optical diffusion film and the LED array layer satisfies h ⁇ p ⁇ 5h, preferably 2h ⁇ p ⁇ The relationship of 4h can effectively avoid light crosstalk.
  • the pixel filling rate of the LED chip can be improved, and particles on the screen can be eliminated. And prevent blurring caused by light crosstalk.
  • the diffusion angle of the optical diffusion film is explained below with reference to FIGS. 5-7d.
  • FIG. 5 is a schematic diagram of the angle ⁇ between the emitted light and the normal after passing through the optical diffusion film, where the intensity of the parallel light is I parallel , and the intensity of the emitted light after passing through the optical diffusion film is I ( ⁇ ) , I 0 is the intensity of the emitted light when ⁇ is 0.
  • FIG. 6 is a relationship curve between the incident parallel light intensity I and the outgoing light intensity I ( ⁇ ) after being diffused by the optical diffusion film in parallel with the angle ⁇ , and thereby defining the diffusion angle of the optical diffusion film.
  • the horizontal axis represents the angle ⁇
  • the vertical axis represents the emitted light intensity I ( ⁇ ). It can be seen from FIG. 6 that the light intensity I ( ⁇ ) of the outgoing light after the parallel light passes through the optical diffusion film changes with the angle ⁇ .
  • the light intensity I ( ⁇ ) gradually decreases as ⁇ gradually increases.
  • the light intensity I ( ⁇ ) is reduced to a half of the central light intensity I 0 (that is, the light intensity when the value of ⁇ is 0)
  • the corresponding full angle 2 ⁇ is defined as the diffusion angle of the optical diffusion film.
  • the optical diffusion film used in the present invention generally uses transparent PC or PET as a substrate, and may include a bulk diffusion film or a surface diffusion film.
  • the bulk diffusion film is provided with bulk scattering particles, and a bulk diffusion film having diffusion particles can be obtained using a precision optical coating device.
  • the bulk diffusion particles are, for example, inorganic particles such as silica and titanium dioxide particles, or organic particles such as acrylic resin and epoxy resin particles.
  • the surface of the surface diffusion film has a rough structure and can be obtained by a roll-to-roll embossing process.
  • FIG. 7a-7d illustrate the brightness distribution diagrams of adjacent LED chips under different diffusion angles.
  • FIG. 7a illustrates the brightness distribution of a diffusion film with a diffusion angle of 5 degrees
  • FIG. 7b illustrates the brightness distribution of a diffusion film with a diffusion angle of 10 degrees
  • FIG. 7c illustrates the brightness of a diffusion film with a diffusion angle of 40 degrees
  • Fig. 7d illustrates the brightness distribution of a diffusion film with a diffusion angle of 60 degrees.
  • the diffusion angle of the optical diffusion film in the present invention should be greater than 10 degrees, and more preferably greater than 40 degrees.
  • the isotropic diffusion film can be selected as the optical diffusion film. As shown in FIG. 8a, when an isotropic diffusion film is used, it can be seen from the viewer side that the diffusion angle of the diffusion film in all directions is the same.
  • the optical diffusion film can also choose an anisotropic diffusion film.
  • viewers generally view the LED display screen in a relatively large horizontal field of view and a relatively small vertical field of view. Therefore, horizontal and Diffusion films with elliptical Gaussian distributions with different vertical diffusion angles.
  • an anisotropic diffusion film as shown in FIG. 8b it can be seen from the viewer that the diffusion angle of the diffusion film in the horizontal direction is greater than The diffusion angle in the vertical direction, so that the field of view in the horizontal direction is increased.
  • the viewing angle of the upper floor for the vertical field of view is relatively large, so the anisotropic diffusion film is set to have a vertical angle of diffusion greater than the horizontal direction.
  • the diffusion angle in any direction can be set to be greater than the diffusion angle in other directions.
  • multiple LED chips are integrated into one LED sub-module, which has an independent driving unit. Then, a plurality of sub-modules are spliced into an array form into an LED module having a medium size. If the size of the LED display screen is large, multiple medium-sized LED modules need to be spliced again.
  • the LED array layer is formed by the above-mentioned splicing LED sub-module or LED module.
  • the LED display screen is formed by using the module splicing method.
  • a problem occurs in one or more sub-module areas of the LED display screen and the picture quality is reduced or damaged, only the sub-module or module in question can be replaced without replacing.
  • the entire LED display screen can save maintenance costs.
  • the optical diffusion film is formed above the LED array layer closer to the audience side than in the LED display screen, the above-mentioned undesired patchwork can be covered by the optical diffusion film, thereby improving the visual effect of the product. Make the LED display screen surface look more flat and beautiful.
  • the optical film is usually formed as a roll having a width of 1.5 meters to 1.6 meters, and the optical diffusion film can be formed by splicing multiple optical films.
  • the optical film roll can be cut into 7 pieces with a width of about 1.5 meters and a height of It is 5 meters long. Then the 7 pieces of strips are spliced in order, so that the spliced optical film appears to form a whole.
  • the width of the optical film roll is large, when forming a screen with a width of 10 meters as shown in FIG. 9, only the appearance of the six seams in the films 1-7 can be processed, which can reduce the The stitching process of forming an optical diffusion film on the entire LED display screen is difficult.
  • a horizontal splicing method may also be adopted.
  • the film material can be cut into four strips with a height of 1.25 meters and a width of 10 meters, and then the four strips are spliced together in sequence.
  • the spliced optical diffusion film can be wrapped in a front surface or a back surface with a certain tension, so as to be stretched into a flat surface.
  • FIG. 9 and FIG. 10 only give an exemplary description of the size of the LED display screen and the cutting of the optical film roll. Those skilled in the art should easily understand that the LED display screen can adopt any desired size, and the optical film roll can also be appropriately cut and spliced according to actual needs, and is not limited to the specific splicing methods provided in FIGS. 9 and 10.
  • the seam width between adjacent optical diffusion films is less than 100 microns.
  • the method as shown in FIGS. 11 and 12 can be used to splice the optical diffusion film.
  • two pieces of optical film material can be spliced together by a method of splicing tape.
  • two pieces of optical film material (film material 1 and film material 2) are placed in parallel along the long side direction, and the distance between the optical film materials is observed through a movable microscope and adjusted so that between the two long sides The spacing is within 100 microns. Then use the same diffusion tape and adhesive glue on the back to bond the two film materials together.
  • the method shown in FIG. 12 can also be used to overlap the optical film materials, and the two film materials can be connected together by thermal welding or ultrasonic welding.
  • the seam of the thin film material can be aligned with the seam of the LED module as shown in FIG. 13a, or the seam of the thin film material can be made to be not as shown in FIG. 13b.
  • the seams of the LED modules are aligned.
  • the spliced optical diffusion film is fixed on the LED display screen frame by means of a spring or a rope, thereby ensuring that the surface of the optical diffusion film has a uniform distribution. Tension, so that the entire optical diffusion film and the LED array layer are stretched and flattened.
  • a certain distance h can be maintained between the LED sub-module or the LED module and the optical diffusion film through the positioning structure.
  • the LED array layer is arranged on a positioning structure.
  • the positioning structure is set for each LED sub-module or LED module, and can have a plurality of heights.
  • the positioning structure can be cooperatively connected by setting grooves and protrusions. In order to ensure accurate adjustment, a certain distance h is maintained between the LED sub-module or the LED module and the optical diffusion film.
  • a positioning structure is provided for the entire LED array layer, that is, the positioning structure is integrated, and the entire LED array layer is provided on the positioning structure, so as to maintain a distance h from the optical diffusion film.
