A method for processing a reflector, the reflector, and a mini LED backlight module

Abstract

The application discloses a reflector processing method, a reflector and a Mini LED backlight module. The reflector processing method comprises the following steps: adding first injection plastic and second injection plastic into two barrels of a double-color injection molding machine, wherein a mold is installed in the double-color injection molding machine, a cavity of the mold is divided into a first chamber and a second chamber, the first chamber is communicated with the second chamber, and the first injection plastic and the second injection plastic are different in color; the first injection plastic and the second injection plastic in the two barrels are injected into the first chamber and the second chamber at one time; and the double-color injection molding machine is opened, so that the mold is opened to obtain a reflector product. According to the processing method, the two parts with different colors in the reflector are processed by the double-color injection molding machine, so that the reflector with double colors is formed, and the light uniformity of the reflector is improved.

Description

Technical Field

[0001] This invention relates to the field of Mini LED structures, and more particularly to a method for processing a reflector, a reflector, and a Mini LED backlight module. Background Technology

[0002] Mini LED backlight products have the advantages of high color saturation, wide color gamut, local dimming capability, and long lifespan, and are now widely used in consumer electronics, automotive electronics, and industrial control products.

[0003] However, when the HDR effect is enabled, the LEDs corresponding to the scenes that need to be displayed are lit, while the LEDs corresponding to the scenes that do not need to be displayed are turned off. In practice, the edges of the scenes that need to be displayed are lit because the LEDs are lit, which makes the edges of the scenes appear to have a white halo. This results in a poor viewing experience for the human eye and greatly reduces the display effect. Summary of the Invention

[0004] The main objective of this invention is to propose a reflector processing method, a reflector, and a Mini LED backlight module, aiming to solve the halo problem that exists in existing Mini LED backlight products.

[0005] To achieve the above objectives, this invention proposes a method for processing a reflector. The reflector includes a cup body and a light guide. A reflective surface is provided on the side wall of the inner cavity of the cup body. A through hole communicating with the inner cavity is provided at the bottom of the cup body. The reflective surface is used to even out light. The light guide is disposed within the through hole and is hemispherical, protruding towards the cup opening. A mounting groove is provided on the side of the light guide facing away from the cup opening for mounting LED beads. The reflector processing method includes the following steps:

[0006] The first injection plastic and the second injection plastic are added to the two barrels of the two-color injection molding machine. The two-color injection molding machine is equipped with a mold. The cavity of the mold is divided into a first chamber and a second chamber. The first chamber is connected to the second chamber. The first injection plastic and the second injection plastic are different colors.

[0007] The first injection plastic and the second injection plastic, which are located in the two barrels, are injected into the first chamber and the second chamber at the same time;

[0008] The two-color injection molding machine is opened to allow the mold to open and obtain the finished reflector.

[0009] Optionally, the step of adding the first injection molding compound and the second injection molding compound to the two-color injection molding machine includes:

[0010] The first injection molding compound and the second injection molding compound are baked to remove moisture, so as to obtain a dry first injection molding compound and a dry second injection molding compound;

[0011] The dried first injection plastic is mixed with diffusion powder according to a preset ratio;

[0012] The dried first injection molding compound and the dried second injection molding compound, after being mixed with the diffusion powder, are respectively added to the two barrels of the two-color injection molding machine.

[0013] Optionally, the ratio of the diffusion powder to the first injection molding compound ranges from 0.5% to 3%.

[0014] Optionally, in the step of sequentially injecting the first injection plastic and the second injection plastic, which are located in two barrels, into the first chamber and the second chamber, the first injection plastic is used to form the cup body and the second injection plastic is used to form the light guide.

[0015] The step of sequentially injecting the first injection plastic and the second injection plastic, which are located in two barrels, into the first chamber and the second chamber includes:

[0016] The mold, the hot runner of the two-color injection molding machine, and the barrel of the two-color injection molding machine are heated so that the mold, the hot runner of the two-color injection molding machine, and the barrel of the two-color injection molding machine all reach their respective preset temperatures.

[0017] The first injection plastic and the second injection plastic are heated to a molten state;

[0018] The first injection plastic in its molten state is injected into the first cavity;

[0019] The second injection plastic in its molten state is injected into the second cavity.

