A three-dimensional reflective sheet for reducing mini-led backlight halo

Abstract

The application relates to the technical field of mini-LED, and provides a three-dimensional reflecting sheet for reducing mini-LED backlight halos, which comprises a plurality of integrally connected reflecting covers, each reflecting cover comprising: a reflecting bottom surface, the center of which is provided with a relief hole; a reflecting side surface, which is connected to the edge of the reflecting bottom surface along the circumference of the reflecting bottom surface, and which, together with the reflecting bottom surface, surrounds a cup-shaped cover body space; the adjacent reflecting covers are connected through the reflecting side surfaces, and the reflecting bottom surfaces and the reflecting side surfaces are integrally connected, so that the three-dimensional reflecting sheet is formed into an integral structure; the three-dimensional reflecting sheet can simultaneously process light rays from multiple directions, can block light beams from entering other control areas through the reflecting side surfaces, can reduce light leakage, and can reduce halos.

Description

Technical Field

[0001] This application relates to the field of mini-LED technology, and more specifically, to a three-dimensional reflective sheet for reducing backlight halo in mini-LEDs. Background Technology

[0002] Miniature light-emitting diode (LED) chips are characterized by being environmentally friendly, having high brightness, low energy consumption, long lifespan, and low operating voltage. They have been widely used in displays of electronic products such as mobile phones, televisions, and computers.

[0003] In the field of mini-LED, mini-LED lamps and other components are placed on PCB (Printed Circuit Board). Reflective sheets are usually laid on the PCB to cover other components in order to reduce light loss and diffuse reflection on other components.

[0004] In traditional technology, the reflector is a planar structure. When performing local dimming, light is easily reflected by the reflector to other control areas, resulting in light leakage and halos in other control areas, which affects the display effect.

[0005] Therefore, existing technologies still need improvement and development. Utility Model Content

[0006] The purpose of this application is to propose a three-dimensional reflective sheet for reducing the halo effect of mini-LED backlight, so as to solve the technical problem in the prior art that light is easily reflected by the reflective sheet to other control areas, resulting in halo effects in other control areas.

[0007] To achieve the above objectives, the technical solution adopted in this application is: to provide a three-dimensional reflective sheet for reducing the halo effect of mini-LED backlight, wherein the mini-LED backlight includes a PCB board and mini-LED lamp groups disposed on the PCB board, and the three-dimensional reflective sheet is used to mount on the PCB board and includes multiple integrally connected reflectors, each of the reflectors including:

[0008] The bottom surface is reflective, with a clearance hole in the center;

[0009] The reflective side is connected to the edge of the reflective bottom surface along the circumference of the reflective bottom surface, and the reflective bottom surface and the reflective side form a cup-shaped cover space.

[0010] The adjacent reflectors are connected by the reflective side surfaces, and the reflective bottom surface and the reflective side surfaces are integrally connected, so that the three-dimensional reflective sheet is constructed as a single structure;

[0011] When the reflective bottom surface abuts against the PCB board, the mini-LED light group passes through the clearance hole and is housed within the cover space. The reflective bottom surface is located below the mini-LED light group, and the reflective side surface is located to the side of the mini-LED light group.

[0012] Furthermore, there is a first included angle between the reflective side surface and the reflective bottom surface, and the first included angle is any angle value between 90° and 120°.

[0013] Furthermore, taking the reflective bottom surface as a reference surface, the height of the reflective side surface is not lower than the height of the mini-LED light group.

[0014] In some embodiments, the height of the reflective side is 2mm-7mm higher than the height of the mini-LED light assembly.

[0015] Furthermore, each of the reflectors includes a plurality of planar reflective surfaces, which are sequentially connected along the circumference of the reflective bottom surface;

[0016] Alternatively, the reflective side surface is a cylindrical curved surface or a frustum curved surface, and the reflective bottom surface is connected to an opening at one end of the reflective side surface, wherein the area of ​​the opening at the other end of the reflective bottom surface is not less than the area of ​​the reflective bottom surface.

[0017] In some embodiments, a transition surface is connected between the reflective sides of adjacent reflectors, the transition surface being integrally connected to the reflective sides and parallel to the reflective bottom surface.