  • the positioning structure may use, for example, a mechanical protrusion positioning structure, a groove is provided on the optical diffusion film for coordinated positioning with the positioning structure, or a protrusion is provided on the optical diffusion film, and a groove is provided on the positioning structure for and Optical diffusion film.
  • the LED sub-module or LED module is disposed on the surface of the mechanical protrusion positioning structure away from the audience side, and the optical diffusion film is disposed in the mechanical protrusion positioning structure on the same side as the LED sub-module or module but at a distance of h. At the location, the optical diffusion film is closer to the viewer side than the LED sub-module or module.
  • the application range of the LED display screen can be effectively improved through the combination of the LED array layer and the optical diffusion film, and the pixel filling rate of the LED chip can be improved, thereby reducing the effect of graininess on the screen
  • the problem of non-softness improves the display effect of the LED display screen, thereby improving the visual enjoyment and experience of the audience.
  • the LED sub-modules or the joints between the LED modules can be shielded, and the visual effect of the product is improved.
  • the vertical stitching method when forming an LED display screen with a width of 10 meters and a height of 5 meters, only 6 patchwork needs to be processed in the vertical stitching method, and only 3 patchwork can be processed in the horizontal stitching method.
  • the horizontal or vertical seam may be aligned with the seam between the LED sub-modules or modules, or may not be aligned with the seam of the LED sub-modules or modules, so that the seam between the LED sub-modules or the LED modules can be further covered .
  • the splicing technology of the optical film can greatly reduce the seam area of the entire screen surface.
  • the seam can be controlled within 100 microns by using adhesive tape or welding methods, so that the audience will not see the seam under the LED chip lighting conditions. Seam.
  • the relationship between the distance p between adjacent LED chips and the distance h between the optical diffusion film and the LED array layer satisfies the following condition: h ⁇ p ⁇ 5h, preferably 2h ⁇ p ⁇ 4h, so that it can be prevented
  • the light emitted by adjacent LED chips will crosstalk with each other, which can improve the sharpness of the picture.
  • the diffusion angle of the optical diffusion film in the present invention should be greater than 10 degrees, preferably greater than 40 degrees. When the diffusion angle is larger, the shielding effect of the optical diffusion film on the spaces between the LED chips is better.
  • the light-emitting area per unit pixel becomes smaller and smaller.
  • the brightness value in the light-emitting area of the LED chip is very high, and the brightness value in the non-LED chip light-emitting area is very low.
  • a test device needs to perform a weighted average of the entire pixel area in the later period. After adding the diffusion film, the light spot of the LED chip has a size close to that of the pixel, that is, it has a higher pixel fill rate, and the brightness of the unit pixel is more uniform.
  • the test equipment does not need to be calibrated and the areas with and without light are averaged. Test accuracy will be higher.

Abstract

An LED display screen, comprising: an LED array layer, consisting of multiple LED chips and being used for emitting light; and an optical diffusion film provided on the light emitting side of the LED array layer, wherein the light emitted by the LED array layer is diffused to the viewer side through the optical diffusion film.

Description

LED显示屏幕LED display screen 技术领域Technical field
本发明涉及LED显示技术领域,尤其涉及一种LED显示屏幕。The invention relates to the technical field of LED displays, and in particular to an LED display screen.
背景技术Background technique
传统的电影放映设备采用投影机和投影屏幕相结合的方式。由于投影机中镜头的设计缺陷和LED显示屏幕的反光特性,导致采用该方式的传统投影放映设备具有画面均匀性差、亮度低、画面对比度差和能耗高的缺点。Traditional film projection equipment uses a combination of a projector and a projection screen. Due to the design defect of the lens in the projector and the reflective characteristics of the LED display screen, the traditional projection projection equipment using this method has the disadvantages of poor picture uniformity, low brightness, poor picture contrast and high energy consumption.
由于观众对电影视觉效果的要求不断提高,越来越多的影院放映采用4K分辨率的片源。为了降低成本并提高画面的对比度,采用LED芯片的LED显示屏幕一般采用一个像素对应一个LED芯片的方式进行显示,也可以如图1所示,采用红、绿、蓝三个LED芯片形成一个像素。As the audience's requirements for movie visual effects continue to increase, more and more theater shows use 4K resolution sources. In order to reduce costs and improve the contrast of the screen, LED display screens using LED chips generally use one pixel for one LED chip to display. Alternatively, as shown in Figure 1, three pixels, red, green, and blue, are used to form a pixel. .
LED显示屏幕的尺寸通常在10米×5米至20米×10米的范围内或更大。当LED显示屏幕中画面的分辨率固定时,其包含的LED芯片的间距p也会相应地被调整。例如,当LED显示屏幕的宽度为10米时,相邻LED芯片之间的间距为2.5毫米,而当LED显示屏幕的宽度为20米时,相邻LED之间的间距为5毫米。LED芯片的间距和LED芯片的尺寸的比率通常大于5:1,使得LED芯片的像素填充率不高,从而带来LED显示屏幕上画面由于颗粒感强而不柔和的问题。虽然可以通过增加LED显示屏幕中所包含的LED芯片数量的方法来提高LED芯片的像素填充率,从而提高柔和度,但是这种方法会明显增加芯片数量和驱动功耗,从而使放映成本和放映功耗升高。The size of the LED display screen is usually in the range of 10 meters × 5 meters to 20 meters × 10 meters or larger. When the resolution of the picture in the LED display screen is fixed, the pitch p of the LED chips included in it is adjusted accordingly. For example, when the width of the LED display screen is 10 meters, the distance between adjacent LED chips is 2.5 mm, and when the width of the LED display screen is 20 meters, the distance between adjacent LEDs is 5 mm. The ratio of the pitch of the LED chip to the size of the LED chip is usually greater than 5: 1, which makes the pixel filling rate of the LED chip not high, which causes the problem that the picture on the LED display screen is not soft due to the strong graininess. Although the pixel filling rate of LED chips can be increased by increasing the number of LED chips included in the LED display screen, thereby improving the softness, this method will significantly increase the number of chips and drive power consumption, which will result in projection costs and projections. Increased power consumption.
发明内容Summary of the Invention
为解决上述所提到的由于颗粒感强而不柔和的问题,本发明公开了一种LED显示屏幕,其由LED阵列层和光学扩散膜构成,能够在不显著提高成本和功耗的条件下显著提高LED芯片的像素填充率,从而在该LED显示屏幕上显示更加柔和的画面。In order to solve the above-mentioned problem of strong and not soft due to graininess, the present invention discloses an LED display screen, which is composed of an LED array layer and an optical diffusion film, which can be used without significantly increasing cost and power consumption. The pixel filling rate of the LED chip is significantly improved, so that a softer picture is displayed on the LED display screen.
在本发明的第一方面提供一种LED显示屏幕,其包括:LED阵列层, 其由多个LED芯片组成,并用于发出光;以及光学扩散膜,其设置在所述LED阵列层的光出射侧,其中,所述LED阵列层中发出的光透过所述光学扩散膜而扩散到观众侧。According to a first aspect of the present invention, an LED display screen is provided, which includes: an LED array layer composed of a plurality of LED chips and used to emit light; and an optical diffusion film disposed on the LED array layer to emit light Side, wherein the light emitted from the LED array layer is diffused to the audience side through the optical diffusion film.
根据本发明中的LED显示屏幕能够有效地提高采用了LED芯片和光学扩散膜的屏幕的应用范围,提高LED显示屏幕的显示效果,并提高观众的视觉享受和体验。The LED display screen according to the present invention can effectively increase the application range of the screen using the LED chip and the optical diffusion film, improve the display effect of the LED display screen, and improve the visual enjoyment and experience of the audience.
