WO2022266857A1 - 光学膜片、背光模组、显示装置及光学膜片的制造方法 - Google Patents

光学膜片、背光模组、显示装置及光学膜片的制造方法 Download PDF

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WO2022266857A1
WO2022266857A1 PCT/CN2021/101634 CN2021101634W WO2022266857A1 WO 2022266857 A1 WO2022266857 A1 WO 2022266857A1 CN 2021101634 W CN2021101634 W CN 2021101634W WO 2022266857 A1 WO2022266857 A1 WO 2022266857A1
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Prior art keywords
coating
optical film
coating structure
substrate
gap
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PCT/CN2021/101634
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English (en)
French (fr)
Inventor
陈瑞麟
李品勋
陈元璋
郑彦平
蔡旻谚
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瑞仪光电(南京)有限公司
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Priority to PCT/CN2021/101634 priority Critical patent/WO2022266857A1/zh
Publication of WO2022266857A1 publication Critical patent/WO2022266857A1/zh

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    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • 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
    • G—PHYSICS
    • G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
    • G09F—DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
    • G09F9/00—Indicating arrangements for variable information in which the information is built-up on a support by selection or combination of individual elements
    • G09F9/30—Indicating 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

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  • the disclosure relates to an optical film and its application and manufacturing method, in particular to an optical film, a backlight module and a display device using the optical film, and a manufacturing method of the optical film.
  • Optical films are widely used in backlight modules and display devices, and optical films can produce different optical effects mainly by coating different coatings on transparent substrates.
  • the purpose of this disclosure is to provide an optical film, a backlight module and a display device using the optical film, and a manufacturing method of the optical film, wherein the optical film can be improved by changing the coating structure design of the optical film.
  • the temperature resistance of the film under different environmental conditions can avoid the problem that the deformation of the backlight module and the display device affects the display appearance of the backlight module and the display device.
  • the optical film includes a substrate and at least one layer of coating structure.
  • the substrate has two opposing surfaces.
  • the coating structure is arranged on one of the two opposite surfaces of the substrate, and the coating structure is composed of a plurality of coating units, wherein there is a gap between any two adjacent coating units.
  • each of the coating units and the base material have different expansion coefficients.
  • the above-mentioned coating structure includes a first coating structure and a second coating structure, which are respectively provided on two opposite surfaces of the substrate, and any two phases in the first coating structure There is a first gap between adjacent coating units, and there is a second gap between any two adjacent coating units in the second coating structure, wherein the coefficient of expansion of the first coating structure is smaller than that of the second coating
  • the expansion coefficient of the structure, and the width dimension of the first gap is smaller than the width dimension of the second gap.
  • the above-mentioned coating structure includes a first coating structure and a second coating structure, which are respectively provided on two opposite surfaces of the substrate, and any two phases in the first coating structure There is a first gap between adjacent coating units, and there is a second gap between any two adjacent coating units in the second coating structure, wherein the coefficient of expansion of the first coating structure is smaller than that of the second coating The coefficient of expansion of the structure, and the number of first gaps is less than the number of second gaps.
  • the above-mentioned gaps are linear grooves, arc grooves, oblique grooves, zigzag grooves or staggered grooves.
  • the sum of the widths of the above-mentioned gaps is greater than (L0* ⁇ T*CTE)+C, wherein L0 is the initial length of the substrate, ⁇ T is the temperature change value before and after the expansion of the substrate, and CTE is the base The coefficient of expansion of the material, C is a constant.
  • the backlight module includes a light guide plate, a light source and the aforementioned optical film.
  • the light source is adjacent to the light incident surface of the light guide plate.
  • the optical film is arranged on the light guide plate, and covers the light source and a part of the light guide plate close to the light incident surface.
  • the display device includes a light guide plate, a light source, the aforementioned optical film and a display panel.
  • the light source is adjacent to the light incident surface of the light guide plate.
  • the optical film is arranged on the light guide plate, and covers the light source and a part of the light guide plate close to the light incident surface.
  • the display panel is arranged above the light guide plate.
  • a method for manufacturing an optical film includes the following steps.
  • a screen is set on the substrate, wherein the screen includes a frame corresponding to the base and a plurality of shielding structures.
  • the shielding structure is connected to the frame body and is located within the range surrounded by the frame body, and at least a part of the shielding structure is inclined or bent relative to at least one edge of the screen, and there is a through hole between any two adjacent shielding structures.
  • the paint is coated on the substrate through the through holes of the screen, wherein the coating includes passing the paint through the holes to form a plurality of coating units on the substrate. Remove the screen with a gap between any two adjacent coating units.
  • the manufacturing method after removing the screen plate, the manufacturing method further includes a cutting step, so as to cut the base material into a plurality of membrane units, wherein each membrane unit The crop line does not completely overlap the gap.
