Lamp panel, LED display device and preparation method of lamp panel

Abstract

The invention provides a lamp panel, an LED display device and a preparation method of the lamp panel. The lamp beads are arranged on the front side of the substrate; the first integrated lens layer is arranged on the front side of the substrate, the front side face of the first integrated lens layer is of a first continuous wave curved surface structure, and the first integrated lens layer can make light beams emitted by the lamp beads spread in the direction perpendicular to the substrate when penetrating through the first continuous wave curved surface structure; and the second integrated lens layer is arranged on the front side of the first integrated lens layer, the front side face of the second integrated lens layer is of a second continuous wave curved surface structure, and the second integrated lens layer can make the light beams penetrating through the first integrated lens layer deflect when penetrating through the second continuous wave curved surface structure. According to the technical scheme, the problem that the display effect of a lamp panel in the related technology is poor can be effectively solved.

Description

Technical Field

[0001] The present invention relates to the technical field of LED displays, and more particularly, to a light board, an LED display device, and a method for manufacturing a light board. Background Art

[0002] Autostereoscopic 3D technology (also known as free-view 3D or glasses-free 3D) is a 3D display technology that allows users to view 3D images without wearing any special glasses. This technology utilizes the principle of human binocular stereoscopic vision. By providing different images to the left and right eyes respectively, it simulates the different depths and spatial positions of objects in the real world, thus generating a sense of stereoscopy in the brain.

[0003] Currently, in the related art, technologies for providing autostereoscopic 3D effects usually include the parallax barrier technology. Among them, the linear parallax barrier is one type of the parallax barrier technology. In practical applications, the linear parallax barrier is more common because of its simple design and easy manufacturing. The linear parallax barrier is composed of a series of parallel linear stripes, which can be solid or composed of alternating transparent and opaque parts. This method controls different light beams from entering the left or right eye by blocking some light beams, thereby forming a 3D effect. However, using this method limits the viewing angle of the audience, especially limiting the image resolution and brightness (since some light beams are blocked, resulting in a large light loss, meaning that the overall image quality may be reduced and the brightness will also decrease). Summary of the Invention

[0004] The main objective of the present invention is to provide a light board, an LED display device, and a method for manufacturing a light board to solve the problem of poor display effect of the light board in the related art.

[0005] To achieve the above objective, according to one aspect of the present invention, a light board is provided, including: a substrate; a plurality of lamp beads disposed on the front side of the substrate; a first integral lens layer disposed on the front side of the substrate, the front surface of the first integral lens layer being a first continuous wavy surface structure, and the first integral lens layer being capable of causing the light beams emitted by the lamp beads to propagate in a direction perpendicular to the substrate when passing through the first continuous wavy surface structure; a second integral lens layer disposed on the front side of the first integral lens layer, the front surface of the second integral lens layer being a second continuous wavy surface structure, and the second integral lens layer being capable of causing the light beams passing through the first integral lens layer to deflect when passing through the second continuous wavy surface structure.

[0006] Further, the first continuous wavy surface structure has a plurality of wave trough segments, and the plurality of wave trough segments are arranged in one-to-one correspondence with the plurality of lamp beads.

[0007] Further, the second continuous wavy surface structure has transition segments located between adjacent wave crests and wave troughs. There are multiple transition segments, and the multiple transition segments are arranged in one-to-one correspondence with multiple lamp beads.

[0008] Further, the center line of the lamp bead passes through the middle of the corresponding wave trough segment; and / or, the center line of the lamp bead passes through the middle of the corresponding transition segment.

[0009] Further, the first continuous wavy surface structure extends along a first sine function; and / or, the second continuous wavy surface structure extends along a second sine function.

[0010] Further, the distance between the wave crest and the wave trough of the first continuous wavy surface structure is greater than or equal to 0.2 mm and less than or equal to 0.5 mm; and / or, the distance between the wave crest and the wave trough of the second continuous wavy surface structure is greater than or equal to 0.2 mm and less than or equal to 0.5 mm.

[0011] Further, a plurality of lamp beads are arranged in an array, and the lamp board further includes a light-absorbing layer, and the light-absorbing layer is arranged on the front side of the substrate and located between the plurality of lamp beads.

