Foaming diffusion plate and manufacturing method thereof

Abstract

The invention relates to a foaming diffusion plate and a manufacturing method thereof, the foaming diffusion plate comprises a foaming core layer, a nano toner is dispersed in the foaming core layer, and the nano toner is composed of the following nano oxides in percentage by mass: 42.3%-43.3% of nano Na2O, 9.1%-9.6% of nano MgO, 3.3%-3.5% of nano Al2O3, 18.0%-18.5% of nano SiO2, 0.12%-0.20% of nano K2O, 21.5%-21.9% of nano CaO, 1.2%-1.3% of nano Fe2O3, 1.8%-2.1% of nano SO3 and 1.0%-1.1% of nano Cr2O3.

Description

Technical Field

[0001] This application relates to the field of optical sheet technology, and in particular to a foamed diffuser plate and its manufacturing method. Background Technology

[0002] Quantum dot diffusers, as a cutting-edge material integrating nanotechnology and optical design, have garnered significant attention in display backlight modules in recent years. Their working principle is as follows: under the excitation of a blue LED, quantum dots distributed within the substrate convert a portion of the blue light into high-purity red and green light, which then mixes with the remaining transmitted blue light to form white light. Combined with the scattering effect of the diffused particles, this achieves uniform control of the emitted light. This structure can significantly improve the color performance of liquid crystal displays. Through the narrow-band luminescence characteristics of quantum dots, the color gamut of the backlight spectrum can be effectively expanded, enhancing color saturation and thus improving the visual vividness and fidelity of the image.

[0003] However, quantum dot diffusers still face multiple bottlenecks in practical applications and production: First, quantum dot materials are extremely sensitive to oxygen, moisture, and high temperatures, and are prone to oxidation and thermal quenching, leading to a decrease in luminous efficiency; second, during the preparation of diffusers, quantum dots are difficult to disperse uniformly in polymer substrates, and their performance is prone to degradation during high-temperature extrusion or injection molding, affecting optical consistency and product yield; third, quantum dot raw materials are expensive, and mainstream cadmium (Cd) systems are strictly restricted by environmental regulations such as the EU RoHS, making it difficult to meet the global market's compliance requirements for green manufacturing.

[0004] Therefore, although the current backlight modules using ordinary diffusers are cheaper, their color gamut can usually only reach about 70%~80% NTSC. While quantum dot solutions can improve the color gamut to 100% NTSC or even higher, they have significant shortcomings in terms of stability, process compatibility, environmental compliance and cost control.

[0005] Against this backdrop, developing a novel spectral conversion diffusion plate that combines high color gamut, high stability, process-friendly design, and environmental compliance has become an important direction that urgently needs to be explored in the field of display backlight materials. Summary of the Invention

[0006] In view of this, this application provides a foamed diffusion plate and a method for manufacturing the same.

[0007] In a first aspect, a foamed diffusion plate is proposed, comprising a foamed core layer in which nano-color enhancers are dispersed. The nano-color enhancers are composed of the following nano-oxides by mass percentage: 42.3%~43.3% nano-Na2O, 9.1%~9.6% nano-MgO, 3.3%~3.5% nano-Al2O3, 18.0%~18.5% nano-SiO2, 0.12%~0.20% nano-K2O, 21.5%~21.9% nano-CaO, 1.2%~1.3% nano-Fe2O3, 1.8%~2.1% nano-SO3, and 1.0%~1.1% nano-Cr2O3.

[0008] In some possible implementations, the nano-color enhancer is present in the foamed core layer at a mass percentage of 0.5% to 1.5%.

[0009] In some possible implementations, the mass percentage of the nano-color enhancer in the foamed core layer is negatively correlated with the thickness of the foamed core layer.

[0010] In some possible implementations, when the thickness of the foamed core layer is 1 to 3 mm, the mass percentage of the nano-color enhancer in the foamed core layer is 0.5% to 1.5%.

[0011] In some possible implementations, the foamed core layer is composed of the following components by weight percentage: 98%-99% optical resin substrate, 0.15%-0.55% foaming agent, and 0.5%-1.5% of the nano-color enhancer.

[0012] In some possible implementations, two protective layers are also included, respectively stacked on opposite sides of the foamed core layer.

[0013] In some possible implementations, the surface of the protective layer on the side away from the foamed core layer has a diffusion microstructure.

[0014] In some possible implementations, the protective layer comprises the following components by weight percentage: 96% to 99% optical resin matrix, 0.2% to 1% light diffusing agent, 0.2% to 1% antioxidant, 0.02% to 1% weather resistant agent, 0% to 0.5% lubricant, and 0.2% to 1% UV resistant agent.

[0015] Secondly, a method for manufacturing a foamed diffusion plate is proposed, including: A mixture comprising an optical resin substrate, a foaming agent, and a nano-color enhancer is provided, wherein the nano-color enhancer comprises 0.5% to 1.5% by mass in the mixture, and the nano-color enhancer comprises the following nano-oxides by mass percentage: 42.3% to 43.3% nano-Na2O, 9.1% to 9.6% nano-MgO, 3.3% to 3.5% nano-Al2O3, 18.0% to 18.5% nano-SiO2, 0.12% to 0.20% nano-K2O, 21.5% to 21.9% nano-CaO, 1.2% to 1.3% nano-Fe2O3, 1.8% to 2.1% nano-SO3, and 1.0% to 1.1% nano-Cr2O3; The mixture is molten to obtain a foamed layer melt; A first protective layer melt and a second protective layer melt are respectively stacked and bonded on opposite sides of the foaming layer melt to obtain a slab; After the slab has solidified, it is cut to obtain the foamed diffusion plate.