[0018] Furthermore, the transition surface and the adjacent reflective surface are arranged in a dome shape to create a weight-reducing space.

[0019] In some embodiments, the transition surface, the reflective side surface, and the reflective bottom surface have the same thickness;

[0020] Alternatively, the thickness of the transition surface is greater than the thickness of the reflective side surface and the reflective bottom surface.

[0021] Furthermore, both the reflective bottom surface and the reflective side surface include a stacked substrate layer and a reflective coating, with the reflective coating facing the mini-LED light group within the enclosure space.

[0022] In some embodiments, the plurality of reflectors on the three-dimensional reflective sheet are arranged in an array.

[0023] The beneficial effects of the three-dimensional reflective sheet for reducing mini-LED backlight halo provided in this application are at least as follows: the three-dimensional cup-shaped reflective sheet can guide and focus light more precisely, thereby achieving a more ideal beam distribution. This design can reduce light loss and improve light output efficiency; the three-dimensional reflective sheet can evenly distribute light in the required area, reducing shadows and hot spots; the three-dimensional reflective sheet can handle light from multiple directions simultaneously, and can block the beam from entering other control areas by reflecting the side, reducing light leakage and halo. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 A perspective view of a three-dimensional reflective sheet for reducing mini-LED backlight halo provided in an embodiment of this application;

[0026] Figure 2 for Figure 1 A schematic diagram of the structure of the reflector on the three-dimensional reflector sheet;

[0027] Figure 3 Another perspective view of the three-dimensional reflective sheet for reducing mini-LED backlight halo provided in the embodiments of this application;

[0028] Figure 4 for Figure 3 A schematic diagram of the structure of the reflector on the three-dimensional reflector sheet;

[0029] Figure 5 for Figure 1 Side sectional view of the three-dimensional reflective sheet;

[0030] Figure 6 for Figure 5 A schematic diagram of a three-dimensional reflective sheet mounted on a PCB board;

[0031] Figure 7 This is a side sectional view of another type of three-dimensional reflective sheet;

[0032] Figure 8 This is a side sectional view of another type of three-dimensional reflective sheet;

[0033] Figure 9 This is a schematic diagram of the substrate layer and reflective coating on the reflector.

[0034] The following are the labeling elements in the figure:

[0035] 1. Three-dimensional reflective sheet;

[0036] 2. Reflector;

[0037] 3. Reflective bottom surface; 31. Clearance hole;

[0038] 4. Reflective side;

[0039] 5. Enclosure space;

[0040] 6. Transition surface;

[0041] 7. Weight reduction potential;

[0042] 8. Substrate layer;

[0043] 9. Reflective coating;

[0044] 10. PCB board;

[0045] 101. Mini-LED light assembly. Detailed Implementation

[0046] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of this application.

[0047] It should be noted that when a component is referred to as "fixed to" or "set on" another component, it may be directly or indirectly located on that other component. When a component is referred to as "connected to" another component, it may be directly or indirectly connected to that other component. The terms "upper," "lower," "left," "right," "front," "rear," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate orientations or positions based on the accompanying drawings, and are for ease of description only, and should not be construed as limiting the technical solution. The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features. "A plurality" means two or more, unless otherwise explicitly defined.

[0048] It should be noted that the mini-LED backlight panel mainly consists of a PCB board and mini-LED light groups. The mini-LED light groups are mounted on the PCB board and electrically connected to the light-emitting circuit on the PCB board. At the same time, the PCB board not only provides a platform for electrical connection, but also carries various types of electronic components, such as resistors, capacitors, inductors, crystals, connectors, sensors, electromechanical components, etc. Therefore, the surface of the PCB board is not flat. When the mini-LED light groups emit light, the beam mainly shines towards the front of the light source, but it also shines towards the sides and bottom of the mini-LED light groups. This part of the beam is easily scattered, causing light loss and diffuse reflection.