[0012] Further, the ratio of the thickness of the light-absorbing layer to the thickness of the lamp bead is greater than or equal to 2:15 and less than or equal to 1:3; and / or, the material of the light-absorbing layer is black optical resin or black nanomaterial.

[0013] According to another aspect of the present invention, there is provided an LED display device, including a lamp board, and the lamp board is the above-mentioned lamp board.

[0014] According to another aspect of the present invention, there is provided a method for preparing a lamp board for preparing the above-mentioned lamp board. The preparation method includes: connecting lamp beads to the front side of the substrate; arranging a first liquid glue on the front side of the substrate, and after the first liquid glue is cured to form a first continuous wavy surface structure, a first integral lens layer is obtained; arranging a second liquid glue on the front side of the first integral lens layer, and after the second liquid glue is cured to form a second continuous wavy surface structure, a second integral lens layer is obtained.

[0015] Further, the step of arranging the first liquid glue on the front side of the substrate and obtaining the first integral lens layer after the first liquid glue is cured to form a first continuous wavy surface structure includes: using a dynamic mask to project ultraviolet light with gradient energy onto the first liquid glue, so that part of the first liquid glue is cured to form the wave crest segment of the first continuous wavy surface structure; performing gradient heating and microwave curing on the uncured part of the first liquid glue, so that the uncured part of the first liquid glue is cured to form the wave trough segment of the first continuous wavy surface structure.

[0016] Further, the step of gradient heating and microwave curing the uncured part of the first liquid glue to cure the uncured part of the first liquid glue and form the trough section of the first continuous wave surface structure includes: controlling the substrate to rotate around the center line perpendicular to the substrate at a preset rotation speed, where the preset rotation speed is greater than or equal to 50 RPM and less than or equal to 100 RPM.

[0017] Applying the technical solution of the present invention, the substrate provides an installation basis for other structures of the lamp board. A plurality of lamp beads are arranged on the front side of the substrate, and the lamp beads can emit light to realize the display function of the lamp board. The first integrated lens layer is arranged on the front side of the substrate, and the front side surface of the first integrated lens layer is a first continuous wave surface structure. The first integrated lens layer can make the light beam emitted by the lamp bead propagate in the direction perpendicular to the substrate when passing through the first continuous wave surface structure, so that the light beam emitted by the lamp bead can be collimated, preparing for modulating the propagation direction of the subsequent light beam. Compared with the parallax barrier solution in the related art, the lamp board of the present application uses the first integrated lens layer to collimate the light beam. On the one hand, it can avoid the light loss caused by the occlusion of the non-directionally propagating light beam, and on the other hand, it can avoid the non-directionally propagating light beam emitted by a certain lamp bead from affecting the light beam emitted by other lamp beads, thus ensuring the light beam energy output by the lamp board and ensuring the display effect and brightness of the lamp board. The second integrated lens layer is arranged on the front side of the first integrated lens layer, and the front side surface of the second integrated lens layer is a second continuous wave surface structure. The second integrated lens layer can make the light beam passing through the first integrated lens layer deflect when passing through the second continuous wave surface structure. By modulating the collimated light beam, the light beam can propagate in the designed direction, so that different light beams can form a viewing area seen by the left eye or the right eye, thus realizing the naked-eye 3D display effect. Compared with the parallax barrier or multi-faceted prism solution in the related art, the second continuous wave surface structure of this embodiment can distribute the light beam more smoothly due to its smooth curve form, rather than generating sudden changes at fixed intervals or junctions, because the smooth curve form can simulate the fluctuation and distortion of the light beam in the real world, thus improving the display effect uniformity and display comfort. Therefore, the technical solution of the present application can effectively solve the problem of poor display effect of the lamp board in the related art. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The specification drawings constituting a part of the present application are used to provide a further understanding of the present invention. The schematic embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0019] Figure 1 Shows a cross-sectional schematic view of an embodiment of a lamp board according to the present invention;

[0020] Figure 2 Shows Figure 1An enlarged schematic diagram of a partial structure of a lamp board;

[0021] Figure 3 Shows Figure 1 A schematic diagram of the principle of light deflection of a lamp board;

[0022] Figure 4 Shows a flowchart of an embodiment of a method for preparing a lamp board according to the present invention;

[0023] Figure 5 Shows Figure 4 An alternative process of the preparation method; Figure 1 ;

[0024] Figure 6 Shows Figure 4 An alternative process of the preparation method; Figure 2 .