  • the present disclosure forms a discontinuous coating structure on the coating surface by setting independent coating units on the optical film, so as to avoid the difference between the coating structure and the base due to the difference in expansion coefficient between the substrate and the coating structure.
  • the material is affected by the environment and pulls each other or deforms such as wrinkles and warpages, which affects the overall optical effect.
  • FIG. 1A and FIG. 1B are a schematic side view and a front view respectively illustrating an optical film according to a first embodiment of the present disclosure
  • FIG. 2 is a device diagram illustrating a display device according to a first embodiment of the present disclosure
  • FIG. 3A, FIG. 3B and FIG. 3C are respectively a schematic side view, a front view and a rear view of an optical film according to a second embodiment of the present disclosure
  • 4A and 4B are respectively a front view and a rear view of an optical film according to a third embodiment of the present disclosure.
  • FIG. 5 is a front view illustrating an optical film according to a fourth embodiment of the present disclosure.
  • FIG. 6 is a front view illustrating an optical film according to a fifth embodiment of the present disclosure.
  • FIGS. 7A to 7D are flow charts illustrating a method for manufacturing an optical film according to an embodiment of the present disclosure.
  • FIG. 1A and FIG. 1B are respectively a schematic side view and a front view of an optical film according to a first embodiment of the present disclosure
  • FIG. 2 is a schematic diagram of a first embodiment according to the present disclosure
  • the optical film 100 of this embodiment is mainly used in, for example, the display device 200 shown in FIG. 2 .
  • the display device 200 mainly includes a backlight module 210 and a display panel 220 disposed above the backlight module 210 .
  • the backlight module 210 mainly includes a light guide plate 211 and a light source 212, and the light source 212 is adjacent to the light incident surface 211a of the light guide plate 211.
  • the optical film 100 is disposed on the light guide plate 211 and covers the light source 212 and a part of the light guide plate 211 close to the light incident surface 211a.
  • the optical film 100 is mainly used to block the light leaking from the part of the light guide plate 211 near the light incident surface 211 a, or to change the color of the light entering the light guide plate 211 from the light source 212 .
  • the optical film 100 mainly includes a substrate 110 and at least one layer of coating structure 120 .
  • the substrate 110 has a surface 111 and a surface 112 opposite to each other.
  • the substrate 110 is a polyethylene terephthalate (PET) substrate or a polycarbonate (PC) substrate.
  • the coating structure 120 is arranged on the surface 111 .
  • the coating structure 120 is mainly composed of a plurality of coating units 121 , and there is a gap A1 between any two adjacent coating units 121 .
  • the design of the gap A1 between the coating units 121 is mainly to separate the adjacent coating units 121 from each other, so that the entire coating structure 120 forms a discontinuous surface, thereby preventing the coating units 121 from being affected by the ambient temperature or other factors. Influenced by factors, expansion occurs, thereby avoiding problems such as warping, pulling or wrinkling of the substrate 110 toward one of the surfaces due to the uneven force exerted by the coating unit 121 .
  • the coating unit 121 may be a structure formed by ink printing or coating. Wherein, the color of the ink can be selected from black, white or colored according to requirements.
  • each coating unit 121 and the base material 110 have different coefficients of expansion, so when the coating unit 121 and the base material 110 are affected by the environment and produce different deformation amounts, the space between the coating units 121
  • the design of the gap A1 can reserve or absorb the deformation difference between the coating unit 121 and the substrate 110 .
  • the width G1 of the gap A1 can be designed according to different environmental conditions or other optical requirements.
  • the optical film 100 includes four coating units 121 and three gaps A1 along its long side.
  • the sum of the width G1 of the three gaps A1 can be designed to be greater than (L0* ⁇ T*CTE)+C, where L0 is the initial length of the substrate 110, ⁇ T is the temperature change value before and after the expansion of the substrate 110, and CTE is the base
  • the coefficient of expansion of the material 110, C is a constant.
  • the constant C can be set according to the designer's experience.
  • adjusting the width G1 of the gap A1 according to different preset usage environments can make the optical film 100 not only play its original light-shielding or light-adjusting function, but also the gap A1 can be used as a buffer for the deformation of the coating unit 121. Area.
  • the expansion of the coating structure 120 is greater than the expansion of the substrate 110, or if the width G1 of the gap A1 of any two adjacent coating units 121 calculated by the above formula is too large and If the uniformity of light output is affected, the total number of coating units 121 on the long side can be further increased, and the width G1 of each gap A1 can be reduced.
  • the optical film may also have different structural designs.
  • FIG. 3A , FIG. 3B and FIG. 3C they respectively depict a side view, a front view and a rear view of the optical film according to the second embodiment of the present disclosure.