本发明中的LED显示屏幕不仅适用于电影屏幕,也适用于大型户外广告屏等情况。The LED display screen in the present invention is not only applicable to movie screens, but also to large outdoor advertising screens.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1为现有技术的LED显示屏幕中像素与LED芯片的对应显示方式。FIG. 1 is a corresponding display manner of pixels and LED chips in a conventional LED display screen.
图2a示出了在本发明中LED显示屏幕的剖视图中单个LED芯片的出光分布情况。FIG. 2a shows the light distribution of a single LED chip in a cross-sectional view of an LED display screen in the present invention.
图2b示出了在本发明中LED显示屏幕的正视图中单个LED芯片的出光分布情况。FIG. 2b shows the light distribution of a single LED chip in the front view of the LED display screen in the present invention.
图3为本发明中LED显示屏幕构造的剖视图。FIG. 3 is a cross-sectional view of the structure of an LED display screen in the present invention.
图4a-4d说明LED芯片间距p与光学扩散膜和LED阵列层之间的距离h对交叠串扰区域的影响。Figures 4a-4d illustrate the effect of the pitch p of the LED chip and the distance h between the optical diffusion film and the LED array layer on the area of overlapping crosstalk.
图5为透过光学扩散膜后的出射光与法线之间的角度θ的示意图。FIG. 5 is a schematic diagram of an angle θ between an emitted light and a normal line after passing through the optical diffusion film.
图6为入射平行光光强I 平行经过光学扩散膜扩散之后的出射光强I(θ)与角度θ之间的关系曲线。 FIG. 6 is a relationship curve between the intensity I (θ) of the incident parallel light and the angle θ after being diffused by the optical diffusion film in parallel .
图7a-7d为相邻LED芯片在不同扩散角度下的亮度分布图。7a-7d are brightness distribution diagrams of adjacent LED chips under different diffusion angles.
图8a为光学扩散膜是各向同性扩散膜时的圆形光分布。Fig. 8a is a circular light distribution when the optical diffusion film is an isotropic diffusion film.
图8b为光学扩散膜是各向异性扩散膜时的椭圆形光分布。Fig. 8b is an elliptical light distribution when the optical diffusion film is an anisotropic diffusion film.
图9为纵向邻接方式中拼接光学薄膜以形成LED显示屏幕的示意图。FIG. 9 is a schematic diagram of splicing optical films to form an LED display screen in a longitudinal adjacency manner.
图10为横向邻接方式中拼接光学薄膜以形成LED显示屏幕的示意图。FIG. 10 is a schematic diagram of splicing optical films to form an LED display screen in a lateral adjacency manner.
图11为使用胶带将两块相邻光学薄膜材料拼接在一起的拼接方式。FIG. 11 is a splicing method of splicing two adjacent optical film materials together using adhesive tape.
图12为使用热焊接或者超声焊接将两块相邻光学薄膜材料拼接在一起的拼接方式。FIG. 12 is a splicing method of splicing two adjacent optical film materials together using thermal welding or ultrasonic welding.
图13a为使薄膜材料的拼缝跟LED模组的拼缝进行对齐的拼接方式。FIG. 13a is a splicing method for aligning the seam of the thin film material with the seam of the LED module.
图13b为使薄膜材料的拼缝不跟LED模组的拼缝对齐的拼接方式。FIG. 13b is a splicing method in which the seam of the thin film material is not aligned with the seam of the LED module.
图14为本发明LED显示屏幕中使用的机械突起定位结构。FIG. 14 is a mechanical protrusion positioning structure used in the LED display screen of the present invention.
具体实施方式detailed description
下面,将参照附图详细说明根据本发明的各具体实施例。需要强调的是,附图中的所有尺寸仅是示意性的并且不一定是按照真实比例图示的,因而不具有限定性。例如,应当理解,图示中的微结构、反射膜等组件的尺寸、比例等参数并不是按照实际的尺寸和比例示出的,仅是为了图示方便,但不是用于限定本发明的具体范围。Hereinafter, specific embodiments according to the present invention will be described in detail with reference to the accompanying drawings. It should be emphasized that all dimensions in the drawings are only schematic and are not necessarily illustrated in true scale, and thus are not restrictive. For example, it should be understood that the dimensions, proportions, and other parameters of components such as microstructures and reflective films in the illustrations are not shown according to the actual dimensions and proportions, and are only for convenience of illustration, but are not intended to limit the specifics of the present invention. range.
图2a-2b为本发明LED显示屏幕中单个LED芯片的出光分布情况,其中,图2a为该单个LED芯片出光分布情况的剖视图,图2b为该单个LED芯片出光分布情况的俯视图。2a-2b show the light distribution of a single LED chip in the LED display screen of the present invention, wherein FIG. 2a is a cross-sectional view of the light distribution of the single LED chip, and FIG. 2b is a top view of the light distribution of the single LED chip.
在图2a中的上下方向为垂直于LED显示屏幕的方向,其中上方为观众侧。图2b为从观众侧观看的俯视图。The up-down direction in FIG. 2a is the direction perpendicular to the LED display screen, and the upper side is the audience side. Fig. 2b is a top view as viewed from the audience side.
在图2a中,h为(图2a中未示出的)光学扩散膜与LED芯片之间在垂直于LED显示屏幕表面方向上的距离,D为该单个LED芯片在光学扩散膜上的光斑直径,θ stop为该单个LED芯片所发出光线的发光角度。 In Fig. 2a, h is the distance between the optical diffusion film (not shown in Fig. 2a) and the LED chip in a direction perpendicular to the surface of the LED display screen, and D is the spot diameter of the single LED chip on the optical diffusion film. , Θ stop is the light emitting angle of the light emitted by the single LED chip.
在图2b中,p为LED阵列层中相邻LED芯片之间的间距,r为该单个LED芯片在光学扩散膜上的光斑直径,即r=D/2。In FIG. 2b, p is the distance between adjacent LED chips in the LED array layer, and r is the spot diameter of the single LED chip on the optical diffusion film, that is, r = D / 2.
根据图2a所示,可以通过对应的发光角度θ stop来定义光斑的直径D。 According to Fig. 2a, the diameter D of the light spot can be defined by the corresponding light emission angle θ stop .
光学扩散膜与LED阵列层之间的距离为h时,光学扩散膜的表面上光斑的照度分布E(θ stop)可以根据下述公式(1)计算 When the distance between the optical diffusion film and the LED array layer is h, the illumination distribution E (θ stop ) of the light spot on the surface of the optical diffusion film can be calculated according to the following formula (1)
Figure PCTCN2019100488-appb-000001
Figure PCTCN2019100488-appb-000001
当照度分布E(θ stop)衰减到中心照度E(0)的一定比值a的时候(0<a<0.5),对应的光线角度θ stop为: When the illuminance distribution E (θ stop ) decays to a certain ratio a of the central illuminance E (0) (0 <a <0.5), the corresponding light angle θ stop is:
Figure PCTCN2019100488-appb-000002
Figure PCTCN2019100488-appb-000002
当a=0.1的时候,θ stop的取值大约是56度,对应的光斑直径D和距离h的比值D/h为2tan(θ stop)≈3,即D=2htan(θ stop)。当a的值增大时,对应的光斑直径D会缩小,在实际应用中,可以将通过上述光线角度θ stop所定义的光斑直径D作为LED芯片之间的间距p。 When a = 0.1, the value of θ stop is about 56 degrees, and the ratio D / h of the corresponding spot diameter D and distance h is 2tan (θ stop ) ≈3, that is, D = 2htan (θ stop ). When the value of a is increased, the corresponding spot diameter D is reduced. In practical applications, the spot diameter D defined by the light angle θ stop can be used as the distance p between the LED chips.