[0025] Among them, the above-mentioned drawings include the following reference numerals:

[0026] 10. Substrate;

[0027] 20. Lamp beads;

[0028] 30. First integral lens layer; 31. First continuous wave surface structure; 311. Wave trough section;

[0029] 40. Second integral lens layer; 41. Second continuous wave surface structure; 411. Transition section;

[0030] 50. Light absorption layer. Detailed implementation manners

[0031] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and in no way constitutes a limitation on the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts belong to the scope of protection of the present invention.

[0032] Such as Figures 1 to 3As shown in the figure, the present application provides a light board. An embodiment of the light board of the present application includes: a substrate 10, light beads 20, a first integral lens layer 30, and a second integral lens layer 40; a plurality of light beads 20 are arranged on the front side of the substrate 10; the first integral lens layer 30 is arranged on the front side of the substrate 10, and the front surface of the first integral lens layer 30 is a first continuous wave surface structure 31. The first integral lens layer 30 can enable the light beam emitted by the light bead 20 to propagate in a direction perpendicular to the substrate 10 when passing through the first continuous wave surface structure 31; the second integral lens layer 40 is arranged on the front side of the first integral lens layer 30, and the front surface of the second integral lens layer 40 is a second continuous wave surface structure 41. The second integral lens layer 40 can cause the light beam passing through the first integral lens layer 30 to deflect when passing through the second continuous wave surface structure 41.

[0033] Applying the technical solution of this embodiment, the substrate 10 provides an installation basis for other structures of the light board. A plurality of light beads 20 are arranged on the front side of the substrate 10, and the light beads 20 can emit light to realize the display function of the light board. The first integral lens layer 30 is arranged on the front side of the substrate 10, and the front surface of the first integral lens layer 30 is a first continuous wave surface structure 31. The first integral lens layer 30 can enable the light beam emitted by the light bead 20 to propagate in a direction perpendicular to the substrate 10 when passing through the first continuous wave surface structure 31, so that the light beam emitted by the light bead 20 can be collimated, preparing for modulating the propagation direction of the subsequent light beam. Compared with the parallax barrier solution in the related art, the light board of this embodiment uses the first integral lens layer 30 to collimate the light beam. On the one hand, it can avoid light loss caused by the occlusion of the non-directionally propagating light beam, and on the other hand, it can prevent the non-directionally propagating light beam emitted by a certain light bead from affecting the light beam emitted by other light beads, thereby ensuring the light beam energy output by the light board and ensuring the display effect and brightness of the light board. The second integral lens layer 40 is arranged on the front side of the first integral lens layer 30, and the front surface of the second integral lens layer 40 is a second continuous wave surface structure 41. The second integral lens layer 40 can cause the light beam passing through the first integral lens layer 30 to deflect when passing through the second continuous wave surface structure 41. By modulating the collimated light beam, the light beam can be made to propagate in the designed direction, so that different light beams can form a viewing area that can be seen by the left eye or the right eye, thereby realizing the naked-eye 3D display effect. Compared with the parallax barrier or multi-faceted prism solution in the related art, the second continuous wave surface structure 41 of this embodiment can distribute the light beam more smoothly due to its smooth curve form, rather than generating sudden changes at fixed intervals or junctions, because the smooth curve form can simulate the fluctuations and distortions of the light beam in the real world, thereby improving the display effect uniformity and display comfort. Therefore, the technical solution of this embodiment can effectively solve the problem of poor display effect of the light board in the related art.

[0034] It should be noted that the "first integrated lens layer 30" and the "second integrated lens layer 40" refer to: these two integrated lens layers are integrally formed, rather than formed by splicing multiple single-lens structures. The "first continuous wave surface structure 31" and the "second continuous wave surface structure 41" refer to: the integrated lens layer has a stepped thickness so that the front side of the integrated lens layer forms a continuous wave surface structure. The continuous wave surface structure has alternately arranged wave peaks protruding forward and wave valleys protruding backward, and the adjacent wave peaks and wave valleys are smoothly connected. There is no part parallel to the substrate 10 in the connection part between the wave peaks and wave valleys. For the first continuous wave surface structure 31, with such a setting, most of the light beams can be collimated. For the second continuous wave surface structure 41, the uniformity of the light beam distribution is ensured and mutations are avoided.