[0020] Optionally, in the step of heating the mold, the hot runner of the two-color injection molding machine, and the barrel of the two-color injection molding machine so that the mold, the hot runner of the two-color injection molding machine, and the barrel of the two-color injection molding machine all reach their respective preset temperatures,

[0021] The preset temperature range of the mold is 100℃~120℃;

[0022] The preset temperature range of the hot runner of the two-color injection molding machine is 300℃~315℃;

[0023] The preset temperature range of the barrel of the two-color injection molding machine is 240℃~315℃.

[0024] Optionally, the step of opening the two-color injection molding machine to open the mold and obtain the finished reflector may include:

[0025] Cool the mold until the preset cooling time is met.

[0026] The present invention also proposes a reflector obtained based on the above-described reflector processing method, comprising:

[0027] The cup body has a reflective surface on the side wall of its inner cavity, and a through hole at the bottom of the cup body communicating with its inner cavity. The reflective surface is used to even out light emission; and...

[0028] A light guide is disposed within the through hole. The light guide is hemispherical and protrudes towards the rim of the cup. A mounting groove is provided on the side of the light guide facing away from the rim of the cup for mounting LED beads.

[0029] Optionally, the reflective surface is provided with an uneven surface.

[0030] This invention also proposes a Mini LED backlight module, including a central frame and, sequentially arranged in the central frame, a DBEF, an upper brightness enhancement film, a lower brightness enhancement film, a diffuser plate, a reflector panel, a reflector double-sided adhesive, a Mini LED board, an LED board double-sided adhesive, and a back plate. The reflector panel is formed by a plurality of reflectors arranged at intervals, each of which includes the aforementioned reflectors. The Mini LED board is formed by a plurality of LEDs corresponding to the plurality of reflectors. The reflector double-sided adhesive can connect the reflector panel and the Mini LED board, and the LED board double-sided adhesive can connect the Mini LED board and the back plate.

[0031] In the technical solution provided by this invention, a first injection plastic and a second injection plastic are added to two barrels of a two-color injection molding machine. The two-color injection molding machine is installed inside a mold, and the mold cavity is divided into a first chamber and a second chamber. The first chamber connects to the second chamber, and the first and second injection plastics are of different colors. The first and second injection plastics, located in the two barrels, are sequentially injected into the first and second chambers. The two-color injection molding machine is then opened to allow the mold to open and obtain the finished reflector. This process produces a reflector comprising a cup body and a light guide. The inner wall of the cup body has a reflective surface. The light guide evenly distributes the light emitted by the LED beads, allowing the light passing through the light guide to illuminate the reflective surface for secondary optical effects. This controls the light within the cup body, directing it towards the cup opening, thereby reducing halo effects on the image. The processing method proposed in this invention uses a two-color injection molding machine to process two parts of the reflector with different colors to form a two-color integrated reflector, thereby increasing the light uniformity of the reflector. Attached Figure Description

[0032] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, 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 the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0033] Figure 1 This is a flowchart illustrating an embodiment of the reflector processing method provided by the present invention;

[0034] Figure 2 This is a schematic flowchart of another embodiment of the reflector processing method provided by the present invention;

[0035] Figure 3 A flowchart illustrating yet another embodiment of the reflector processing method provided by the present invention;

[0036] Figure 4 A schematic flowchart of another embodiment of the reflector processing method provided by the present invention;

[0037] Figure 5 This is a cross-sectional schematic diagram of an embodiment of the reflector provided by the present invention.

[0038] Explanation of icon numbers:

[0039] label name label name 100 reflector 12 Through hole 1 Cup body 2 Light guide 11 Reflective surface 21 Mounting slot

[0040] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0041] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0042] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0043] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the meaning of "and / or" throughout the text includes three parallel solutions; for example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0044] Currently, commonly used Mini LED backlight products illuminate the LEDs corresponding to the areas of the image that need to be displayed when HDR is enabled, while the LEDs corresponding to the areas of the image that do not need to be displayed are turned off. In practice, the edges of the images that need to be displayed appear to have a white halo due to the illuminated LEDs, resulting in a poor viewing experience and significantly reducing the display quality.

[0045] To solve the above problems, the present invention provides a reflector 100. Figure 5 This is a specific embodiment of the reflector provided by the present invention.

[0046] Please see Figure 5The reflector 100 includes a cup body 1 and a light guide 2. The inner wall of the cup body 1 is provided with a reflective surface 11. The bottom of the cup body 1 is provided with a through hole 12 communicating with its inner cavity. The reflective surface 11 is used to uniformly distribute light. The light guide 2 is disposed in the through hole 12. The light guide 2 is hemispherical and protrudes towards the cup opening of the cup body. The side of the light guide 2 facing away from the cup opening of the cup body is provided with a mounting groove 21. The mounting groove 21 is used to install LED beads.