  • the optical film 300 of this embodiment includes a substrate 310 , a first coating structure 320 and a second coating structure 330 .
  • the substrate 310 has a surface 311 and a surface 312 opposite to each other.
  • the first coating structure 320 is disposed on the surface 311
  • the second coating structure 330 is disposed on the surface 312 .
  • the first coating structure 320 is mainly composed of a plurality of coating units 321 , and there is a first gap A2 between any two adjacent coating units 321 .
  • the second coating structure 330 is mainly composed of a plurality of coating units 331 , and there is a second gap A3 between any two adjacent coating units 331 .
  • the design of the first gap A2 between the coating units 321 and the second gap A3 between the coating units 321 is mainly to separate adjacent coating units 321 and adjacent coating units 331 from each other, so that The first coating structure 320 and the second coating structure 330 respectively form discontinuous surfaces, thereby preventing the coating unit 321 and the coating unit 331 from expanding, warping, pulling or wrinkling when affected by ambient temperature or other factors pleats etc.
  • the expansion coefficient of the first coating structure 320 is smaller than that of the second coating structure 330
  • the width G2 of the first gap A2 is smaller than the width G3 of the second gap A3 .
  • the expansion coefficient of the first coating structure 320 is smaller than the expansion coefficient of the second coating structure 330, the deformation range of the first coating structure 320 affected by the environment is relatively small, so the width of the first gap A2 can be reduced.
  • G2 is designed to be smaller to ensure that the optical film 300 can produce better light uniformity.
  • the extending direction of the first gap A2 and the extending direction of the second gap A3 can be designed to be different, the purpose of which is to minimize the overlapping area of the first gap A2 and the second gap A3 as much as possible.
  • the extension direction of the first gap A2 and the extension direction of the second gap A3 are perpendicular to each other, so as to ensure better light uniformity.
  • FIG. 4A and FIG. 4B are respectively a front view and a rear view of an optical film according to a third embodiment of the present disclosure.
  • the structure of the optical film 400 of this embodiment is substantially the same as the structure of the optical film 300 shown in FIGS. with different structural designs.
  • the first coating structure 420 is mainly composed of a plurality of coating units 421 , and there is a first gap A4 between any two adjacent coating units 421 .
  • the second coating structure 430 is mainly composed of a plurality of coating units 431, and there is a second gap A5 between any two adjacent coating units 431.
  • the design of the first gap A4 and the second gap A5 is mainly to separate the adjacent coating unit 421 and the adjacent coating unit 431 from each other, so that the first coating structure 420 and the second coating structure
  • the structures 430 respectively form discontinuous surfaces, thereby avoiding the deformation of the coating unit 421 and the coating unit 431 due to ambient temperature or other factors.
  • the expansion coefficient of the first coating structure 420 is smaller than that of the second coating structure 430
  • the number of the first gaps A4 is smaller than the number of the second gaps A5 .
  • each coating unit 431 can be reduced by designing a larger number of second gaps A5 to ensure better light uniformity and avoid coating
  • the unit 431 has the problem of paint pulling or wrinkling due to deformation.
  • FIG. 5 is a front view of an optical film according to a fourth embodiment of the present disclosure.
  • the structure of the optical film 500 of this embodiment is substantially the same as the optical film 100 in FIG. 1A and FIG. 1B , the only difference is that the coating structure 510 of the optical film 500 has a different structural design.
  • the coating structure 510 is mainly composed of a plurality of coating units 520 , and there is a gap A6 between any two adjacent coating units 520 .
  • each gap A6 is a zigzag groove.
  • the gap A6 Through the design of the gap A6, adjacent coating units 520 can be separated from each other, so that the entire coating structure 510 forms a discontinuous surface, so as to prevent the coating unit 520 from being deformed due to the influence of ambient temperature or other factors.
  • the extension direction of the aforementioned gap A6 is not parallel to at least one edge of the optical film 500 , so as to avoid the problem of uneven light emission caused by light passing through the fold line groove.
  • FIG. 6 is a front view of an optical film according to a fifth embodiment of the present disclosure.
  • the structure of the optical film 600 of this embodiment is substantially the same as that of the optical film 100 in FIG. 1A and FIG. 1B , the only difference is that the coating structure 610 of the optical film 600 has a different structural design.
  • the coating structure 610 is mainly composed of a plurality of coating units 620 , and there is a gap A7 between any two adjacent coating units 620 .
  • each gap A7 is an arc groove.
  • the shape of the gap can be designed into other shapes such as linear grooves, staggered grooves, etc. according to the expansion coefficient of the coating structure, and the width of the gap can also be adjusted according to requirements to achieve Same effect as above.
  • FIG. 7A to FIG. 7D are flowcharts illustrating a manufacturing method of an optical film according to an embodiment of the present disclosure.