[0049] In existing technologies, reflective sheets are usually laid on the PCB board to cover other components in order to reduce light loss and diffuse reflection on other components. The reflective sheet is a flat plate. When the reflective sheet is laid on the PCB board, the light beam of the mini-LED light group directed to the bottom will be reflected by the flat reflective sheet to reduce diffuse reflection and light loss.

[0050] However, light beams reflected by a flat reflector are easily reflected to other control areas, resulting in light leakage and halos in other control areas, affecting the display effect, especially during local dimming. For example, a mini-LED backlight panel includes adjacent control areas A and B. The requirement for local dimming is that control area A emits light while control area B does not emit light. On the display, control area A displays color and control area B displays black. If the reflector is a flat plate, the light beam from control area A can easily be reflected to the adjacent control area B, producing halos in control area B. The black in control area B will not be dark enough, reducing the display effect.

[0051] To address the aforementioned issues, the following description, in conjunction with the accompanying drawings, describes a three-dimensional reflective sheet for reducing backlight halos in mini-LEDs according to an embodiment of this application.

[0052] Please see Figure 1 and Figure 3 , Figure 1 and Figure 3 This diagram illustrates the structure of the three-dimensional reflective sheet used to reduce the halo effect of mini-LED backlight.

[0053] See Figure 5 The mini-LED backlight includes a PCB board 10 and mini-LED lamp groups 101 disposed on the PCB board 10. A three-dimensional reflector 1 is mounted on the PCB board 10 and includes multiple integrally connected reflectors 2. (See reference...) Figures 1-8 Each reflector 2 includes a reflective bottom surface 3 and a reflective side surface 4. The reflective bottom surface 3 is used to reflect the light beam emitted by the mini-LED light group 101 toward the bottom surface, and the reflective side surface 4 is used to reflect the light beam emitted by the mini-LED light group 101 toward the side.

[0054] Specifically, a clearance hole 31 is provided in the center of the reflective bottom surface 3, and the reflective side surface 4 is connected to the edge of the reflective bottom surface 3 along the circumference of the reflective bottom surface 3. The reflective bottom surface 3 and the reflective side surface 4 form a cup-shaped cover space 5. Adjacent reflective covers 2 are connected through the reflective side surface 4. The reflective bottom surface 3 and the reflective side surface 4 are integrally connected so that the three-dimensional reflective sheet 1 is constructed as an integral structure.

[0055] Among them, see Figure 5 When the reflective bottom surface 3 abuts against the PCB board 10, the mini-LED light group 101 passes through the clearance hole 31 and is housed in the cover space 5. The reflective bottom surface 3 is located below the mini-LED light group 101, and the reflective side surface 4 is located to the side of the mini-LED light group 101.

[0056] The three-dimensional reflector 1, shaped like a cup, can guide and focus light more precisely, thereby achieving a more ideal beam distribution. This design can reduce light loss and improve light output efficiency. The three-dimensional reflector 1 can distribute light evenly in the required area, reducing shadows and hot spots. The three-dimensional reflector 1 can process light from multiple directions at the same time and can block the beam from entering other control areas through the reflective side 4, reducing light leakage and halo.

[0057] In some embodiments, the three-dimensional reflective sheet 1 is made from a sheet of material by stamping, using a mold and a punch press to form multiple cup-shaped reflectors 2 on the sheet of material.

[0058] The mold includes an upper mold (punch) and a lower mold (die). The lower mold is cup-shaped, which determines the shape of the reflector 2 formed after stamping.

[0059] When manufacturing the three-dimensional reflective sheet 1, the mold is installed on the punch press, and the punch press parameters, such as pressure and speed, are adjusted to match the required stamping conditions. The sheet material is then fed into the punch press, and the sheet material is stamped and shaped by the cooperation of the upper and lower dies.

[0060] It can be seen that all parts of the three-dimensional reflective sheet 1 are integrally formed, that is, no additional connectors are needed to fix the parts. When using it, the three-dimensional reflective sheet 1 can be directly placed on the PCB board 10 without the need for a separate installation step. It is convenient to use and easy to transport and store.

[0061] Furthermore, the layout of the mini-LED light group 101 on the actual installed PCB board 10 can be pre-designed, and a three-dimensional reflective sheet 1 can be made according to the pre-design. The completed three-dimensional reflective sheet 1 can be directly applied to the PCB board 10.