[0047] In the technical solution provided by the present invention, the LED beads located in the mounting groove 21 emit light, which enters the light guide 2. The light guide 2 can evenly open the light emitted by the LED beads. The light passing through the light guide 2 then shines on the reflective surface 11. The reflective surface 11 performs secondary optical action on the light to control the light within the range of the cup body 1, and then emits it towards the mouth of the cup body 1, thereby achieving the purpose of reducing the halo phenomenon of the image.

[0048] It should be noted that, in the embodiments of the present invention, the cup body 1 is made of white polycarbonate material, and the light guide 2 is made of transparent polycarbonate material. Making the cup body 1 and the light guide 2 made of polycarbonate material enables the reflector 100 to have the characteristics of high strength, high toughness and heat resistance, thereby increasing the service life of the reflector 100. At the same time, the transparent polycarbonate material also has the characteristic of high transparency, which enables the light guide 2 to reduce the loss of light in the light guide 2 during the process of turning on the light.

[0049] Specifically, the reflective surface 11 is provided with an uneven surface. By making the reflective surface 11 frosted, it is possible to perfectly reflect and refract light, thereby better controlling the light within the range of the cup body 1.

[0050] This invention also proposes a method for processing a reflector 100, as described above. Please refer to [reference needed]. Figure 1 The reflector processing method includes the following steps:

[0051] S100: Add the first injection plastic and the second injection plastic into the two barrels of the two-color injection molding machine;

[0052] It should be noted that the two-color injection molding machine is equipped with a mold, and the cavity of the mold is divided into a first chamber and a second chamber. The first chamber is connected to the second chamber, and the first injection plastic and the second injection plastic are different colors.

[0053] Specifically, the first injection molding compound and the second injection molding compound respectively constitute the cup body 1 and the light guide 2 in the reflector 100. Since the first chamber is connected to the second chamber, the first injection molding compound and the second injection molding compound are connected.

[0054] S200: Inject the first injection plastic and the second injection plastic, which are located in the two barrels, into the first chamber and the second chamber at one time;

[0055] It should be noted that the present invention does not limit the order in which the first injection plastic and the second injection plastic are injected into the mold. The two-color injection molding machine has two feeding pipes, and the first injection plastic and the second injection plastic can be injected into the mold sequentially or simultaneously.

[0056] S400. Open the two-color injection molding machine to open the mold and obtain the finished reflector.

[0057] The reflector 100 is thus processed in such a way that the mold is in a closed state during the processing to facilitate thermosetting of the reflector 100.

[0058] Furthermore, the step of adding the first injection molding compound and the second injection molding compound to the two-color injection molding machine includes:

[0059] S101. The first injection molding compound and the second injection molding compound are baked to remove moisture, so as to obtain a dry first injection molding compound and a dry second injection molding compound;

[0060] Since the first and second injection molding compounds were stored outdoors before use and inevitably carry moisture, directly injecting them into the mold would affect the quality of the finished reflector 100. Therefore, before adding the first and second injection molding compounds to the two-color injection molding machine, they need to be baked and dehumidified for at least two hours at a temperature of 100°C. This ensures that the first and second injection molding compounds are dry. Setting the baking temperature to 100°C also prevents the first and second injection molding compounds from being heated to a molten state due to excessive temperature, thus ensuring the stability of the processing flow.

[0061] S102. The dried first injection plastic is mixed with diffusion powder according to a preset ratio;

[0062] It should be noted that, in the embodiments of the present invention, the dried first injection plastic corresponds to the cup body 1, and the reflective surface 11 is provided with concave and convex surfaces, so that the cup body 1 is difficult to demold in the subsequent demolding step. However, by mixing the dried first injection plastic with the diffusion powder in a preset ratio, the molded cup body 1 can have good smoothness and demolding properties, so that the cup body 1 can be demolded smoothly in the subsequent steps.

[0063] S103. The dried first injection molding compound and the dried second injection molding compound, after being mixed with the diffusion powder, are respectively added to the two barrels of the two-color injection molding machine;

[0064] The processed first injection molding compound and the second injection molding compound are respectively added to the two barrels of the two-color injection molding machine, and the two barrels of the two-color injection molding machine are sealed to isolate the dried first injection molding compound and the dried second injection molding compound, which are mixed with the diffusion powder, from the outside world and prevent them from being affected by external moisture.