  • the manufacturing method of the optical film includes the following steps. First, a substrate 700 such as that shown in FIG. 7A is provided. Next, a screen 800 as shown in FIG. 7B is disposed on the substrate 700 .
  • the mesh panel 800 includes a frame body 810 and a plurality of shielding structures 820 .
  • the frame body 810 covers the base material 700 correspondingly, and the shielding structure 820 is connected to the frame body 810 and is located within the range surrounded by the frame body 810 .
  • the shielding structure 820 is inclined relative to at least one edge of the mesh plate 800 , and there is a through hole 830 between any two adjacent shielding structures 820 .
  • the through hole 830 can expose a portion of the substrate 700 .
  • paint is coated on the base material 700 through the through hole 830 of the mesh plate 800 .
  • Applying the paint includes passing the paint through the through holes 830 to form a plurality of coating units 900 on the substrate 700 .
  • the screen 800 is removed after the coating units 900 are formed, and a gap A8 can be formed between any two adjacent coating units 900 .
  • the mesh plate 800 since the mesh plate 800 has the design of the shielding structure 820 and the through hole 830, when coating the paint on the mesh plate 800, the paint passing through the through hole 830 will form the coating unit 900 on the substrate 700, The part of the substrate 700 covered by the masking structure 820 will form a gap A8 after the screen plate 800 is removed.
  • the design of the gap A8 is mainly to make the adjacent coating units 900 independent from each other, so as to prevent the coating from forming a continuous surface. After the independent coating units 900 are formed on the surface of the substrate 700, an optical film that will not be deformed by ambient temperature or other factors can be obtained.
  • the manufacturing method of the optical film further includes a cutting step to cut the base material 700 into a plurality of film units.
  • the cutting line S1 (such as the dotted line shown in FIG. 7D ) of each membrane unit does not completely overlap with the gap A8.
