Reflector and manufacturing method thereof, backlight module and liquid crystal display device

Abstract

The present invention relates to the technical field of display devices, and specifically discloses a reflector and a manufacturing method thereof, a backlight module and a liquid crystal display device, wherein the reflector has a preset structure, and the structural shape of the reflector has a preset corresponding relationship with the LED arrangement mode, and the reflector is installed inside a back plate, and reflects light to the corresponding LED arrangement mode; wherein the reflector is prepared from the following components in percentage by mass: 70-80% PET carrier, 5-8% titanium dioxide, and 12-25% PMMA. The present invention enables the same back plate to be compatible with a variety of LED arrangements, thereby improving the versatility of the back plate; and when the reflector is installed with the back plate, there is no need for manual cutting and folding, thereby saving labor.

Description

Technical Field

[0001] The present invention relates to the technical field of display devices, and in particular to a reflection plate and a manufacturing method thereof, a backlight module and a liquid crystal display device. Background Art

[0002] Liquid crystal display devices have penetrated into our lives, such as monitors and TVs. The backlight module is an important component of liquid crystal display devices, and its function is to provide a stable and uniform surface light source for liquid crystal display devices. Its working principle is that a number of LEDs arranged in an array emit light, and the light changes the light path through the lens, and then is reflected by the reflector to the optical film to form a surface light source.

[0003] Taking a 32-inch LCD display device as an example, the current mainstream LED layout methods in the market include single light bar solution and dual light bar solution. The single light bar solution is simple to assemble and low in cost, and more cost-effective; the dual light bar solution has high uniformity and better visual experience. The single light bar solution requires a reflective lens with a larger light-emitting angle, such as the attached Figure 1 As shown in the figure, the light from the reflective lens is mainly directed to the periphery of the LED, requiring a slow transition around the reflector to avoid sudden changes in brightness and darkness, and to obtain a uniform surface light source. The double light bar lens uses a refractive lens, as shown in the attached figure. Figure 2 As shown, the refractive lens mainly directs light directly above the LED, and the folding edges of the reflector plate need to be far away from the LED. If the reflector plate transitions slowly around, uneven brightness in the transition area will occur.

[0004] In the related art, the reflector is a prefabricated soft sheet structure, which is cut flat according to the LED arrangement method when in use, and is manually folded into a shape that fits the back panel with a reserved seam line, and finally placed in the back panel. In this way, on the one hand, since the reflector needs to fit in the back panel cavity, and the choice of LED arrangement method also has different requirements for the curvature of the reflector, the shape of the back panel corresponding to the reflector is also different, resulting in multiple LED arrangements being incompatible with the same back panel, so that when another LED arrangement method is adopted, a new back panel mold needs to be made, and the cost of the back panel mold is relatively expensive, which undoubtedly increases the company's production and manufacturing costs; on the other hand, since the reflector and the back panel need to be manually cut and folded when installed, it consumes labor. Summary of the invention

[0005] The main purpose of the present invention is to propose a reflector and a manufacturing method thereof, a backlight module and a liquid crystal display device, aiming to achieve that the same back panel can be compatible with a variety of LED arrangements and improve the versatility of the back panel; and the reflector and the back panel do not require manual cutting and folding when installed, saving labor.

[0006] To achieve the above object, the present invention provides a reflective plate, which is prepared from the following components in percentage by mass: 70-80% PET carrier, 5-8% titanium dioxide, and 12-25% PMMA.

[0007] Optionally, the reflective plate has a hard preset structure, and there is a preset corresponding relationship between the structural shape of the reflective plate and the LED arrangement; the reflective plate is installed inside the back plate and reflects light from the corresponding LED arrangement.

[0008] Optionally, the particle size of the titanium dioxide is 30-200 nm.

[0009] Optionally, the thickness of the reflective plate is 0.15-3 mm or 3-5 mm.

[0010] Optionally, a titanium dioxide layer is provided on the surface of the reflector plate for reflecting light, and the thickness of the titanium dioxide layer is 30-200 nm.

[0011] Optionally, a silver reflective film is provided on the surface of the reflective plate used for reflecting light.

[0012] To achieve the above object, the present invention further provides a method for manufacturing a reflector, comprising the following steps:

[0013] S10: 70-80% of PET carrier, 5-8% of titanium dioxide, and 12-25% of PMMA are mixed, dispersed, extruded, and pelletized to obtain a masterbatch;

[0014] S20: Processing the masterbatch through a molding process to obtain the reflector.