[0065] Furthermore, in the step of mixing the dried first injection molding compound with the diffusion powder according to a preset ratio, the ratio of the diffusion powder to the dried first injection molding compound ranges from 0.5% to 3%.

[0066] It should be noted that users can adjust the diffusion powder and the dried first injection plastic in different ratios according to their own required parameters.

[0067] Specifically, in an embodiment of the present invention, in the step of sequentially injecting the first injection plastic and the second injection plastic, which are located in two material cylinders, into the first chamber and the second chamber, the first injection plastic corresponds to forming the cup body 1, and the second injection plastic corresponds to forming the light guide 2; the step of sequentially injecting the first injection plastic and the second injection plastic, which are located in two material cylinders, into the first chamber and the second chamber includes:

[0068] S201. The mold, the hot runner of the two-color injection molding machine, and the barrel of the two-color injection molding machine are heated so that the mold, the hot runner of the two-color injection molding machine, and the barrel of the two-color injection molding machine all reach their respective preset temperatures.

[0069] It should be noted that the first and second injection plastics are respectively injected into the mold from the two barrels of the two-color injection molding machine, passing through the hot runner and the feed tube of the two-color injection molding machine. Preheating the mold, the hot runner, and the feed tube of the two-color injection molding machine can reduce waiting time and prevent the first and second injection plastics from solidifying during injection into the mold, thereby preventing blockage of the feed tube of the two-color injection molding machine.

[0070] S202. Heat the first injection molding compound and the second injection molding compound to a molten state;

[0071] It should be noted that the two-color injection molding machine heats the first and second injection plastics during the injection process into the mold. That is, when the first and second injection plastics are respectively located in the two barrels of the two-color injection molding machine, both the first and second injection plastics are in a solid state. During the injection process into the mold, they are heated through the hot runner and the barrel of the two-color injection molding machine to transform the first and second injection plastics into a molten state.

[0072] S203. Inject the first injection plastic in its molten state into the first cavity;

[0073] In an embodiment of the present invention, the first injection molding material is used to form the cup body 1, and the cup body 1 is first formed in the first cavity.

[0074] S204. Inject the second injection plastic in its molten state into the second cavity.

[0075] In an embodiment of the present invention, the second injection molding compound is used to form the light guide 2. After the first injection molding compound is injected, the second injection molding compound is injected into the second cavity so that the light guide 2 is formed in the second cavity. Since the first cavity and the second cavity are connected, the light guide 2 is connected to the cup body 1 when the light guide 2 is formed.

[0076] Furthermore, in the step of heating the mold, the hot runner of the two-color injection molding machine, and the barrel of the two-color injection molding machine so that the mold, the hot runner of the two-color injection molding machine, and the barrel of the two-color injection molding machine all reach their respective preset temperatures, the preset temperature range of the mold is 100℃~120℃, the preset temperature range of the hot runner of the two-color injection molding machine is 300℃~315℃, and the preset temperature range of the barrel of the two-color injection molding machine is 240℃~315℃.

[0077] In an embodiment of the present invention, both the first injection molding compound and the second injection molding compound are made of polycarbonate material with a melting point of 220°C to 230°C. Heating the hot runner of the two-color injection molding machine to 300°C to 315°C and the barrel of the two-color injection molding machine to 240°C to 315°C ensures that the first and second injection molding compounds are heated to a molten state during the injection process. At the same time, the mold is also heated to 100°C to 120°C to prevent the injection molding compounds from cooling too quickly in the mold, thereby affecting the quality of the finished product.

[0078] Specifically, before the step of opening the two-color injection molding machine to open the mold and obtain the finished reflector, the method further includes:

[0079] S300. Cool the mold until the preset cooling time is met.

[0080] After the two-color injection molding machine completes the injection molding, the mold needs to be cooled down to shorten the cooling time of the product inside the mold.

[0081] Furthermore, the mold is cooled down until a preset cooling time is met, wherein the preset cooling time ranges from 15 seconds to 30 seconds.