  • the cutting line S1 will not form a line overlap with the gap A8, but will only form a dotted intersection with the gap A8. This method can avoid the overlap between the cutting line S1 and the gap A8. The light leakage situation.
  • the shielding structure 820 of the mesh panel 800 in the foregoing embodiment has an inclined design relative to the edge of the mesh panel 800 .
  • the shielding structure of the screen can also be designed to be bent relative to the edge of the screen to form, for example, the gap A6 shown in FIG. 5 or the gap A7 shown in FIG. 6 .
  • the present disclosure forms a discontinuous coating structure on the coating surface by setting independent coating units on the optical film, so as to avoid the coating structure caused by the difference in expansion coefficient between the substrate and the coating structure.
  • the layer structure and the substrate are affected by the environment and pull each other or deform such as wrinkles and warps, which will affect the overall optical effect.

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Abstract

一种光学膜片、背光模组、显示装置及光学膜片的制造方法。光学膜片包含基材以及至少一层涂层结构。基材具有相对的两个表面。涂层结构设在基材的相对两个表面的其中一者上。涂层结构由多个涂布单元组成，其中任意两个相邻的涂布单元之间具有间隙。

Description

光学膜片、背光模组、显示装置及光学膜片的制造方法 技术领域
本揭露涉及一种光学膜片及其应用与制造方法，特别是涉及一种光学膜片、使用此光学膜片的背光模组及显示装置、及光学膜片的制造方法。
背景技术
光学膜片广泛应用在背光模组及显示装置中，且光学膜片主要可通过在透明基材上涂布不同的涂料而产生不同的光学效果。
然而，由于基材与涂料本身的材料不同，所以其膨胀系数亦不同，故光学膜片在不同温度的使用环境下会因为基材与涂料的膨胀系数不同而产生不可逆的翘曲或皱褶等形变，进而严重影响背光模组与显示装置的整体显示外观。
发明内容
因此，本揭露的目的在于提供一种光学膜片、使用此光学膜片的背光模组及显示装置、及光学膜片的制造方法，其中通过改变光学膜片的涂层结构设计，可提升光学膜片在不同的使用环境条件下对于温度的耐受性，进而避免背光模组及显示装置因形变而影响背光模组及显示装置的显示外观的问题。
根据本揭露的上述目的，提出一种光学膜片。光学膜片包含基材以及至少一层涂层结构。基材具有相对的两个表面。涂层结构设在基材的两个相对表面的其中一者上，涂层结构由多个涂布单元组成，其中，任意两个相邻的涂布单元之间具有间隙。
依据本揭露的一实施例，上述的每一个涂布单元与基材具有不同的膨胀系数。
依据本揭露的一实施例，上述的涂层结构包含第一涂层结构及第二涂 层结构，其分别设在基材的两个相对表面上，第一涂层结构中的任意两个相邻的涂布单元之间具有第一间隙，第二涂层结构中的任意两个相邻的涂布单元之间具有第二间隙，其中，第一涂层结构的膨胀系数小于第二涂层结构的膨胀系数，且第一间隙的宽度尺寸小于第二间隙的宽度尺寸。
依据本揭露的一实施例，上述的涂层结构包含第一涂层结构及第二涂层结构，其分别设在基材的两个相对表面上，第一涂层结构中的任意两个相邻的涂布单元之间具有第一间隙，第二涂层结构中的任意两个相邻的涂布单元之间具有第二间隙，其中，第一涂层结构的膨胀系数小于第二涂层结构的膨胀系数，且第一间隙的数量少于第二间隙的数量。
依据本揭露的一实施例，上述的间隙为直线沟槽、弧线沟槽、斜线沟槽、折线沟槽或交错形沟槽。
依据本揭露的一实施例，上述的间隙的宽度的总和大于(L0*ΔT*CTE)+C，其中，L0为基材的初始长度，ΔT为基材膨胀前后的温度变化值，CTE为基材的膨胀系数，C为常数。
根据本揭露的上述目的，提出一种背光模组。背光模组包含导光板、光源及前述的光学膜片。光源邻设于导光板的入光面。光学膜片设置在导光板上，且覆盖的光源与导光板靠近入光面的一部分。
根据本揭露的上述目的，提出一种显示装置。显示装置包含导光板、光源、前述的光学膜片及显示面板。光源邻设于导光板的入光面。光学膜片设置在导光板上，且覆盖的光源与导光板靠近入光面的一部分。显示面板设置在导光板的上方。