[0035] It should be noted that the expression "mutations occur at fixed intervals or junctions" refers to: for a parallax barrier, it is blocked by alternately spaced occlusion bars, and there are light-transmitting gaps between adjacent occlusion bars. The light-transmitting gaps can transmit light while the occlusion bars can block light. There is no transition between the light-transmitting gaps and the adjacent occlusion bars, so mutations are likely to occur. Similarly, for a multi-faceted prism, the multi-faceted prism has multiple straight faces, and the adjacent straight faces are arranged at an angle. The junction between the adjacent straight faces is the edge of the multi-faceted prism, and light is likely to mutate here. The expression "a smooth curve form can simulate the fluctuations and distortions of light beams in the real world" refers to: in the real world, the light beams received by people's eyes are all obtained through diffuse reflection and various refractions by the complex surfaces of objects. The refraction formed by a smooth curve can be closer to the light beams propagated through diffuse reflection and various refractions by these complex surfaces, and is closer to the state of the real world than the direct refraction of light beams through straight faces or edge structures.

[0036] As Figures 1 to 3 shown, the first continuous wave surface structure 31 has multiple wave valley segments 311, and the multiple wave valley segments 311 are arranged in one-to-one correspondence with the multiple lamp beads 20. Specifically, the wave valley segments 311 are arranged corresponding to the lamp beads 20, so that most of the light beams emitted by the lamp beads 20 can be collimated by the first continuous wave surface structure 31, so that most of the light beams can propagate in a direction perpendicular to the substrate 10, so that most of the light beams can be modulated by the second integrated lens layer 40 and undergo corresponding deflections, ensuring that most of the light beams can be deflected into the designed viewing area and ensuring the display effect of the lamp board. More specifically, the center line of the lamp bead 20 passes through the middle of the corresponding wave valley segment 311, further ensuring that most of the light beams can be collimated.

[0037] As Figures 1 to 3As shown, the second continuous wavy surface structure 41 has a transition section 411 located between adjacent wave crests and wave troughs. There are multiple transition sections 411, and the multiple transition sections 411 are arranged in one-to-one correspondence with the multiple lamp beads 20. More specifically, the center line of the lamp bead 20 passes through the middle of the corresponding transition section 411. Compared with the wave crest and the wave trough, the transition section 411 has a curve state with a consistent direction and smooth change. For example, the direction of the transition section 411 can extend from back to front or from front to back as a whole (in contrast, both the wave crest and the wave trough have parts extending from back to front and parts extending from front to back). In this way, the collimated light beam can be modulated and deflected by the transition section 411 with the same direction, ensuring that most of the light beams can be deflected ideally (for example, the light beam emitted by a certain lamp bead is expected to be deflected by the surface extending from back to front according to the design after being collimated, and the transition section can meet the requirements of such a surface, but both the wave crest and the wave trough have parts of the surface that do not meet such requirements, resulting in the loss of the light beam deflected by the surface that does not meet the requirements).

[0038] As Figures 1 to 3 shown, the first continuous wavy surface structure 31 extends along the first sine function; the second continuous wavy surface structure 41 extends along the second sine function. Using the sine function can simplify the design and manufacturing process of the front side of the integrated lens layer because the periodicity and regularity of the sine function make the shape of the front side of the integrated lens layer easier to control and predict. In addition, in this embodiment, the distance between the wave crest and the wave trough of the first continuous wavy surface structure 31 is greater than or equal to 0.2 mm and less than or equal to 0.5 mm; the distance between the wave crest and the wave trough of the second continuous wavy surface structure 41 is greater than or equal to 0.2 mm and less than or equal to 0.5 mm. Specifically, the distance between the wave crest and the wave trough of the first continuous wavy surface structure 31 can be 0.2 mm, 0.25 mm, 0.3 mm, 0.38 mm or 0.5 mm, and the distance between the wave crest and the wave trough of the second continuous wavy surface structure 41 can be 0.2 mm, 0.25 mm, 0.3 mm, 0.38 mm or 0.5 mm. It should be noted that both the first continuous wavy surface structure 31 and the second continuous wavy surface structure 41 have wave crests and wave troughs. The wave crest and the wave trough are the highest and lowest points of the continuous wavy surface structure respectively. The wave band near the wave crest is the wave crest section, and the wave band near the wave trough is the wave trough section.