[0062] In addition, the three-dimensional reflector 1 of this application is different from the reflector base currently in use. The general structure of the reflector base includes a base, a reflective surface, a support structure and a mounting interface. That is to say, each mini-LED light group 101 on the PCB board 10 needs to be installed with a separate reflector base. Its base has a thick support structure and needs to be fixed to the PCB board 10 with a mounting interface.

[0063] It can be seen that the three-dimensional reflector 1 of this application has the following differences and advantages compared with the reflector base (also known as reflector or reflector cup): the reflector can be more easily adapted to different lamp shapes and sizes, providing greater design flexibility. In contrast, the reflector base usually has a fixed geometry and a smaller range of applications.

[0064] The three-dimensional reflector 1 is thinner and lighter than the reflector base, which helps to create more compact and lightweight lamps.

[0065] The manufacturing cost of 3D reflective sheet 1 is lower, especially for mass production applications. Furthermore, due to its lightweight nature, 3D reflective sheet 1 may also reduce transportation costs and the overall cost of the final product.

[0066] The three-dimensional reflector 1 can usually be directly attached or installed inside the lamp, simplifying the installation process. If maintenance or replacement is required, the three-dimensional reflector 1 is also easier to operate, without having to disassemble the entire reflective base structure.

[0067] The three-dimensional reflector design allows for better airflow, thereby improving the heat dissipation performance of the LED light assembly.

[0068] In some implementations, see Figure 6 The reflective side 4 and the reflective bottom surface 3 have a first included angle, which is α. The first included angle α refers to the angle between the reflective side 4 and the reflective bottom surface 3 in the direction of the lampshade space.

[0069] In some implementations, see Figure 8 The first included angle α is 90°. (See also...) Figure 6 The first included angle α can also be 115°. Furthermore, the first included angle α can be any angle value in the range of 90° to 120°.

[0070] Further, see Figure 5 With the reflective bottom surface 3 as the reference surface, the height of the reflective side surface 4 is not lower than the height of the mini-LED light group 101.

[0071] Understandably, in the backlight module, the mini-LED light group 101 is set on the PCB board 10. In the light emission direction of the mini-LED light group 101, a diffuser plate and a display screen are set at intervals. After the light from the mini-LED light group 101 shines on the diffuser plate, it is processed and the image is displayed on the display screen.

[0072] Setting the height of the reflective side 4 higher than the height of the mini-LED light group 101 allows for greater reflection of the light emitted from the mini-LED light group 101 to the side, preventing light from entering other control areas and further reducing the risk of halos in other control areas.

[0073] In some implementations, the height of the reflective side 4 is 2mm-7mm higher than the height of the mini-LED lamp assembly 101.

[0074] The distance between the diffuser plate and the mini-LED light group 101 is pre-designed, and the distance is generally 5-10mm. The mini-LED light group 101 itself has a certain height. Therefore, the height of the reflective side 4 is 2mm-7mm higher than the height of the mini-LED light group 101.

[0075] Furthermore, the top of the three-dimensional reflector 1 rests against the diffuser plate. For example, the distance between the diffuser plate and the mini-LED lamp group 101 is 10mm, the height of the mini-LED lamp group 101 itself is 3mm, and the height of the reflective side 4 is 7mm higher than the height of the mini-LED lamp group 101. That is, the top of the three-dimensional reflector 1 rests against the diffuser plate, and each reflector 2 in the three-dimensional reflector 1 forms a relatively sealed control area with the diffuser plate. The light beam in this part of the control area can be reflected by the reflective side 4 and the reflective bottom surface 3, and all of them are directed from the light-emitting front to the diffuser plate without light leakage.

[0076] Of course, the top of the three-dimensional reflector 1 may not only rest against the diffuser plate. For example, the distance between the diffuser plate and the mini-LED lamp group 101 is 10mm, the height of the mini-LED lamp group 101 itself is 3mm, and the height of the reflective side 4 is 5mm higher than the height of the mini-LED lamp group 101. That is, the top of the three-dimensional reflector 1 does not only rest against the diffuser plate and there is a 2mm gap between it and the diffuser plate. In this part of the control area, the light beam can be reflected by the reflective side 4 and the reflective bottom surface 3 and is directed from the light-emitting front to the diffuser plate. Compared with a planar reflector, the risk of light entering other control areas can be greatly reduced.