根据本揭露的上述目的，提出一种光学膜片的制造方法。制造方法包含以下步骤。提供基材。于基材上设置网板，其中网板包含对应于基材的框体以及多个遮蔽结构。遮蔽结构连接框体且位于框体所包围的范围内，且遮蔽结构的至少一部分相对于网板的至少一个边缘倾斜或弯折，任意两个相邻的遮蔽结构之间具有通孔。透过网板的通孔于基材上涂布涂料，其中涂布涂料包含使涂料穿过通孔以在基材形成多个涂布单元。移除网板，其中任意两个相邻的涂布单元之间具有间隙。
依据本揭露的一实施例，于上述的制造方法中，移除网板后，制造方 法更包含进行裁切步骤，以将基材裁切成多个膜片单元，其中每一个膜片单元的裁切线与间隙不完全重叠。
由上述可知，本揭露通过在光学膜片上设置各自独立的涂布单元而形成涂布面不连续的涂层结构，以避免基材与涂层结构因膨胀系数不同而造成涂层结构与基材受到环境影响而互相拉扯或发生皱褶、翘曲等变形而导致影响其整体光学效果的问题。
附图说明
为了使本揭露的上述和其他目的、特征、优点与实施例更加明显易懂，现参考附图进行说明如下：
图1A及图1B是分别绘示依照本揭露的第一实施方式的光学膜片的侧面示意图及前视图；
图2是绘示依照本揭露的第一实施方式的显示装置的装置示意图；
图3A、图3B及图3C是分别绘示依照本揭露的第二实施方式的光学膜片的侧面示意图、前视图及后视图；
图4A及图4B是分别绘示依照本揭露的第三实施方式的光学膜片的前视图及后视图；
图5是绘示依照本揭露的第四实施方式的光学膜片的前视图；
图6是绘示依照本揭露的第五实施方式的光学膜片的前视图；以及
图7A至图7D是绘示依照本揭露的实施方式的光学膜片的制造方法的流程图。
具体实施方式
请同时参照图1A至图2，其中图1A及图1B是分别绘示依照本揭露的第一实施方式的光学膜片的侧面示意图及前视图，图2是绘示依照本揭露的第一实施方式的显示装置的装置示意图。本实施方式的光学膜片100主要使用在例如图2所示的显示装置200中。如图2所示，显示装置200主要包含背光模组210、以及设置在背光模组210上方的显示面板220。背光模组210主要包含导光板211及光源212，且光源212邻设于导光板 211的入光面211a。光学膜片100设置在导光板211上，且覆盖光源212与导光板211靠近入光面211a的一部分。光学膜片100主要用来遮挡从导光板211靠近入光面211a的部分漏出的光线，或是用以改变从光源212进入导光板211中的光线颜色。
如图1A及图1B所示，光学膜片100主要包含基材110及至少一层涂层结构120。基材110具有相对的表面111及表面112。其中，基材110为聚对苯二甲酸乙二醇脂(PET)基材或聚碳酸酯(PC)基材。涂层结构120设置在表面111上。在本实施例中，涂层结构120主要由多个涂布单元121组成，且任意两个相邻的涂布单元121之间具有间隙A1。涂布单元121之间的间隙A1设计主要是使相邻的涂布单元121互相隔开，而使整个涂层结构120形成不连续的表面，进而可避免涂布单元121因受到环境温度或其他因素影响而产生膨胀，进而避免基材110因受到涂布单元121不均匀的受力而朝向其中一个表面的方向发生翘曲、拉扯或皱褶等问题。在一实施例中，涂布单元121可为油墨印刷或涂布所形成的结构。其中，油墨的颜色可依据需求而选择黑色、白色或是彩色。在一实施例中，每一个涂布单元121与基材110具有不同的膨胀系数，故当涂布单元121与基材110受到环境影响而产生不同的变形量时，通过涂布单元121之间的间隙A1的设计可预留或吸收涂布单元121与基材110的变形差异量。
在一实施例中，可根据环境条件的不同或其他光学需求来设计间隙A1的宽度G1，以图1B为例，光学膜片100沿其长边包含4个涂布单元121与3个间隙A1，这3个间隙A1的宽度G1总和可设计成大于(L0*ΔT*CTE)+C，其中，L0为基材110的初始长度，ΔT为基材110膨胀前后的温度变化值，CTE为基材110的膨胀系数，C为常数。在一些例子中，常数C可依据设计者的经验而设定。由此，根据预设使用环境的不同，调整间隙A1的宽度G1，可以使光学膜片100除了能够发挥其原有的遮光或调光功能外，其间隙A1可作为涂布单元121形变的缓冲区。在其他的实施例中，若涂层结构120的膨胀量大于基材110的膨胀量，或者若经由上述公式所计算出的任何两个相邻涂布单元121的间隙A1的宽度G1过大而影响出光均匀度，则可更进一步增加长边上的涂布单元121的总数量，便 能将每一个间隙A1的宽度G1缩小。
要说明的是，在上述的本发明中，光学膜片亦可有不同的结构设计。例如图3A、图3B及图3C所示，其是分别绘示依照本揭露的第二实施方式的光学膜片的侧面示意图、前视图及后视图。本实施方式的光学膜片300包含基材310、第一涂层结构320及第二涂层结构330。基材310具有相对的表面311及表面312。第一涂层结构320设置在表面311上，且第二涂层结构330设置在表面312上。在本实施例中，第一涂层结构320主要由多个涂布单元321组成，且任意两个相邻的涂布单元321之间具有第一间隙A2。第二涂层结构330主要由多个涂布单元331组成，且任意两个相邻的涂布单元331之间具有第二间隙A3。