在实际应用中,在像素填充率一定的情况下,可将光斑直径D作为LED芯片之间的间距p,且D=2htan(θ stop),则可通过下述公式(3)来计算间距p In practical applications, when the pixel filling rate is constant, the spot diameter D can be used as the distance p between the LED chips, and D = 2htan (θ stop ), then the distance p can be calculated by the following formula (3)
p=2h tan(θ stop)   (3) p = 2h tan (θ stop ) (3)
在下述表格1中列出了a、θ stop和2tan(θ stop)的不同对应值: The different corresponding values of a, θ stop and 2tan (θ stop ) are listed in Table 1 below:
表格1Table 1
aa θ stop θ stop 2tan(θ stop) 2tan (θ stop )
0.050.05 61.7761.77 3.723.72
0.10.1 55.7855.78 2.942.94
0.20.2 4848 2.222.22
0.30.3 42.342.3 1.821.82
通过上述表格可以看出,随着a值逐渐增大,对应的光斑直径D(即LED芯片之间的间距p)逐渐缩小。It can be seen from the above table that as the value of a gradually increases, the corresponding spot diameter D (that is, the distance p between the LED chips) gradually decreases.
单个LED芯片的出光分布可以近似为朗伯分布,其发出的光强I(θ stop)可根据下述公式(4)计算 The light distribution of a single LED chip can be approximated as a Lambertian distribution, and its light intensity I (θ stop ) can be calculated according to the following formula (4)
I(θ stop)=Icos(θ stop)         (4) I (θ stop ) = Icos (θ stop ) (4)
其中,θ stop为单个LED芯片所发出光线的发光角度,且I是θ stop为0时的出射光光强。 Among them, θ stop is the light emitting angle of the light emitted by a single LED chip, and I is the intensity of the light emitted when θ stop is 0.
图3为本发明中LED显示屏幕构造的剖视图。同时说明了该LED显示屏幕中由LED形成的光斑的位置和大小。FIG. 3 is a cross-sectional view of the structure of an LED display screen in the present invention. The position and size of the light spot formed by the LED in the LED display screen are also explained.
如图3所示,本发明中LED显示屏幕包括LED阵列层和光学扩散膜。将光学扩散膜按照一定的距离h放置为比LED阵列层更靠近观众侧的位置处,即设置在LED阵列层的光出射侧。由此,从LED阵列层中发出的光通过光学扩散膜散射到观众侧。As shown in FIG. 3, the LED display screen in the present invention includes an LED array layer and an optical diffusion film. The optical diffusion film is placed at a position closer to the viewer side than the LED array layer according to a certain distance h, that is, it is disposed on the light emitting side of the LED array layer. Thereby, the light emitted from the LED array layer is scattered to the viewer side by the optical diffusion film.
虽然图3中以示例性的方式说明了LED阵列层包含有三个LED芯片,即LED1、LED2和LED3,但本领域技术人员应当能理解该LED阵列层可以根据需要包含任意数量的LED芯片。如图3所示,由芯片LED1、LED2和LED3形成的光斑分别为光斑光强度1(或光斑照度的空间分布1)、光斑光强度2(或光斑照度的空间分布2)和光斑光强度3(或光斑照度的空间分布3)。Although FIG. 3 illustrates by way of example that the LED array layer includes three LED chips, namely LED1, LED2, and LED3, those skilled in the art should understand that the LED array layer may include any number of LED chips as required. As shown in FIG. 3, the light spots formed by the chips LED1, LED2, and LED3 are respectively the light spot light intensity 1 (or the spatial distribution of light spot illumination 1), the light spot light intensity 2 (or the spatial distribution of light spot illumination 2), and the light spot light intensity 3 (Or spatial distribution of spot illumination 3).
LED芯片的像素填充率定义为LED芯片的发光面积和像素面积的比例。当在LED芯片表面覆盖有光学扩散膜的时候,由于光学扩散膜表面的照射区域由光斑直径D(或光斑半径r)来定义,可以将像素填充率定义为光斑面积和像素面积的比率:The pixel fill ratio of an LED chip is defined as the ratio of the light emitting area and the pixel area of the LED chip. When the surface of the LED chip is covered with an optical diffusion film, since the illuminated area on the surface of the optical diffusion film is defined by the spot diameter D (or spot radius r), the pixel fill ratio can be defined as the ratio of the spot area to the pixel area:
Figure PCTCN2019100488-appb-000003
Figure PCTCN2019100488-appb-000003
在图3中,水平方向表示光斑的位置,垂直方向上表示光斑光强度或光斑照度的空间分布。在图3中示出了由实线表示的光学扩散膜(称为光学扩散膜1)以及由虚线表示的光学扩散膜(称为光学扩散膜2)的位置。通过图3可以看出,当扩散膜设置到一定距离时,相邻LED芯片形成的光斑在扩散膜上交叠,便能填充相邻LED芯片之间的黑色区域,提高像素填充率,消除画面颗粒感,但当h减少时,在光学扩散膜2上形成的光斑变小,就不能完全填充相邻LED芯片之间的黑色区域,则就不能消除颗粒感。In FIG. 3, the horizontal direction indicates the position of the light spot, and the vertical direction indicates the spatial distribution of the light intensity or the light intensity of the light spot. The positions of an optical diffusion film (referred to as an optical diffusion film 1) indicated by a solid line and an optical diffusion film (referred to as an optical diffusion film 2) indicated by a broken line are shown in FIG. 3. It can be seen from FIG. 3 that when the diffusion film is set to a certain distance, the light spots formed by adjacent LED chips overlap on the diffusion film, which can fill the black areas between adjacent LED chips, improve the pixel filling rate, and eliminate the screen. Graininess, but when h is reduced, the light spots formed on the optical diffusion film 2 become smaller, and the black area between adjacent LED chips cannot be completely filled, and the graininess cannot be eliminated.
基于上述比较结果可知,随着光学扩散膜和LED阵列层之间的距离h逐渐增加,LED芯片的光斑在光学扩散膜的表面逐渐增大,从而能够填充相邻LED芯片之间的黑色区域,并提高LED芯片的像素填充率。Based on the above comparison results, it can be known that as the distance h between the optical diffusion film and the LED array layer gradually increases, the spot of the LED chip gradually increases on the surface of the optical diffusion film, so that the black area between adjacent LED chips can be filled. And increase the pixel fill rate of the LED chip.
因此,本发明中的LED显示屏幕能够通过光学扩散膜有效地遮蔽LED芯片之间的空隙,从而提高LED芯片的像素填充率,可以使LED芯片的像素填充率达到70%以上。Therefore, the LED display screen in the present invention can effectively shield the gaps between the LED chips through the optical diffusion film, thereby improving the pixel filling rate of the LED chip, and making the pixel filling rate of the LED chip reach 70% or more.
然而,当光学扩散膜和LED阵列层之间的距离h增加一定程度后,相邻LED芯片发出的光线会相互串扰,进而影响了画面的清晰度。However, when the distance h between the optical diffusion film and the LED array layer is increased to a certain extent, the light emitted by adjacent LED chips will crosstalk with each other, which affects the clarity of the screen.
为解决上述由于光线串扰而导致画面不清晰的问题,同时提高像素填充率,在本发明中,使相邻LED芯片之间的间距p与光学扩散膜和LED阵列层之间的距离h之间的关系满足下述条件:h<p<5h,优选 2h<p<4h。In order to solve the above-mentioned problem that the picture is not clear due to light crosstalk and improve the pixel filling rate, in the present invention, the distance p between adjacent LED chips and the distance h between the optical diffusion film and the LED array layer are made The relationship satisfies the following conditions: h <p <5h, preferably 2h <p <4h.