[0039] As Figures 1 to 3 shown, multiple lamp beads 20 are arranged in an array, and the lamp board further includes a light absorbing layer 50. The light absorbing layer 50 is arranged on the front side of the substrate 10 and located between the multiple lamp beads 20. Specifically, the multiple lamp beads 20 are in Figure 2A row of lamp beads is formed in the direction perpendicular to the paper surface. For the integrated lens layer, in the direction perpendicular to the paper surface, the height of the cross-section of the integrated lens layer is consistent. Since the light emitted by the lamp beads 20 is non-directional, a small part of the light will directly propagate to the substrate 10 and be reflected by the substrate 10. This part of the light can be absorbed by the light-absorbing layer 50, thereby avoiding the propagation path of the light reflected by the substrate 10 not conforming to the designed direction.

[0040] In this embodiment, the ratio of the thickness of the light-absorbing layer 50 to the thickness of the lamp beads 20 is greater than or equal to 2:15 and less than or equal to 1:3. Specifically, for the light-absorbing layer 50 satisfying the above relationship, on the one hand, it minimizes the blockage of the lamp beads 20, thereby ensuring less light loss, and on the other hand, it ensures that the light-absorbing layer 50 can absorb the light beams that may be reflected by the substrate 10. The ratio of the thickness of the light-absorbing layer 50 to the thickness of the lamp beads 20 can be 2:15, 1:6, 3:15, 4:15 or 1:3.

[0041] In this embodiment, the material of the light-absorbing layer 50 is black optical resin or black nanomaterial. Black optical resin is a special photosensitive resin material with high light absorption rate and low reflectivity. Black nanomaterials include carbon nanotubes, carbon nanospheres, titanium nanoxide, copper nanometer, etc.

[0042] Taking a small-pitch direct-view LED lamp board with a lamp bead pitch of 1.25 mm and a size of 4800 mm * 2700 mm as an example (the following calculations are all for obtaining a comfortable and good viewing experience):

[0043] d1 = 1.25 mm; d2 = 1.25 mm (if d2 is too large, it will cause light crosstalk between adjacent lamp beads, affecting the 3D effect); d3 = 65 mm (the vast majority); d6 = 4800 mm; d7 = 2700 mm; d4 = 1.5 * (sqrt{4800^2 + 2700^2}); d5 = (5 - 8) * (sqrt{4800^2 + 2700^2});

[0044] Among them, d1 is the distance P between lamp beads; d2 = the distance between adjacent wave crests and wave troughs in the front-back direction; d3 = the binocular distance; d4 = the minimum distance of the user from the lamp board; d5 = the maximum distance of the user from the lamp board; d6 = the length of the lamp board, d7 = the width of the lamp board.

[0045] In addition, the present application also provides an LED display device. The LED display device of the present application includes a lamp board, wherein the lamp board is the above-mentioned lamp board. The above-mentioned lamp board can effectively solve the problem of poor display effect of the lamp board in the related art, and the LED display device with the above-mentioned lamp board also has the above-mentioned advantages.

[0046] Such as Figures 4 to 6As shown in the figure, the present application also provides a method for manufacturing a lamp board. The manufacturing method of the present application is used to manufacture a lamp board, where the lamp board is the above-mentioned lamp board. The above-mentioned lamp board can effectively solve the problem of poor display effect of the lamp board in the related art, and the manufacturing method for manufacturing the above-mentioned lamp board also has the above-mentioned advantages.

[0047] Specifically, as Figure 4 shown, the manufacturing method includes: Step S10: Connect the lamp beads 20 to the front side of the substrate 10; Step S20: Set the first liquid glue on the front side of the substrate 10. After the first liquid glue cures and forms the first continuous wave surface structure 31, the first integrated lens layer 30 is obtained; Step S30: Set the second liquid glue on the front side of the first integrated lens layer 30. After the second liquid glue cures and forms the second continuous wave surface structure 41, the second integrated lens layer 40 is obtained. Specifically, by stacking the lamp beads, the first integrated lens layer, and the second integrated lens layer in this way, it is easy to obtain the lamp board of the present application, which has the advantages of simple processing and easy implementation.