[0077] In some implementations, see Figure 1 , Figure 2 , Figures 5-9Each reflector 2 includes multiple planar reflective surfaces 4, which are connected sequentially along the circumference of the reflective bottom surface 3.

[0078] Further, see Figure 3 and Figure 4 The reflective side surface 4 is a cylindrical curved surface or a frustum curved surface, and the reflective bottom surface 3 is connected to the opening at one end of the reflective side surface 4. The area of ​​the opening at the other end of the reflective bottom surface 3 is not less than the area of ​​the reflective bottom surface 3.

[0079] Furthermore, the surface design of the three-dimensional reflector 1 can be a complex geometric shape such as parabola, ellipse, or cone, depending on the required beam distribution pattern.

[0080] See Figure 1 , Figure 2 , Figures 5-9 The multiple reflective surfaces 4 adopt a polyhedral structure, with four planar reflective surfaces 4. The light path is optimized by the coordinated work of multiple reflective surfaces to achieve the ideal lighting effect.

[0081] In some embodiments, the reflective side 4 is textured or patterned to further adjust the directionality and diffusion of the light. For example, the side of the reflective side 4 closest to the lamp assembly is provided with a Fresnel lens thread to refine the beam so that the beam emitted from the three-dimensional reflector 1 is close to the PCB board 10.

[0082] In some implementations, see Figure 1 , Figure 3 , Figure 5 , Figure 6 , Figure 8 and Figure 9 A transition surface 6 connects the reflective sides 4 of adjacent reflectors 2. The transition surface 6 is integrally connected to the reflective sides and parallel to the reflective bottom surface 3. From the manufacturing process perspective, part of the reflector 2 is formed by stamping the sheet metal, while the transition surface 6 is the part of the sheet metal that has not been stamped. The purpose of setting the transition surface 6 is to improve the structural strength of the entire three-dimensional reflector 1. The transition surface 6 not only serves as a connection but also acts as a support beam between the various reflectors 2, improving the compressive and deformation resistance of the three-dimensional reflector 1.

[0083] Furthermore, the transition surface 6 is parallel to the reflective bottom surface 3, which in some cases allows the transition surface 6 to smoothly abut against the diffuser plate, and the transition surface 6 and the adjacent reflective side surface 4 form a platform structure with high structural strength.

[0084] Further, see Figure 1 , Figure 5 , Figure 6 , Figure 8 and Figure 9The transition surface 6 and the adjacent reflective side surface 4 are arranged in a dome shape with a weight reduction space 7. That is, the transition surface 6 and the reflective side surface 4 are hollowed out on the side facing the PCB board 10, which makes the three-dimensional reflective sheet 1 thinner and lighter, achieving the effect of reducing weight. In addition, the hollowed-out weight reduction space 7 is suitable for air flow, which makes it easier to dissipate heat from the mini-LED light group 101.

[0085] Furthermore, the transition surface 6, the reflective side surface 4, and the reflective bottom surface 3 have the same thickness.

[0086] In some embodiments, the thickness of the transition surface 6 is greater than the thickness of the reflective side surface 4 and the reflective bottom surface 3.

[0087] Depending on the application requirements, the thickness of each part of the three-dimensional reflective sheet 1 can be set to be the same or different, so as to ensure sufficient mechanical strength to support the three-dimensional structure and maintain lightweight.

[0088] When the thickness of the transition surface 6 is greater than the thickness of the reflective side surface 4 and the reflective bottom surface 3, it is equivalent to the strength of the support beam between each reflector 2 being higher, which can improve the overall strength of the three-dimensional reflector 1.

[0089] In some implementations, see Figure 9 Both the reflective bottom surface 3 and the reflective side surface 4 include a substrate layer 8 and a reflective coating 9 stacked together, with the reflective coating 9 facing the mini-LED light group 101 inside the cover space 5.