图4a-4d说明LED芯片间距p与光学扩散膜和LED阵列层之间的距离h对交叠串扰区域的影响。结合图4a-4d可以看出,随着p与h之间的比值逐渐变小,交叠串扰区域之间变小。经过本发明的发明人反复研究得知,使相邻LED芯片之间的间距p与光学扩散膜和LED阵列层之间的距离h之间的关系满足h<p<5h、优选2h<p<4h的关系时,能够有效地避免光线串扰。Figures 4a-4d illustrate the effect of the pitch p of the LED chip and the distance h between the optical diffusion film and the LED array layer on the area of overlapping crosstalk. It can be seen in conjunction with Figs. 4a-4d that as the ratio between p and h gradually becomes smaller, the area between overlapping crosstalk becomes smaller. After repeated studies by the inventor of the present invention, it is found that the relationship between the distance p between adjacent LED chips and the distance h between the optical diffusion film and the LED array layer satisfies h <p <5h, preferably 2h <p < The relationship of 4h can effectively avoid light crosstalk.
故在本发明中通过设置扩散膜邻LED芯片之间的间距p与光学扩散膜和LED阵列层之间的距离h之间的关系,能够提高LED芯片的像素填充率,能够消除屏幕上的颗粒感,同时防止由于光线串扰而导致画面不清晰。Therefore, in the present invention, by setting the relationship between the distance p between the diffusion film adjacent to the LED chip and the distance h between the optical diffusion film and the LED array layer, the pixel filling rate of the LED chip can be improved, and particles on the screen can be eliminated. And prevent blurring caused by light crosstalk.
在下文中参考图5-7d来说明光学扩散膜的扩散角度。The diffusion angle of the optical diffusion film is explained below with reference to FIGS. 5-7d.
图5为透过光学扩散膜后的出射光与法线之间的角度θ的示意图,其中,平行光光强为I 平行,透过光学扩散膜之后发散的出射光光强为I(θ),I 0是θ为0时的出射光光强。 FIG. 5 is a schematic diagram of the angle θ between the emitted light and the normal after passing through the optical diffusion film, where the intensity of the parallel light is I parallel , and the intensity of the emitted light after passing through the optical diffusion film is I (θ) , I 0 is the intensity of the emitted light when θ is 0.
图6为入射平行光光强I 平行经过光学扩散膜扩散之后的出射光强I(θ)与角度θ之间的关系曲线,并由此定义光学扩散膜的扩散角度。 FIG. 6 is a relationship curve between the incident parallel light intensity I and the outgoing light intensity I (θ) after being diffused by the optical diffusion film in parallel with the angle θ, and thereby defining the diffusion angle of the optical diffusion film.
在图6中,横轴表示角度θ,纵轴表示出射光光强I(θ)。由图6可知,平行光经过光学扩散膜后的出射光光强I(θ)随角度θ变化。In FIG. 6, the horizontal axis represents the angle θ, and the vertical axis represents the emitted light intensity I (θ). It can be seen from FIG. 6 that the light intensity I (θ) of the outgoing light after the parallel light passes through the optical diffusion film changes with the angle θ.
当θ=0时,该光强I(θ)达到最大值I 0。当θ逐渐变大时光强I(θ)逐渐减弱。当光强I(θ)减弱到中心光强I 0(即θ值为0时的光强)一半的位置时,对应的全角2θ就定义为光学扩散膜的扩散角度。 When θ = 0, the light intensity I (θ) reaches a maximum value I 0 . The light intensity I (θ) gradually decreases as θ gradually increases. When the light intensity I (θ) is reduced to a half of the central light intensity I 0 (that is, the light intensity when the value of θ is 0), the corresponding full angle 2θ is defined as the diffusion angle of the optical diffusion film.
在本发明中使用的光学扩散膜一般采用透明的PC或者PET作为基材,可以包括体扩散膜或表面扩散膜。The optical diffusion film used in the present invention generally uses transparent PC or PET as a substrate, and may include a bulk diffusion film or a surface diffusion film.
该体扩散膜中设置有体散射粒子,可以使用精密光学涂布设备得到有扩散粒子的体扩散膜。该体扩散粒子例如为二氧化硅、二氧化钛颗粒等无机颗粒或者丙烯酸树脂、环氧系树脂颗粒等有机颗粒。The bulk diffusion film is provided with bulk scattering particles, and a bulk diffusion film having diffusion particles can be obtained using a precision optical coating device. The bulk diffusion particles are, for example, inorganic particles such as silica and titanium dioxide particles, or organic particles such as acrylic resin and epoxy resin particles.
该表面扩散膜的表面具有粗糙结构,可以通过卷对卷的压印工艺而获得。The surface of the surface diffusion film has a rough structure and can be obtained by a roll-to-roll embossing process.
图7a-7d说明了相邻LED芯片在不同扩散角度下的亮度分布图。其 中,图7a中说明扩散角度为5度的扩散膜的亮度分布,图7b说明扩散角度为10度扩散膜的扩散膜的亮度分布,图7c说明扩散角度为40度扩散膜的扩散膜的亮度分布,图7d说明扩散角度为60度扩散膜的扩散膜的亮度分布。7a-7d illustrate the brightness distribution diagrams of adjacent LED chips under different diffusion angles. Among them, FIG. 7a illustrates the brightness distribution of a diffusion film with a diffusion angle of 5 degrees, FIG. 7b illustrates the brightness distribution of a diffusion film with a diffusion angle of 10 degrees, and FIG. 7c illustrates the brightness of a diffusion film with a diffusion angle of 40 degrees. Fig. 7d illustrates the brightness distribution of a diffusion film with a diffusion angle of 60 degrees.
根据图7a-7d的亮度分布图可知,当相邻LED芯片之间的间距p一定时,当该扩散角度越大时,相邻LED芯片亮度分布交叠的区域多,对应的在扩散膜形成的对应的LED光斑面积就大,能够填充的相邻LED芯片之间的黑色区域就越多,就能够使光学扩散膜对LED芯片之间空隙的遮蔽效果越好。故本发明中光学扩散膜的扩散角度应大于10度,更优选为大于40度。According to the brightness distribution diagrams of Figs. 7a-7d, it can be known that when the distance p between adjacent LED chips is constant, when the diffusion angle is larger, there are more areas where the brightness distribution of adjacent LED chips overlaps, correspondingly forming a diffusion film. The corresponding LED spot area is larger, and the more black areas between adjacent LED chips that can be filled, the better the shielding effect of the optical diffusion film on the spaces between the LED chips. Therefore, the diffusion angle of the optical diffusion film in the present invention should be greater than 10 degrees, and more preferably greater than 40 degrees.
根据不同需求,光学扩散膜可选择各向同性的扩散膜。如图8a所示,在采用各向同性的扩散膜时,从观众侧可以看出,该扩散膜在各个方向的扩散角度都是相同的。According to different needs, the isotropic diffusion film can be selected as the optical diffusion film. As shown in FIG. 8a, when an isotropic diffusion film is used, it can be seen from the viewer side that the diffusion angle of the diffusion film in all directions is the same.