涂布单元321之间的第一间隙A2及涂布单元321之间的第二间隙A3的设计主要是分别使相邻的涂布单元321与相邻的涂布单元331互相隔开，而使第一涂层结构320及第二涂层结构330分别形成不连续的表面，进而可避免涂布单元321与涂布单元331在受到环境温度或其他因素影响时而产生膨胀、翘曲、拉扯或皱褶等问题。在本实施例中，第一涂层结构320的膨胀系数小于第二涂层结构330的膨胀系数，且第一间隙A2的宽度G2小于第二间隙A3的宽度G3。也就是说，由于第一涂层结构320的膨胀系数小于第二涂层结构330的膨胀系数，故第一涂层结构320受到环境影响的变形幅度较小，故可以将第一间隙A2的宽度G2设计得较小，以确保光学膜片300可产生较佳的出光均匀度。在另一实施例中，第一间隙A2的延伸方向与第二间隙A3的延伸方向可以设计成不同，其目的在于使第一间隙A2与第二间隙A3的重叠面积尽可能地缩小。较佳的是，第一间隙A2的延伸方向与第二间隙A3的延伸方向互相垂直，以确保较佳的出光均匀度。
请参照图4A及图4B，其是分别绘示依照本揭露的第三实施方式的光学膜片的前视图及后视图。本实施方式的光学膜片400的结构与图3A至图3C所示的光学膜片300的结构大致上相同，差异仅在于光学膜片400的第一涂层结构420及第二涂层结构430具有不同的结构设计。如图4A及图4B，第一涂层结构420主要由多个涂布单元421组成，且任意两个相邻的涂布单元421之间具有第一间隙A4。第二涂层结构430主要由多个涂 布单元431组成，且任意两个相邻的涂布单元431之间具有第二间隙A5。同样地，第一间隙A4与第二间隙A5的设计主要是分别使相邻的涂布单元421与相邻的涂布单元431互相隔开，而使第一涂层结构420及第二涂层结构430分别形成不连续的表面，进而可避免涂布单元421与涂布单元431因受到环境温度或其他因素影响而产生形变的问题。在本实施例中，第一涂层结构420的膨胀系数小于第二涂层结构430的膨胀系数，且第一间隙A4的数量少于第二间隙A5的数量。也就是说，由于第二涂层结构430的膨胀系数大于第一涂层结构420的膨胀系数，故第二涂层结构430受到环境影响的变形幅度较大，并当考虑第二间隙A5的宽度不能过大而导致影响出光均匀度时，可通过设计较多的第二间隙A5的数量，而将每一个涂布单元431的宽度减小，以确保较佳的出光均匀度，同时避免涂布单元431因形变而产生涂料拉扯或皱褶的问题。
另请参照图5，其是绘示依照本揭露的第四实施方式的光学膜片的前视图。本实施方式的光学膜片500的结构与图1A及图1B的光学膜片100大致上相同，差异仅在于光学膜片500的涂层结构510具有不同的结构设计。如图5所示，涂层结构510主要由多个涂布单元520组成，且任意两个相邻的涂布单元520之间具有间隙A6。在本实施例中，每一间隙A6为折线沟槽。借由间隙A6的设计，可使相邻的涂布单元520互相隔开，而使整个涂层结构510形成不连续的表面，达到避免涂布单元520因受到环境温度或其他因素影响而产生变形的问题。在另一实施例中，前述间隙A6的延伸方向相对于光学膜片500的至少一个边缘不平行，以避免光线通过折线沟槽而导致出光不均匀的问题。
另请参照图6，其是绘示依照本揭露的第五实施方式的光学膜片的前视图。本实施方式的光学膜片600的结构与图1A及图1B的光学膜片100大致上相同，差异仅在于光学膜片600的涂层结构610具有不同的结构设计。如图6所示，涂层结构610主要由多个涂布单元620组成，且任意两个相邻的涂布单元620之间具有间隙A7。在本实施例中，每一间隙A7为弧线沟槽。借由间隙A7的设计，可使相邻的涂布单元620互相隔开，而使整个涂层结构610形成不连续的表面，达到避免涂布单元620因受到环 境温度或其他因素影响而产生变形的问题。要说明的是，在其他实施例中，间隙的形状可依据涂层结构的膨胀系数而设计成其他形状例如直线沟槽、交错形沟槽等，间隙的宽度亦可因应需求而调整，以达到与前述相同的功效。
本发明另提供一种光学膜片的制造方法，请同时参照图7A至图7D，图7A至图7D是绘示依照本揭露的实施方式的光学膜片的制造方法的流程图。光学膜片的制造方法包含以下步骤。首先，提供例如图7A所示的基材700。接着，于基材700上设置如图7B所示的网板800。其中，网板800包含框体810以及多个遮蔽结构820。框体810对应地覆盖基材700，遮蔽结构820连接框体810且位于框体810所包围的范围内。在本实施例中，遮蔽结构820相对于网板800的至少一个边缘倾斜，且任意两个相邻的遮蔽结构820之间具有通孔830。由此，当网板800设置在基材700上时，通孔830可露出基材700的一部分。
接着如图7C所示，透过网板800的通孔830于基材700上涂布涂料。涂布涂料包含使涂料穿过这些通孔830以在基材700形成多个涂布单元900。然后，如图7D所示，在形成涂布单元900后移除网板800，可在任意两个相邻的涂布单元900之间形成间隙A8。也就是说，由于网板800具有遮蔽结构820与通孔830的设计，故在将涂料涂布在网板800上时，穿过通孔830的涂料会在基材700形成涂布单元900，而基材700被遮蔽结构820覆盖的部分，在网板800移除后会形成间隙A8，此间隙A8设计主要是使相邻的涂布单元900各自独立，避免涂料形成连续的表面，故在基材700表面形成各自独立的涂布单元900后即可得到不会受环境温度或其他因素影响而变形的光学膜片。