[0090] The substrate material of the substrate layer 8 includes plastics (such as polycarbonate PC, acrylic PMMA) and metals (such as aluminum). These materials have good processing performance and can provide high reflectivity.

[0091] Furthermore, in order to achieve high reflectivity, silver plating, aluminum plating or other metallization treatments are applied to the surface of substrate layer 8, or a white high-reflectivity coating is used to form a reflective coating 9.

[0092] The reflective coating 9 has a smooth surface. High-quality surface treatment is crucial for reducing light scattering and loss, so it is necessary to ensure that the surface is smooth and flawless.

[0093] Further, see Figure 1 and Figure 3 Multiple reflectors 2 on the three-dimensional reflector sheet 1 are arranged in an array.

[0094] The above are merely preferred embodiments of this application and are not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A three-dimensional reflective sheet for reducing halo effect in mini-LED backlights, the mini-LED backlight comprising a PCB board and mini-LED lamp groups disposed on the PCB board, characterized in that, The three-dimensional reflective sheet is used for mounting on a PCB board and includes multiple integrally connected reflective covers, each of which includes: The bottom surface is reflective, with a clearance hole in the center; The reflective side is connected to the edge of the reflective bottom surface along the circumference of the reflective bottom surface, and the reflective bottom surface and the reflective side form a cup-shaped cover space. The adjacent reflectors are connected by the reflective side surfaces, and the reflective bottom surface and the reflective side surfaces are integrally connected, so that the three-dimensional reflective sheet is constructed as a single structure; When the reflective bottom surface abuts against the PCB board, the mini-LED light group passes through the clearance hole and is housed within the cover space. The reflective bottom surface is located below the mini-LED light group, and the reflective side surface is located to the side of the mini-LED light group.

2. The three-dimensional reflective sheet for reducing mini-LED backlight halo according to claim 1, characterized in that, The reflective side surface and the reflective bottom surface have a first included angle, which is any angle value between 90° and 120°.

3. The three-dimensional reflective sheet for reducing mini-LED backlight halo according to claim 1, characterized in that, With the reflective bottom surface as the reference surface, the height of the reflective side surface is not lower than the height of the mini-LED light group.

4. The three-dimensional reflective sheet for reducing mini-LED backlight halo according to claim 3, characterized in that, The height of the reflective side is 2mm-7mm higher than the height of the mini-LED light assembly.

5. The three-dimensional reflective sheet for reducing mini-LED backlight halo according to claim 1, characterized in that, Each of the reflectors includes multiple planar reflective surfaces, which are sequentially connected along the circumference of the reflective bottom surface; Alternatively, the reflective side surface is a cylindrical curved surface or a frustum curved surface, and the reflective bottom surface is connected to an opening at one end of the reflective side surface, wherein the area of ​​the opening at the other end of the reflective bottom surface is not less than the area of ​​the reflective bottom surface.

6. The three-dimensional reflective sheet for reducing mini-LED backlight halo according to claim 1, characterized in that, A transition surface is connected between the reflective sides of adjacent reflectors, and the transition surface is integrally connected to the reflective side and parallel to the reflective bottom surface.

7. The three-dimensional reflective sheet for reducing mini-LED backlight halo according to claim 6, characterized in that, The transition surface and the adjacent reflective surface are arranged in a dome shape to create a weight-reducing space.

8. The three-dimensional reflective sheet for reducing mini-LED backlight halo according to claim 6, characterized in that, The transition surface, the reflective side surface, and the reflective bottom surface have the same thickness; Alternatively, the thickness of the transition surface is greater than the thickness of the reflective side surface and the reflective bottom surface.

9. The three-dimensional reflective sheet for reducing mini-LED backlight halo according to claim 1, characterized in that, Both the reflective bottom surface and the reflective side surface include a stacked substrate layer and a reflective coating, with the reflective coating facing the mini-LED light group within the enclosure space.

10. The three-dimensional reflective sheet for reducing mini-LED backlight halo according to claim 1, characterized in that, The multiple reflectors on the three-dimensional reflective sheet are arranged in an array.

Images