[0015] Optionally, step S20 includes the following steps:

[0016] S21: if the diagonal dimension of the reflective plate is ≤55 inches, the masterbatch is made into the reflective plate by a blister process; wherein the thickness of the reflective plate made by the blister process is 0.15-3 mm;

[0017] S22: If the diagonal dimension of the reflective plate is greater than 55 inches, the masterbatch is made into the reflective plate by an injection molding process; wherein the thickness of the reflective plate made by the injection molding process is 3-5 mm.

[0018] To achieve the above object, the present invention further provides a backlight module, comprising a back plate and a reflective plate connected to each other, wherein the reflective plate is any one of the reflective plates described above, or is manufactured using any one of the manufacturing methods described above.

[0019] To achieve the above object, the present invention further provides a liquid crystal display device, which includes the above backlight module.

[0020] The reflector of the present invention is prepared by the following components in percentage by mass: 70-80% PET carrier, 5-8% titanium dioxide, and 12-25% PMMA. Thus, the reflector after manufacture has a hard preset structure, and there is a preset correspondence between the structural shape of the reflector and the LED arrangement mode; because its preset structure itself has a certain strength and thickness, the reflector does not need to be supported by fitting the back plate cavity to be shaped, that is to say, the reflector of the present invention does not need to rely on the back plate, and can meet the light reflection requirements of the LED arrangement mode by using its own structural shape. Thus, the back plate can be made into a universal shape, and when facing different LED arrangements, the corresponding reflector can be replaced, so that the back plate can be compatible with a variety of LED arrangements, improving the versatility of the back plate; and because the reflector has been processed to form a preset structure before installation, there is no need for manual cutting and folding during the installation process, which saves labor and provides the prerequisite for fully automated installation. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0022] Figure 1 It is a structural schematic diagram of a single light bar solution in the background technology;

[0023] Figure 2 It is a structural schematic diagram of the dual light bar solution in the background technology;

[0024] Figure 3 This is a flow chart of the steps of an embodiment of a method for manufacturing a reflector plate of the present invention;

[0025] Figure 4 This is the second step flow chart of an embodiment of a method for manufacturing a reflector of the present invention.

[0026] The realization of the purpose, functional features and advantages of the present invention will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0027] The following will be combined with the accompanying drawings in the present invention to clearly and completely describe the technical solution in the present invention. Obviously, what is described is only a part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0028] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back, etc.), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0029] In addition, if the descriptions of "first", "second", etc. in the present invention are only used for descriptive purposes, they cannot be understood as indicating or implying their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In addition, the technical solutions between the various embodiments can be combined with each other, but they must be based on the ability of ordinary technicians in the field to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0030] This embodiment discloses a reflector, which is made of the following components in mass percentage: 70-80% PET carrier, 5-8% titanium dioxide, and 12-25% PMMA. The reflector has a hard preset structure, and there is a preset corresponding relationship between the structural shape of the reflector and the LED arrangement; the reflector is installed inside the back plate and reflects light from the corresponding LED arrangement.

[0031] The reflector of the present invention is prepared by the following components in percentage by mass: 70-80% PET carrier, 5-8% titanium dioxide, and 12-25% PMMA. Thus, the reflector after manufacture has a hard preset structure, and there is a preset correspondence between the structural shape of the reflector and the LED arrangement mode; because its preset structure itself has a certain strength and thickness, the reflector does not need to be supported by fitting the back plate cavity to be shaped, that is to say, the reflector of the present invention does not need to rely on the back plate, and can meet the light reflection requirements of the LED arrangement mode by using its own structural shape. Thus, the back plate can be made into a universal shape, and when facing different LED arrangements, the corresponding reflector can be replaced, so that the back plate can be compatible with a variety of LED arrangements, improving the versatility of the back plate; and because the reflector has been processed to form a preset structure before installation, there is no need for manual cutting and folding during the installation process, which saves labor and provides the prerequisite for fully automated installation.