但该光学扩散膜也可以选择各向异性的扩散膜,并且在实际应用的场景中,观众一般在比较大的水平视场和比较小的垂直视场中观看LED显示屏幕,因此一般采用水平和竖直方向扩散角度不同的椭圆高斯散射分布的扩散膜,例如,在采用如图8b所示的各向异性的扩散膜时,从观众侧可以看出,该扩散膜在水平方向的扩散角度大于在垂直方向的扩散角度,从而使得水平方向的视场得到增加。However, the optical diffusion film can also choose an anisotropic diffusion film. In practical applications, viewers generally view the LED display screen in a relatively large horizontal field of view and a relatively small vertical field of view. Therefore, horizontal and Diffusion films with elliptical Gaussian distributions with different vertical diffusion angles. For example, when an anisotropic diffusion film as shown in FIG. 8b is used, it can be seen from the viewer that the diffusion angle of the diffusion film in the horizontal direction is greater than The diffusion angle in the vertical direction, so that the field of view in the horizontal direction is increased.
当然,在其他实际的应用场景中,电影院分上下二层楼时,处于上层楼对于垂直方向的视场的视角要求比较大,那么各向异性的扩散膜设置为垂直方向的扩散角度大于水平方向的扩散角度,当然,根据其他具体的实际需求,可以设置成任一方向的扩散角度大于其他方向的扩散角度。Of course, in other practical application scenarios, when the movie theater is divided into two floors, the viewing angle of the upper floor for the vertical field of view is relatively large, so the anisotropic diffusion film is set to have a vertical angle of diffusion greater than the horizontal direction. Of course, according to other specific practical requirements, the diffusion angle in any direction can be set to be greater than the diffusion angle in other directions.
接着,在下文中描述本发明中LED显示屏幕的形成方法。Next, a method for forming an LED display screen in the present invention is described below.
首先,将多个LED芯片集成到一个LED子模块中,该LED子模块具有独立的驱动单元。然后,将多个子模块以阵列形式拼接为具有中等尺寸的LED模块。如果LED显示屏幕的尺寸较大,则需要将多个中等尺寸的LED模块再次进行拼接。First, multiple LED chips are integrated into one LED sub-module, which has an independent driving unit. Then, a plurality of sub-modules are spliced into an array form into an LED module having a medium size. If the size of the LED display screen is large, multiple medium-sized LED modules need to be spliced again.
通过上述拼接LED子模块或LED模块的方式形成上述LED阵列层。The LED array layer is formed by the above-mentioned splicing LED sub-module or LED module.
通过使用该模块拼接的方式形成LED显示屏幕,当该LED显示屏幕中的一个或多个子模块区域中出现问题而导致画质降低或损坏,可以只替换出现问题的子模块或模块,而无需替换整个LED显示屏幕,由此能够节省维护的成本。The LED display screen is formed by using the module splicing method. When a problem occurs in one or more sub-module areas of the LED display screen and the picture quality is reduced or damaged, only the sub-module or module in question can be replaced without replacing. The entire LED display screen can save maintenance costs.
但是在上述模块拼接方式中,由于根据现有技术无法理想地控制各模块之间或子模块之间拼接边界的平整度和间隙,因此可能在该拼接边界处存在具有高低起伏的拼缝,甚至有的拼缝是肉眼可见的。该情况可能会影响产品的视觉效果,因此是不理想的。However, in the above-mentioned module splicing method, since the flatness and gap of the splicing boundary between each module or between sub-modules cannot be ideally controlled according to the prior art, there may be patchy seams with undulations at the splicing boundary, or even The patchwork is visible to the naked eye. This situation is not ideal because it may affect the visual effects of the product.
然而在本发明中,由于在比LED显示屏幕中LED阵列层更靠近观众侧的上方形成有光学扩散膜,上述不理想的拼缝可以由光学扩散膜而遮盖,从而提高了产品的视觉效果,使LED显示屏幕表面看起来更平整美观。However, in the present invention, since the optical diffusion film is formed above the LED array layer closer to the audience side than in the LED display screen, the above-mentioned undesired patchwork can be covered by the optical diffusion film, thereby improving the visual effect of the product. Make the LED display screen surface look more flat and beautiful.
光学薄膜通常形成为具有幅宽为1.5米-1.6米的卷材,光学扩散膜可以由多块光学薄膜拼接形成。例如,如图9所示的纵向邻接方式中,如果期望制造的LED显示屏幕的宽度为10米且高度为5米,则可以将该光学薄膜卷材裁剪成7块宽度为1.5米左右、高度为5米的长条。然后将这7块长条依次拼接,使拼接后的光学薄膜看起来形成为一个整体。The optical film is usually formed as a roll having a width of 1.5 meters to 1.6 meters, and the optical diffusion film can be formed by splicing multiple optical films. For example, in the vertical abutment method shown in FIG. 9, if the width of the LED display screen to be manufactured is 10 meters and the height is 5 meters, the optical film roll can be cut into 7 pieces with a width of about 1.5 meters and a height of It is 5 meters long. Then the 7 pieces of strips are spliced in order, so that the spliced optical film appears to form a whole.
由于光学薄膜卷材的宽度较大,在形成如图9中所示的宽度为10米的屏幕时,只需要处理好薄膜1-7中的6条拼缝的外观即可,由此能够降低整个LED显示屏幕上形成光学扩散膜的拼接处理难度。Because the width of the optical film roll is large, when forming a screen with a width of 10 meters as shown in FIG. 9, only the appearance of the six seams in the films 1-7 can be processed, which can reduce the The stitching process of forming an optical diffusion film on the entire LED display screen is difficult.
另外,在形成本发明中LED显示屏幕时,例如也可以采用横向拼接方式。例如,如图10所示的横向拼接方式中,可以将薄膜材料裁成4块高度1.25米、宽度为10米的长条,再将这4块长条依次拼接在一起。利用金属框架等框架结构,可以将拼接好的光学扩散膜以正面包裹或者反面包裹的方式施加一定的张力,从而绷紧为一个平面。In addition, when forming the LED display screen in the present invention, for example, a horizontal splicing method may also be adopted. For example, in the horizontal splicing method shown in FIG. 10, the film material can be cut into four strips with a height of 1.25 meters and a width of 10 meters, and then the four strips are spliced together in sequence. Utilizing a frame structure such as a metal frame, the spliced optical diffusion film can be wrapped in a front surface or a back surface with a certain tension, so as to be stretched into a flat surface.
在形成如图10中所示的宽度为10米的屏幕时,只需要处理好薄膜1-4中的3条拼缝的外观即可,由此能够进一步降低整个LED显示屏幕上形成光学扩散膜的拼接处理难度。When forming a screen with a width of 10 meters as shown in FIG. 10, it is only necessary to handle the appearance of the three seams in the films 1-4, thereby further reducing the formation of an optical diffusion film on the entire LED display screen. Difficulty of stitching processing.
需要说明的是,图9和10中仅给出了LED显示屏幕尺寸以及裁剪光学薄膜卷材的示例性说明。本领域技术人员应当很容易明白,LED显 示屏幕可以采用任何期望尺寸,且光学薄膜卷材也可以根据实际需要进行适当地裁剪拼接,而不限于图9和10中提供的具体拼接方式。It should be noted that FIG. 9 and FIG. 10 only give an exemplary description of the size of the LED display screen and the cutting of the optical film roll. Those skilled in the art should easily understand that the LED display screen can adopt any desired size, and the optical film roll can also be appropriately cut and spliced according to actual needs, and is not limited to the specific splicing methods provided in FIGS. 9 and 10.
为了使观众基本感受不到LED显示屏幕上光学扩散膜之间的拼缝,希望该拼缝即使在LED芯片光照的条件下也尽量不可见。具体来说,对于透明的光学扩散膜,期望相邻光学扩散膜之间的拼缝宽度小于100微米。In order to make the audience hardly feel the seam between the optical diffusion films on the LED display screen, it is hoped that the seam will be as invisible as possible even under the condition of the LED chip light. Specifically, for a transparent optical diffusion film, it is desirable that the seam width between adjacent optical diffusion films is less than 100 microns.