[0082] Furthermore, the present invention provides a Mini LED backlight module, the Mini LED backlight module including a central frame and a DBEF, an upper brightness enhancement film, a lower brightness enhancement film, a diffuser plate, a reflector panel, a reflector double-sided adhesive, a Mini LED board, an LED board double-sided adhesive, and a back plate arranged sequentially in the central frame from top to bottom. The reflector panel is formed by a plurality of reflectors 100 arranged at intervals, each of the reflectors including the aforementioned reflectors. The Mini LED board is formed by a plurality of LEDs corresponding to the plurality of reflectors 100. The reflector double-sided adhesive can connect the reflector panel and the Mini LED board, and the LED board double-sided adhesive can connect the Mini LED board and the back plate.

[0083] It should be noted that, in the embodiments of the present invention, the arrangement of the reflector 100 is not limited.

[0084] It is understood that since the reflector adopts all the technical solutions of the above embodiments, the Mini LED backlight module also has the beneficial effects brought about by the technical solutions of the above embodiments, which will not be repeated here.

[0085] The above description is only a preferred embodiment of the present invention and does not limit the patent scope of the present invention. All equivalent structural transformations made under the concept of the present invention using the contents of the present invention specification and drawings, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A method for manufacturing a reflector, the reflector comprising a cup body and a light guide, wherein a reflective surface is provided on the side wall of the inner cavity of the cup body, a through hole communicating with the inner cavity is provided at the bottom of the cup body, the reflective surface is used to uniformly distribute light, the light guide is disposed within the through hole, the light guide is configured as a hemispherical shape and protrudes towards the cup opening of the cup body, and a mounting groove is provided on the side of the light guide facing away from the cup opening of the cup body, the mounting groove being used to mount LED beads, characterized in that... The reflector manufacturing method includes the following steps: The first injection plastic and the second injection plastic are added to the two barrels of the two-color injection molding machine. The two-color injection molding machine is equipped with a mold. The cavity of the mold is divided into a first chamber and a second chamber. The first chamber is connected to the second chamber. The first injection plastic and the second injection plastic are different colors. The first injection plastic and the second injection plastic, which are located in the two barrels, are injected into the first chamber and the second chamber at the same time; The two-color injection molding machine is turned on so that the mold is opened to obtain the finished reflector; The light emitted by the lamp bead can enter the light guide, which is used to even out the light, and then the light passes through the light guide and shines on the reflective surface.

2. The reflector processing method as described in claim 1, characterized in that, The step of adding the first injection plastic and the second injection plastic into the two barrels of the two-color injection molding machine includes: The first injection molding compound and the second injection molding compound are baked to remove moisture, so as to obtain a dry first injection molding compound and a dry second injection molding compound; The dried first injection plastic is mixed with diffusion powder according to a preset ratio; The dried first injection molding compound and the dried second injection molding compound, after being mixed with the diffusion powder, are respectively added to the two barrels of the two-color injection molding machine.

3. The reflector processing method as described in claim 2, characterized in that, The ratio of the diffusion powder to the first injection molding compound is in the range of 0.5% to 3%.

4. The reflector processing method as described in claim 1, characterized in that, In the step of sequentially injecting the first injection plastic and the second injection plastic, which are located in two barrels, into the first chamber and the second chamber, the first injection plastic forms the cup body and the second injection plastic forms the light guide. The step of sequentially injecting the first injection plastic and the second injection plastic, which are located in two barrels, into the first chamber and the second chamber includes: The mold, the hot runner of the two-color injection molding machine, and the barrel of the two-color injection molding machine are heated so that the mold, the hot runner of the two-color injection molding machine, and the barrel of the two-color injection molding machine all reach their respective preset temperatures. The first injection plastic and the second injection plastic are heated to a molten state; The first injection plastic in its molten state is injected into the first cavity; The second injection plastic in its molten state is injected into the second cavity.

5. The reflector processing method as described in claim 4, characterized in that, In the step of heating the mold, the hot runner of the two-color injection molding machine, and the barrel of the two-color injection molding machine so that the mold, the hot runner of the two-color injection molding machine, and the barrel of the two-color injection molding machine all reach their respective preset temperatures, The preset temperature range of the mold is 100℃~120℃; The preset temperature range of the hot runner of the two-color injection molding machine is 300℃~315℃; The preset temperature range of the barrel of the two-color injection molding machine is 240℃~315℃.

6. The reflector processing method as described in claim 1, characterized in that, Before the step of opening the two-color injection molding machine to open the mold and obtain the finished reflector, the following steps are also included: Cool the mold until the preset cooling time is met.

7. The reflector processing method as described in claim 6, characterized in that, The preset cooling time range is 15 seconds to 30 seconds.

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