[0032] At the same time, the above components make the reflective plate of this embodiment have the characteristics of strong stiffness, good dispersibility, high concentration, good whiteness, strong hiding power, anti-yellowing, etc., wherein its reflectivity can reach more than 93%, and the surface glossiness at an angle of 60 degrees is ≤40%. Among them, the reflectivity means that the light absorption rate of the reflective plate is low, and the surface glossiness at an angle of 60 degrees is ≤40%, which means that the light is more likely to be diffusely reflected after being irradiated to the reflective plate, thereby improving the light output effect of the backlight module.

[0033] The particle size of the titanium dioxide is 30-200 nm. In this way, the titanium dioxide is better mixed and dispersed with the PET carrier and PMMA, so as to improve the mixing degree of the titanium dioxide, the PET carrier and PMMA.

[0034] The thickness of the reflector is 0.15-3mm or 3-5mm. Specifically, the thickness of 0.15-3mm is for when the diagonal dimension of the reflector is less than or equal to 55 inches, and the thickness of 3-5mm is for when the diagonal dimension of the reflector is greater than 55 inches. In this way, when the diagonal dimension of the reflector is greater than a certain value, the reflector may break or sag and deform during operation. Therefore, the thickness of the reflector needs to be designed to be thicker to make it harder and stronger.

[0035] Furthermore, the surface of the reflector for reflecting light is provided with a titanium dioxide layer, and the thickness of the titanium dioxide layer is 30-200 nm. In this way, by providing a titanium dioxide layer on the surface of the reflector for reflecting light, the titanium dioxide layer is used to further improve the reflectivity of the reflector to more than 95%. It should be noted that the mass percentage of titanium dioxide in the titanium dioxide layer in this embodiment is not included in the mass percentage of each component of the reflector above, and the mass percentage of titanium dioxide in this titanium dioxide layer should be calculated separately.

[0036] Alternatively, the light reflecting surface of the reflector is provided with a silver reflective film. In this way, by providing the silver reflective film on the light reflecting surface of the reflector, the reflectivity of the reflector is further improved by the silver reflective film to reach more than 98%.

[0037] This embodiment also discloses a method for manufacturing a reflector, which includes the following steps, referring to the accompanying drawings:

[0038] Step S10: 70-80% of PET carrier, 5-8% of titanium dioxide, and 12-25% of PMMA are mixed, dispersed, extruded, and pelletized to obtain a masterbatch;

[0039] Step S20: Processing the masterbatch through a molding process to obtain the reflector.

[0040] Specifically, according to the above steps, the experimental data of Examples 1-5 and their reflectivity and surface gloss at an angle of 60 degrees are as follows:

[0041]

[0042] It can be seen from the above table that after 70-80% PET carrier, 5-8% titanium dioxide and 12-25% PMMA are mixed, dispersed, extruded and pelletized to obtain a masterbatch, the masterbatch is then processed through a molding process to obtain the reflective plate, and its reflectivity and surface gloss at an angle of 60 degrees can achieve the expected effect, meeting the design requirements of this application.

[0043] Further, in step S20, referring to the accompanying drawings, the following steps are included:

[0044] Step S21: if the diagonal dimension of the reflective plate is ≤55 inches, the masterbatch is made into the reflective plate by a vacuum forming process; wherein the thickness of the reflective plate made by the vacuum forming process is 0.15-3 mm;

[0045] Step S22: if the diagonal dimension of the reflective plate is greater than 55 inches, the masterbatch is made into the reflective plate by injection molding; wherein the thickness of the reflective plate made by the injection molding process is 3-5 mm.

[0046] In this arrangement, considering that due to the difference in manufacturing process, the thickness of the reflector plate made by the blister process is less than that of the reflector plate made by the injection molding process, the reflector plate with a diagonal size of ≤55 inches is processed by the blister process, and the reflector plate with a diagonal size of >55 inches is processed by the injection molding process.

[0047] This embodiment also discloses a backlight module, including a connected back plate and a reflector, wherein the reflector is a reflector of any of the above embodiments, or is made by the manufacturing method of any of the above embodiments. The reflector of any of the above embodiments, or the reflector made by the manufacturing method of any of the above embodiments, is applied to the backlight module. Different from the reflector of the soft sheet structure in the related art, the present invention adopts a reflector with a preset structure, and there is a preset correspondence between the structural shape of the reflector and the LED arrangement mode; because its preset structure itself has a certain strength and thickness, the reflector does not need to be supported by fitting the back plate cavity to be shaped, that is, the reflector of the present invention does not need to rely on the back plate, and can meet the light reflection requirements of the LED arrangement mode by using its own structural shape. Thus, the back plate can be made into a universal shape, and when facing different LED arrangements, the corresponding reflector can be replaced, so that the back plate can be compatible with a variety of LED arrangements, and the versatility of the back plate is improved; and because the reflector has been processed to form a preset structure before installation, there is no need to perform manual cutting and folding during the installation process, saving labor and providing a prerequisite for achieving fully automated installation.