具体来说,可以使用如图11和图12中所示的方法拼接光学扩散膜。Specifically, the method as shown in FIGS. 11 and 12 can be used to splice the optical diffusion film.
如图11所示,可以通过胶带拼接的方法将两块光学薄膜材料拼接在一起。具体来说,将两块光学薄膜材料(薄膜材料1和薄膜材料2)沿着长边方向平行放置,通过可以移动的显微镜观测该光学薄膜材料的间距并进行调节,使得两条长边之间的间距在100微米以内。然后在背面用同样具有扩散功能的胶带与粘接胶水结合使用,将两块薄膜材料粘接在一起。As shown in FIG. 11, two pieces of optical film material can be spliced together by a method of splicing tape. Specifically, two pieces of optical film material (film material 1 and film material 2) are placed in parallel along the long side direction, and the distance between the optical film materials is observed through a movable microscope and adjusted so that between the two long sides The spacing is within 100 microns. Then use the same diffusion tape and adhesive glue on the back to bond the two film materials together.
另外,也可以采用如图12所示的方法,将光学薄膜材料交叠在一起,通过热焊接或者超声焊接将两块薄膜材料连接在一起。In addition, the method shown in FIG. 12 can also be used to overlap the optical film materials, and the two film materials can be connected together by thermal welding or ultrasonic welding.
在本发明的LED显示屏幕中,可以如图13a中所示,使薄膜材料的拼缝跟LED模组的拼缝进行对齐,也可以如图13b中所示,使薄膜材料的拼缝不跟LED模组的拼缝对齐。In the LED display screen of the present invention, the seam of the thin film material can be aligned with the seam of the LED module as shown in FIG. 13a, or the seam of the thin film material can be made to be not as shown in FIG. 13b. The seams of the LED modules are aligned.
在通过模块拼接方式形成LED阵列层并拼接完成光学扩散膜之后,将拼接后的光学扩散膜通过弹簧或拉绳等方式固定在LED显示屏幕框架上,从而保证该光学扩散膜表面具有分布均匀的张力,从而使整块光学扩散膜以及LED阵列层被拉伸平整。After the LED array layer is formed by the module splicing method and the optical diffusion film is spliced, the spliced optical diffusion film is fixed on the LED display screen frame by means of a spring or a rope, thereby ensuring that the surface of the optical diffusion film has a uniform distribution. Tension, so that the entire optical diffusion film and the LED array layer are stretched and flattened.
例如可以通过定位结构使LED子模块或LED模块与光学扩散膜之间保持一定的距离h。LED阵列层设置在定位结构上,该定位结构设置为针对每一LED子模块或LED模块,可以有多个,并具有给定高度,定位结构之间通过设置凹槽和凸起进行配合连接,以保证准确调节使LED子模块或LED模块与光学扩散膜之间保持一定的距离h。For example, a certain distance h can be maintained between the LED sub-module or the LED module and the optical diffusion film through the positioning structure. The LED array layer is arranged on a positioning structure. The positioning structure is set for each LED sub-module or LED module, and can have a plurality of heights. The positioning structure can be cooperatively connected by setting grooves and protrusions. In order to ensure accurate adjustment, a certain distance h is maintained between the LED sub-module or the LED module and the optical diffusion film.
或者针对整个LED阵列层设置一个定位结构,即定位结构为一体设置,整个LED阵列层设置在定位结构上,从而保持与光学扩散膜之间的距离h。该定位结构例如可以使用机械突起定位结构,光学扩散膜上设置 凹槽,用于和定位结构之间进行配合定位,也可以在光学扩散膜上设置凸起,定位结构上设置凹槽用于和光学扩散膜配合。Alternatively, a positioning structure is provided for the entire LED array layer, that is, the positioning structure is integrated, and the entire LED array layer is provided on the positioning structure, so as to maintain a distance h from the optical diffusion film. The positioning structure may use, for example, a mechanical protrusion positioning structure, a groove is provided on the optical diffusion film for coordinated positioning with the positioning structure, or a protrusion is provided on the optical diffusion film, and a groove is provided on the positioning structure for and Optical diffusion film.
如图14所示,LED子模块或LED模块设置在该机械突起定位结构中远离观众侧的表面上,且光学扩散膜设置在机械突起定位结构中与LED子模块或模块同侧但相距h的位置处,光学扩散膜比LED子模块或模块更靠近观众侧。As shown in FIG. 14, the LED sub-module or LED module is disposed on the surface of the mechanical protrusion positioning structure away from the audience side, and the optical diffusion film is disposed in the mechanical protrusion positioning structure on the same side as the LED sub-module or module but at a distance of h. At the location, the optical diffusion film is closer to the viewer side than the LED sub-module or module.
组装光学扩散膜和LED子模块或模块的时候,需要控制屏幕和LED模块的接触力,使该接触力足够小以防止造成屏幕外观的突起和不连续。When assembling the optical diffusion film and the LED sub-module or module, it is necessary to control the contact force between the screen and the LED module, so that the contact force is small enough to prevent protrusions and discontinuities that cause the appearance of the screen.
根据本发明中上述的LED显示屏幕,能够通过LED阵列层和光学扩散膜相结合的方式有效地提高LED显示屏幕的应用范围,提高LED芯片的像素填充率,从而减少由于画面上颗粒感带来不柔和的问题,提高LED显示屏幕的显示效果,从而提高观众的视觉享受和体验。According to the above-mentioned LED display screen in the present invention, the application range of the LED display screen can be effectively improved through the combination of the LED array layer and the optical diffusion film, and the pixel filling rate of the LED chip can be improved, thereby reducing the effect of graininess on the screen The problem of non-softness improves the display effect of the LED display screen, thereby improving the visual enjoyment and experience of the audience.
另外,由于利用了光学扩散膜的拼接技术,可以遮蔽LED子模块或LED模块之间的拼缝,提高了产品的视觉效果。例如,当形成宽度为10米且高度为5米的LED显示屏幕时,在纵向拼接方式中仅需要处理6条拼缝,而在横向拼接方式中可以仅需要处理3条拼缝。该横向或纵向的拼缝可以与LED子模块或模块之间的拼缝对齐,也可以不与LED子模块或模块的拼缝对齐,从而能够进一步遮蔽LED子模块或LED模块之间的拼缝。In addition, because the splicing technology of the optical diffusion film is used, the LED sub-modules or the joints between the LED modules can be shielded, and the visual effect of the product is improved. For example, when forming an LED display screen with a width of 10 meters and a height of 5 meters, only 6 patchwork needs to be processed in the vertical stitching method, and only 3 patchwork can be processed in the horizontal stitching method. The horizontal or vertical seam may be aligned with the seam between the LED sub-modules or modules, or may not be aligned with the seam of the LED sub-modules or modules, so that the seam between the LED sub-modules or the LED modules can be further covered .
另外,光学薄膜的拼接技术可以大幅降低整个屏幕表面的拼缝面积,通过胶带粘接或者焊接的方法可以将拼缝控制在100微米以内,从而使得在LED芯片光照条件下观众不会看到拼缝。In addition, the splicing technology of the optical film can greatly reduce the seam area of the entire screen surface. The seam can be controlled within 100 microns by using adhesive tape or welding methods, so that the audience will not see the seam under the LED chip lighting conditions. Seam.
另外,由于相邻LED芯片之间的间距p与光学扩散膜和LED阵列层之间的距离h之间的关系满足下述条件:h<p<5h,优选2h<p<4h,从而能够防止相邻LED芯片发出的光线会相互串扰,从而能够提高画面的清晰度。In addition, the relationship between the distance p between adjacent LED chips and the distance h between the optical diffusion film and the LED array layer satisfies the following condition: h <p <5h, preferably 2h <p <4h, so that it can be prevented The light emitted by adjacent LED chips will crosstalk with each other, which can improve the sharpness of the picture.