[0048] As Figure 5 shown, Step S20: Setting the first liquid glue on the front side of the substrate 10, and after the first liquid glue cures and forms the first continuous wave surface structure 31 to obtain the first integrated lens layer 30 includes: Step S21: Using a dynamic mask to project ultraviolet light with gradient energy onto the first liquid glue, so that part of the first liquid glue cures and forms the peak section of the first continuous wave surface structure 31; Step S22: Gradient heating and microwave curing of the uncured part of the first liquid glue, so that the uncured part of the first liquid glue cures and forms the trough section 311 of the first continuous wave surface structure 31. Specifically, the dynamic mask enables the first liquid glue to receive ultraviolet light with different irradiation energies. The position with higher irradiation energy cures faster, and from high to low irradiation energy, the curing degree also decreases step by step, forming a wave peak in terms of shape structure; under the influence of the thermocapillary effect (there is a temperature gradient during the heating process, the surface tension changes with temperature, the surface tension in the high-temperature area is low, and the surface tension in the low-temperature area is high, causing the first liquid glue to flow from the high-temperature area to the low-temperature area), the uncured part of the first liquid glue forms a trough, and then it is cured by microwave.

[0049] As Figure 6As shown, step S22: Gradient heating and microwave curing are performed on the uncured part of the first liquid glue, so that the uncured part of the first liquid glue is cured and forms the trough section 311 of the first continuous wave surface structure 31, including: step S221: Control the substrate 10 to rotate around the center line perpendicular to the substrate 10 at a preset speed, where the preset speed is greater than or equal to 50 RPM and less than or equal to 100 RPM. By using the above steps, rotating the substrate 10 has many advantages: 1. During the heating process, each area of the substrate 10 is periodically exposed to different radiation intensity areas of the heater, achieving dynamic thermal equilibrium (for example, using an IR heater, which usually has uneven radiation intensity distribution, strong radiation in the center and weak radiation at the edge); 2. Avoid film stress cracks or crystal defects caused by local overheating; 3. Release the thermal stress caused by the difference in thermal expansion coefficients between the substrate 10 (such as Si, sapphire) and the deposited material (such as GaN, metal); 4. The centrifugal force generated by rotation can promote the flow of the first liquid glue, relieve stress concentration, reduce the risk of warping, ensure the smooth curve of the first integrated lens layer 30, and avoid the deformation of its edge shape. The formation methods of the second continuous wave surface structure 41 and the second integrated lens layer 40 are similar to those of the first continuous wave surface structure 31 and the first integrated lens layer 30, which will not be elaborated here and are mentioned in the specific preparation method.

[0050] In addition, in other embodiments, the first continuous wave surface structure, the first integrated lens layer, the second continuous wave surface structure, and the second integrated lens layer can also be prepared by using a die pressing method. Specifically, taking the first continuous wave surface structure and the first integrated lens layer as an example, a layer of transparent epoxy resin glue is encapsulated on the PCB substrate with the lamp beads installed. With the help of a die (a die with a lens layer-like structure), press down and hold the position, then lock the die, heat and cure at 160 °C, and after curing, remove the die to form the first continuous wave surface structure and the first integrated lens layer (the composition of this layer of transparent epoxy resin glue is divided into component A (resin) and component B (hardener), where component B is an anhydride hardener and the curing temperature is 160 °C).

[0051] The specific preparation method of this embodiment is as follows:

[0052] 1. The lamp beads are soldered to the PCB substrate through a soldering process (there are corresponding copper pad arrays on the PCB substrate). When soldering the lamp beads, there is no need to distinguish between left (L) / right (R) lamp beads. Each lamp bead is physically the same, and their functions and structures are not specifically distinguished for left-eye or right-eye images. The 3D effect is achieved through the control of the displayed content, rather than through the differences in the lamp beads themselves;

[0053] 2. Then, the PCB substrate completed in the previous step is baked in the furnace to make the combination of the lamp beads and the PCB substrate stable;

[0054] 3. Clean the front side of the PCB substrate and fill the gaps between the lamp beads with light-absorbing material to form a light-absorbing layer. The thickness of this layer is about 1 / 6 of the height of the lamp bead. Since the first integrated lens layer will be further encapsulated on the front side of the light-absorbing layer, the flatness requirement for the light-absorbing layer is relatively low;