要说明的是，通过上述的方法可直接制作单张的光学膜片，亦可进一步通过裁切的方式，将制作好的单张膜片裁切成数个小的膜片单元。因此，在一些实施例中，光学膜片的制造方法更包含进行裁切步骤，以将基材700裁切成多个膜片单元。在此实施例中，每一个膜片单元的裁切线S1(例如图7D所示的虚线)与间隙A8不完全重叠。具体而言，在裁切基材700时，裁切线S1不会与间隙A8形成线重叠，而只会与间隙A8形成点 相交的情况，这作法可避免裁切线S1与间隙A8重叠的部分产生漏光的情形。
要说明的是，前述实施例的网板800的遮蔽结构820具有相对于网板800的边缘形成倾斜的设计。在其他例子中，网板的遮蔽结构亦可设计成相对于网板的边缘形成弯折，以形成例如图5所示之间隙A6或是图6所示之间隙A7。
由上述本揭露实施方式可知，本揭露通过在光学膜片上设置各自独立的涂布单元而形成涂布面不连续的涂层结构，以避免基材与涂层结构因膨胀系数不同而造成涂层结构与基材受到环境影响而互相拉扯或发生皱褶、翘曲等变形而导致影响其整体光学效果的问题。
虽然本发明的实施例已揭露如上，然而其并非用以限定本发明，任何本领域技术人员，在不脱离本发明的实施例的精神和范围内，应当可以做出些许更动与润饰，故本发明的实施例的保护范围应当以所附的权利要求书所界定的保护范围为准。
【附图标记列表】
100：光学膜片
110：基材
111：表面
112：表面
120：涂层结构
121：涂布单元
200：显示装置
210：背光模组
211：导光板
211a：入光面
212：光源
300：光学膜片
310：基材
311：表面
312：表面
320：第一涂层结构
321：涂布单元
330：第二涂层结构
331：涂布单元
400：光学膜片
420：第一涂层结构
421：涂布单元
430：第二涂层结构
431：涂布单元
500：光学膜片
510：涂层结构
520：涂布单元
600：光学膜片
610：涂层结构
620：涂布单元
700：基材
800：网板
810：框体
820：遮蔽结构
830：通孔
900：涂布单元
A1：间隙
A2：第一间隙
A3：第二间隙
A4：第一间隙
A5：第二间隙
A6：间隙
A7：间隙
A8：间隙
G1：宽度
G2：宽度
G3：宽度
L0：基材的初始长度
S1：裁切线。

Claims (10)

  1. 一种光学膜片，包含：
    基材，其具有相对的两个表面；以及
    至少一层涂层结构，所述涂层结构设在所述基材的所述两个表面的其中一者上，所述涂层结构由多个涂布单元组成，其中，任意两个相邻的涂布单元之间具有间隙。
  2. 根据权利要求1所述的光学膜片，其中，每一所述涂布单元与所述基材具有不同的膨胀系数。
  3. 根据权利要求1所述的光学膜片，其中，所述涂层结构包含第一涂层结构及第二涂层结构，其分别设在所述基材的所述两个表面上，所述第一涂层结构中的任意两个相邻的涂布单元之间具有第一间隙，所述第二涂层结构中的任意两个相邻的涂布单元之间具有第二间隙，其中，所述第一涂层结构的膨胀系数小于所述第二涂层结构的膨胀系数，且所述第一间隙的宽度尺寸小于所述第二间隙的宽度尺寸。
  4. 根据权利要求1所述的光学膜片，其中，所述涂层结构包含第一涂层结构及第二涂层结构，其分别设在所述基材的所述两个表面上，所述第一涂层结构中的任意两个相邻的涂布单元之间具有第一间隙，所述第二涂层结构中的任意两个相邻的涂布单元之间具有第二间隙，其中，所述第一涂层结构的膨胀系数小于所述第二涂层结构的膨胀系数，且所述第一间隙的数量少于所述第二间隙的数量。
  5. 根据权利要求1所述的光学膜片，其中，每一所述间隙为直线沟槽、弧线沟槽、斜线沟槽、折线沟槽或交错形沟槽。
  6. 根据权利要求1所述的光学膜片，其中，所述间隙的宽度的总和大于(L0*ΔT*CTE)+C，其中，L0为所述基材的初始长度，ΔT为所述基材膨胀前后的温度变化值，CTE为所述基材的膨胀系数，C为常数。
  7. 一种背光模组，包含：
    导光板；
    光源，其邻设于所述导光板的入光面；
    根据权利要求1至6中任一项所述的光学膜片，其设置在所述导光板上，且覆盖所述光源与所述导光板靠近所述入光面的一部分。
  8. 一种显示装置，包含：
    导光板；
    光源，其邻设于所述导光板的入光面；
    根据权利要求1至6中任一项所述的光学膜片，其设置在所述导光板上，且覆盖所述光源与所述导光板靠近所述入光面的一部分；以及
    显示面板，其设置在所述导光板的上方。
  9. 一种光学膜片的制造方法，包含：
    提供基材；
    于所述基材上设置网板，其中，所述网板包含对应于所述基材的框体、以及连接所述框体且位于所述框体所包围的范围内的多个遮蔽结构，且所述多个遮蔽结构的至少一部分相对于所述网板的至少一个边缘倾斜或弯折，任意两个相邻的遮蔽结构之间具有通孔；
    透过所述网板的所述通孔于所述基材上涂布涂料，其中，涂布所述涂料包含使所述涂料穿过所述通孔以在所述基材形成多个涂布单元；以及
    移除所述网板，其中，任意两个相邻的所述涂布单元之间具有间隙。
  10. 根据权利要求9所述的方法，其中，于移除所述网板后，所述方法更包含进行裁切步骤，以将所述基材裁切成多个膜片单元，其中，每一所述膜片单元的裁切线与所述间隙不完全重叠。
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