[0048] This embodiment also discloses a liquid crystal display device, which includes the backlight module of the above embodiment. In this way, the backlight module of the above embodiment is applied to the liquid crystal display device. Since the backlight module includes a reflector of any of the above embodiments, or a reflector made by the manufacturing method of any of the above embodiments, the present invention adopts a reflector with a preset structure, and there is a preset correspondence between the structural shape of the reflector and the LED arrangement mode; since its preset structure itself has a certain strength and thickness, the reflector does not need to be supported by fitting the back plate cavity to be shaped, that is, the reflector of the present invention does not need to rely on the back plate, and can meet the light reflection requirements of the LED arrangement mode by using its own structural shape. Thus, the back plate can be made into a universal shape, and when facing different LED arrangement modes, the corresponding reflector can be replaced, so that the back plate can be compatible with a variety of LED arrangement modes, and the versatility of the back plate is improved; and since the reflector has been processed to form a preset structure before installation, there is no need to perform manual cutting and folding during the installation process, saving labor and providing a prerequisite for achieving fully automated installation.

[0049] It should be noted that the reflective plate and the manufacturing method thereof, the backlight module and the other contents of the liquid crystal display device disclosed in the present invention are prior arts and will not be described in detail here.

[0050] The above are only optional embodiments of the present invention, and are not intended to limit the patent scope of the present invention. Any direct / indirect application of the present invention in other related technical fields is included in the patent protection scope of the present invention.

Claims

1. A reflector, characterized in that: The reflector is made of the following components in percentage by mass: 70-80% PET carrier, 5-8% titanium dioxide, and 12-25% PMMA; the reflector has a hard preset structure, and there is a preset corresponding relationship between the structural shape of the reflector and the LED arrangement; the reflector is used to be installed inside the back plate and reflect light from the corresponding LED arrangement; The thickness of the reflective plate is 0.15-3mm or 3-5mm; specifically, the thickness of 0.15-3mm is for when the diagonal size of the reflective plate is less than or equal to 55 inches, and the thickness of 3-5mm is for when the diagonal size of the reflective plate is greater than 55 inches.

2. The reflector according to claim 1, characterized in that: The particle size of the titanium dioxide is 30-200 nm.

3. The reflector according to any one of claims 1 to 2, characterized in that: The surface of the reflector plate used for reflecting light is provided with a titanium dioxide layer, and the thickness of the titanium dioxide layer is 30-200nm.

4. The reflector according to any one of claims 1 to 2, characterized in that: The surface of the reflector plate used for reflecting light is provided with a silver reflective film.

5. A method for manufacturing a reflective plate, characterized in that: Used to manufacture the reflective plate according to any one of claims 1 to 4; Specifically, the manufacturing method of the reflector comprises the following steps: S10: 70-80% of PET carrier, 5-8% of titanium dioxide, and 12-25% of PMMA are mixed, dispersed, extruded, and pelletized to obtain a masterbatch; S20: Processing the masterbatch through a molding process to obtain the reflector.

6. The method for manufacturing a reflector according to claim 5, characterized in that: The step S20 includes the following steps: S21: if the diagonal dimension of the reflective plate is ≤55 inches, the masterbatch is made into the reflective plate by a blister process; wherein the thickness of the reflective plate made by the blister process is 0.15-3 mm; S22: If the diagonal dimension of the reflective plate is greater than 55 inches, the masterbatch is made into the reflective plate by an injection molding process; wherein the thickness of the reflective plate made by the injection molding process is 3-5 mm.

7. A backlight module, characterized in that: It comprises a back plate and a reflective plate connected to each other, wherein the reflective plate is the reflective plate according to any one of claims 1 to 4, or is manufactured by the manufacturing method according to any one of claims 5 to 6.

8. A liquid crystal display device, characterized in that: The liquid crystal display device comprises the backlight module as claimed in claim 7.

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