[0055] 4. Spray a layer of low-viscosity UV glue (i.e., the first liquid glue) on the front side of the PCB substrate with the light-absorbing layer cured. The purpose is to form the first integrated lens layer and ensure its uniformity, providing an ideal substrate for dynamic mask projection. Then, move the PCB substrate into the UV curing area and use the UV + dynamic mask method to borrow the DMD to project a sine light intensity distribution (λ = 500μm, A = 50μm, UV intensity 80mW / cm 2 ), and cure for 30 seconds;

[0056] 5. Move the PCB substrate that has completed the previous step into an IR gradient heating device. Heating conditions: the heating temperature is 60 → 80°C from 0 to 30 seconds, 80 → 120°C from 30 to 60 seconds, and the turntable speed is 50 RPM;

[0057] 6. Move the PCB substrate that has completed the previous step into a PTFE tray and then into an industrial microwave oven with a frequency of 2.45 GHz and a power of 300 W for irradiation treatment for 90 seconds;

[0058] 7. Check the curing effect of the first integrated lens layer by FTIR verification (the change in the content of relevant components, such as the C = C double bond peak, 1630cm -1 , and after curing, the peak area of C = C decreases by 98%, confirming complete curing).

[0059] 8. Still using the UV + dynamic mask method, the DMD digital projection changes the corresponding W (angular velocity) curve mask through phase shift, with a UV intensity of 60mW / cm 2 , and cure for 40 seconds to form the decreasing peak-to-peak region of the second integrated lens layer (covering the peak - valley - peak region of the first integrated lens layer);

[0060] 9. Move the PCB substrate that has completed the previous step into an IR gradient heating device; heating conditions: the heating temperature is 60 → 80°C from 0 to 30 seconds, 80 → 120°C from 30 to 60 seconds, and the turntable speed is 50 RPM; form the increasing peak-to-peak region of the second integrated lens layer (covering the valley - peak - valley region of the first integrated lens layer);

[0061] 10. Move the PCB substrate that has completed the previous step into a PTFE tray and then into an industrial microwave oven with a frequency of 2.45 GHz and a power of 300 W for irradiation treatment for 90 seconds to selectively cure the uncured area;

[0062] 11. Place the PCB substrate that has completed the above steps into a greenhouse at 60 - 80 °C to release the stress of the module, and maximize the avoidance of module warping.

[0063] The application of the above-mentioned light board has the following advantages:

[0064] 1. Improve the uniformity of inspection effect and improve visual comfort: Because the front side of the integrated lens layer is similar to a sine curve, the change of such a sine curve can distribute light more smoothly, rather than generating sudden changes at fixed intervals of a straight barrier;

[0065] 2. Achieve a more delicate 3D effect: The 3D effect can be optimized by adjusting the curve-related parameters;

[0066] 3. By means of multi-field collaborative curing of the glue layer, with its efficient processing method and accurate structure formation method, reduce the mass production cost by more than 80% (compared with the conventional encapsulation module method of the same two-component epoxy resin glue);

[0067] 4. Eliminate the moiré pattern of LED display: Due to its non-linear characteristics, it can improve the comfort of users.

[0068] In the description of the present invention, it should be understood that "a plurality of" means the number is two or more than two. The orientation or positional relationship indicated by orientation words such as "front, back, up, down, left, right", "horizontal, vertical, perpendicular, horizontal" and "top, bottom" is usually based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present invention and simplifying the description. Without contrary instructions, these orientation words do not indicate and imply that the device or component referred to must have a specific orientation or be constructed and operated in a specific orientation, so it cannot be understood as a limitation on the protection scope of the present invention; the orientation words "inside, outside" refer to the inside and outside relative to the contour of each component itself.

[0069] In addition, it should be noted that the use of words such as "first", "second" to limit components is only for the convenience of distinguishing the corresponding components. Without additional statements, the above words have no special meaning, so it cannot be understood as a limitation on the protection scope of the present invention.