另外,本发明中光学扩散膜的扩散角度应大于10度,优选为大于40度,当该扩散角度越大时,光学扩散膜对LED芯片之间空隙的遮蔽效果越较好。In addition, the diffusion angle of the optical diffusion film in the present invention should be greater than 10 degrees, preferably greater than 40 degrees. When the diffusion angle is larger, the shielding effect of the optical diffusion film on the spaces between the LED chips is better.
另外,随着LED芯片尺寸的减少和像素填充率的降低,单位像素的 发光面积越来越小。在LED芯片发光区域亮度值很高,而非LED芯片发光区域亮度值很低,评价单位像素的亮度需要测试设备对整个像素区域进行一个后期的加权平均,测试得到的亮度值并不准确;当加入扩散膜后,LED芯片光斑具有跟像素接近的尺寸,也就是具有更高的像素填充率,单位像素的亮度更加均匀,采用测试设备不需要校准和平均有光和没光的区域,整体的测试准确性会更高。In addition, as the size of the LED chip decreases and the fill rate of the pixel decreases, the light-emitting area per unit pixel becomes smaller and smaller. The brightness value in the light-emitting area of the LED chip is very high, and the brightness value in the non-LED chip light-emitting area is very low. To evaluate the brightness of a unit pixel, a test device needs to perform a weighted average of the entire pixel area in the later period. After adding the diffusion film, the light spot of the LED chip has a size close to that of the pixel, that is, it has a higher pixel fill rate, and the brightness of the unit pixel is more uniform. The test equipment does not need to be calibrated and the areas with and without light are averaged. Test accuracy will be higher.
本领域技术人员应当理解,依据设计要求和其他因素,可以在本发明随附的权利要求或其等同物的范围内进行各种修改、组合、次组合以及改变。Those skilled in the art should understand that, according to design requirements and other factors, various modifications, combinations, sub-combinations, and changes can be made within the scope of the claims appended to the present invention or their equivalents.

Claims (16)

  1. 一种LED显示屏幕,其包括:An LED display screen includes:
    LED阵列层,其由多个LED芯片组成,并用于发出光;以及LED array layer, which is composed of a plurality of LED chips and is used to emit light; and
    光学扩散膜,其设置在所述LED阵列层的光出射侧,其中,所述LED阵列层中发出的光透过所述光学扩散膜而扩散到观众侧。An optical diffusion film is disposed on a light emitting side of the LED array layer, and light emitted from the LED array layer is diffused to a viewer side through the optical diffusion film.
  2. 根据权利要求1所述的LED显示屏幕,其中,所述LED阵列层与所述光学扩散膜在垂直于所述光学扩散膜的方向上的距离为h,所述LED阵列层中相邻所述LED芯片之间的距离为p,且p和h的值满足下述条件:h<p<5h,优选2h<p<4h。The LED display screen according to claim 1, wherein a distance between the LED array layer and the optical diffusion film in a direction perpendicular to the optical diffusion film is h, and the LED array layer is adjacent to the The distance between the LED chips is p, and the values of p and h satisfy the following conditions: h <p <5h, preferably 2h <p <4h.
  3. 根据权利要求1或2所述的LED显示屏幕,其中,所述LED阵列层由多个LED子模块或LED模块拼接而成,每一所述LED子模块中集成有多个所述LED芯片,且每一所述LED模块中集成有多个所述LED子模块。The LED display screen according to claim 1 or 2, wherein the LED array layer is formed by splicing a plurality of LED sub-modules or LED modules, and each of the LED sub-modules integrates a plurality of the LED chips, A plurality of the LED sub-modules are integrated in each of the LED modules.
  4. 根据权利要求3所述的LED显示屏幕,其中,所述光学扩散膜遮蔽多个所述LED子模块或所述LED模块之间的拼缝。The LED display screen according to claim 3, wherein the optical diffusion film shields a plurality of the LED sub-modules or a seam between the LED modules.
  5. 根据权利要求3所述的LED显示屏幕,其中,所述光学扩散膜由多块光学薄膜拼接组成,相邻的所述光学薄膜之间的拼缝宽度小于100微米。The LED display screen according to claim 3, wherein the optical diffusion film is composed of a plurality of optical film splicing, and the width of the seam between adjacent optical films is less than 100 microns.
  6. 根据权利要求5所述的LED显示屏幕,其中,通过使所述多块光学薄膜以纵向拼接方式或横向拼接方式进行拼接。The LED display screen according to claim 5, wherein the plurality of optical films are spliced in a vertical splicing manner or a horizontal splicing manner.
  7. 根据权利要求5所述的LED显示屏幕,其中,所述多块光学薄膜之间的拼缝与多个所述LED子模块或所述LED模块之间的拼缝对齐,或不与多个所述LED子模块或所述LED模块之间的拼缝对齐。The LED display screen according to claim 5, wherein the seam between the plurality of optical films is aligned with or does not align with a plurality of the LED sub-modules or the seam between the LED modules. The LED sub-modules or the seams between the LED modules are aligned.
  8. 根据权利要求5所述的LED显示屏幕,其包括:具有扩散功能的胶带,所述胶带通过设置粘接胶水拼接相邻的所述光学薄膜。The LED display screen according to claim 5, comprising: an adhesive tape having a diffusing function, and the adhesive tape is used to splice adjacent optical films.
  9. 根据权利要求5所述的LED显示屏幕,其中,通过热焊接或者超声焊接拼接相邻的所述光学薄膜。The LED display screen according to claim 5, wherein the adjacent optical films are spliced by thermal welding or ultrasonic welding.
  10. 根据权利要求1或2所述的LED显示屏幕,其中,所述光学扩散膜为体扩散膜或表面扩散膜。The LED display screen according to claim 1 or 2, wherein the optical diffusion film is a bulk diffusion film or a surface diffusion film.
  11. 根据权利要求10所述的LED显示屏幕,其中,所述表面扩散膜的表面具有粗糙结构。The LED display screen according to claim 10, wherein a surface of the surface diffusion film has a rough structure.
  12. 根据权利要求1或2所述的LED显示屏幕,其中,所述光学扩散膜的扩散角度大于10度,且优选大于40度。The LED display screen according to claim 1 or 2, wherein a diffusion angle of the optical diffusion film is greater than 10 degrees, and preferably greater than 40 degrees.
  13. 根据权利要求1或2所述的LED显示屏幕,其中,所述光学扩散膜为各向同性的扩散膜或各向异性的扩散膜。The LED display screen according to claim 1 or 2, wherein the optical diffusion film is an isotropic diffusion film or an anisotropic diffusion film.
  14. 根据权利要求1或2所述的LED显示屏幕,其还包括:定位结构,所述LED阵列层设置在所述定位结构上,其使得所述LED阵列层与所述光学扩散膜之间保持所述距离h。The LED display screen according to claim 1 or 2, further comprising: a positioning structure, wherein the LED array layer is disposed on the positioning structure, so that the LED array layer and the optical diffusion film maintain a space between them. Mentioned distance h.
  15. 根据权利要求14所述的LED显示屏幕,所述定位结构为一体设置。The LED display screen according to claim 14, wherein the positioning structure is integrally provided.
  16. 根据权利要求14所述的LED显示屏幕,包括多个定位结构,所述多个定位结构之间通过设置凹槽与凸起进行配合连接。The LED display screen according to claim 14, comprising a plurality of positioning structures, and the plurality of positioning structures are cooperatively connected by providing grooves and protrusions.
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