[0070] The above are only the preferred embodiments of the present invention and are not used to limit the present invention. For those skilled in the art, the present invention can have various changes and modifications. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A light board, characterized in that: include: base(10); A plurality of lamp beads (20) are arranged on the front side of the substrate (10); A first integrated lens layer (30) is arranged on the front side of the substrate (10); the front side surface of the first integrated lens layer (30) is a first continuous wavy curved surface structure (31); the first integrated lens layer (30) enables the light beam emitted by the lamp bead (20) to propagate in a direction perpendicular to the substrate (10) when passing through the first continuous wavy curved surface structure (31); A second integrated lens layer (40) is arranged on the front side of the first integrated lens layer (30); the front side surface of the second integrated lens layer (40) is a second continuous wavy curved surface structure (41); the second integrated lens layer (40) can cause a light beam passing through the first integrated lens layer (30) to be deflected when passing through the second continuous wavy curved surface structure (41).

2. The light board according to claim 1, characterized in that: The first continuous wave curved surface structure (31) has a plurality of trough sections (311), and the plurality of trough sections (311) are arranged in a one-to-one correspondence with the plurality of lamp beads (20).

3. The light board according to claim 2, characterized in that: The second continuous wave curved surface structure (41) has a transition section (411) located between adjacent wave crests and wave troughs, and there are a plurality of transition sections (411), and the plurality of transition sections (411) are arranged in a one-to-one correspondence with the plurality of lamp beads (20).

4. The light board according to claim 3, characterized in that: The center line of the lamp bead (20) passes through the middle of the corresponding trough section (311); and / or the center line of the lamp bead (20) passes through the middle of the corresponding transition section (411).

5. The light board according to any one of claims 1 to 4, characterized in that: The first continuous wavy curved surface structure (31) extends along a first sinusoidal function; and / or the second continuous wavy curved surface structure (41) extends along a second sinusoidal function.

6. The light board according to any one of claims 1 to 4, characterized in that: The distance between the crest and the trough of the first continuous wavy curved surface structure (31) is greater than or equal to 0.2 mm and less than or equal to 0.5 mm; and / or, The distance between the wave crest and the wave trough of the second continuous wave curved surface structure (41) is greater than or equal to 0.2 mm and less than or equal to 0.5 mm.

7. The light board according to any one of claims 1 to 4, characterized in that: A plurality of the lamp beads (20) are arranged in an array, and the lamp board further comprises a light absorbing layer (50), wherein the light absorbing layer (50) is arranged on the front side of the substrate (10) and is located between the plurality of the lamp beads (20).

8. The light board according to claim 7, characterized in that: The ratio of the thickness of the light absorbing layer (50) to the thickness of the lamp bead (20) is greater than or equal to 2:15 and less than or equal to 1:3; and / or, The material of the light absorbing layer (50) is black optical resin or black nano material.

9. An LED display device, comprising a light board, characterized in that: The light board is the light board according to any one of claims 1 to 8.

10. A method for preparing a light board, used for preparing the light board according to any one of claims 1 to 8, characterized in that: The preparation method comprises: Connecting the lamp bead (20) to the front side of the substrate (10); Disposing a first liquid glue on the front side of the substrate (10), and after the first liquid glue is cured and forms a first continuous wavy curved surface structure (31), a first integrated lens layer (30) is obtained; The second liquid glue is disposed on the front side of the first integrated lens layer (30), and the second liquid glue is cured to form a second continuous wavy curved surface structure (41) to obtain a second integrated lens layer (40).

11. The preparation method according to claim 10, characterized in that: The steps of disposing a first liquid glue on the front side of the substrate (10), and obtaining a first integrated lens layer (30) after the first liquid glue is solidified and forms a first continuous wavy curved surface structure (31) comprises: Using a dynamic mask to project ultraviolet light with gradient energy onto the first liquid glue, so that a portion of the first liquid glue is solidified and forms a wave crest section of a first continuous wavy curved surface structure (31); The uncured portion of the first liquid glue is subjected to gradient heating and microwave curing, so that the uncured portion of the first liquid glue is cured and forms a trough section (311) of the first continuous wavy curved surface structure (31).

12. The preparation method according to claim 11, characterized in that: The step of performing gradient heating and microwave curing on the uncured portion of the first liquid glue so that the uncured portion of the first liquid glue is cured and forms a trough section (311) of the first continuous wavy curved surface structure (31) comprises: The substrate (10) is controlled to rotate at a preset rotation speed around a center line perpendicular to the substrate (10), wherein the preset rotation speed is greater than or equal to 50 RPM and less than or equal to 100 RPM.

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