[0016] In some possible implementations, providing a mixture comprising an optical resin substrate, a foaming agent, and a nano-color enhancer includes: determining a mass percentage of the nano-color enhancer in the mixture based on the thickness of the foamed core layer in the foamed diffuser to be manufactured, wherein the mass percentage of the nano-color enhancer in the mixture is negatively correlated with the thickness of the foamed core layer; After obtaining the slab and before the slab is cured, the method includes: feeding the slab into a roll forming apparatus to imprint diffusion microstructures on the surface of the first protective layer melt and the surface of the second protective layer melt.

[0017] In some possible implementations, the provision of a mixture comprising an optical resin substrate, a foaming agent, and a nano-color enhancer includes: The mass percentage content of various nano-oxides in the nano-color enhancer is determined based on the RGB peak wavelength of the LED light source in the target liquid crystal display, wherein the target liquid crystal display is configured to be manufactured as a foamed diffusion liquid crystal display.

[0018] According to the foamed diffuser plate proposed in this application, a nano-color enhancer composed of various nano-oxides is dispersed within the foamed core layer, and an unexpected synergistic effect is discovered between the nano-color enhancer and the foamed microstructure at a specific ratio. This not only improves the color gamut but also synergistically enhances light emission uniformity and haze, and effectively controls color shift (maintaining a white appearance). Synergistic optimization of the optical performance of the backlight module is achieved without completely avoiding the use of quantum dot materials containing heavy metals. Data shows that using the foamed diffuser plate of this application can improve the color gamut of a display by at least 4 percentage points compared to a display with a conventional diffuser plate, and also improves brightness uniformity.

[0019] It should be noted that the color gamut performance of a display system is jointly determined by three major material systems: the color filter, the LED phosphor, and the optical diffusion film. Under conditions of synergistic optimization of system optical parameters, liquid crystal displays can achieve color gamut performance approaching that of OLEDs. This application, through material innovation in the aforementioned "optical diffusion film" stage, effectively improves color saturation and light emission uniformity while ensuring environmental friendliness and process reliability, providing a more comprehensive and advantageous diffusion plate solution for liquid crystal display backlight modules. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings of the embodiments will be briefly described below. Obviously, the drawings described below only relate to some embodiments of this application, and are not intended to limit this application.

[0021] Figure 1 This is a schematic diagram of the structure of the foamed diffusion plate provided in the embodiments of this application.

[0022] Figure 2 This is a flowchart of the manufacturing method of the foamed diffusion plate provided in the embodiments of this application.

[0023] Explanation of reference numerals in the attached figures: 10-Foamed diffusion plate; 1-First protective layer; 2-Second protective layer; 3-Foamed core layer. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. Based on the described embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application. It is understood that, without conflict, some technical means of the various embodiments described herein can be substituted for or combined with each other.

[0025] In the description of this application, the terms "first," "second," etc., are used only to distinguish the described objects and have no sequential or technical meaning. Therefore, objects specified with "first," "second," etc., may explicitly or implicitly include one or more of those objects, and, for example, the term "first element" itself does not imply the existence of a "second element," nor does the term "second element" itself imply the existence of a "first element." Furthermore, words such as "a" or "one" do not indicate a quantity limitation, but rather indicate the presence of at least one, while "multiple" indicates not less than two.

[0026] Figure 1 A foamed diffuser plate 10 according to an embodiment of this application is shown, which includes a foamed core layer 3 and a first protective layer 1 and a second protective layer 2 respectively laminated and bonded to opposite sides of the foamed core layer. This foamed diffuser plate 10 can be applied to the backlight module of a liquid crystal display.

[0027] In some embodiments, the first protective layer 1 and the second protective layer 2 are made of the same material, both consisting of the following components by mass percentage: 96%–99% optical resin matrix, 0.2%–1% light diffusing agent, 0.2%–1% antioxidant, 0.02%–1% weather resistant agent, 0–0.5% lubricant, and 0.2%–1% UV stabilizer. Since the protective layer of the foamed diffuser plate does not involve any improvement to the embodiments of this application and can be constructed using conventional methods, it will not be described in detail.

[0028] The foamed core layer 3 is the main part of the foamed diffuser plate. It is formed by foaming process and contains a large number of tiny pores. Therefore, when light shines on the foamed diffuser plate 10, the pores in the foamed core layer 3 can enhance the multi-directional scattering ability of light, thereby helping to improve the brightness uniformity of the light-emitting surface of the foamed diffuser plate 10.

[0029] In the embodiments of the application, the foamed core layer 3 is dispersed with nano-color enhancers, which are composed of the following nano-oxides by mass percentage: 42.3%~43.3% nano-Na2O, 9.1%~9.6% nano-MgO, 3.3%~3.5% nano-Al2O3, 18.0%~18.5% nano-SiO2, 0.12%~0.20% nano-K2O, 21.5%~21.9% nano-CaO, 1.2%~1.3% nano-Fe2O3, 1.8%~2.1% nano-SO3, and 1.0%~1.1% nano-Cr2O3.

[0030] The foamed core layer 3 can be composed of three components: an optical resin substrate, a foaming agent, and the aforementioned nano-color enhancer. The mass percentage of the nano-color enhancer in the foamed core layer can be 0.5% to 1.5%. More specifically, in the foamed core layer, the mass percentage of the optical resin substrate can be 97.95% to 99.35%, the mass percentage of the foaming agent can be 0.15% to 0.55%, and the mass percentage of the nano-color enhancer can be 0.5% to 1.5%.

[0031] Since the optical resin substrate and foaming agent material used to form the foamed diffuser plate 10 are well known to those skilled in the art and are commercially available, they will not be described in detail. For example, the foaming agent may be selected from one or more of the following: Kingfa Science & Technology Co., Ltd. LSPS-203 natural foaming agent, Suzhou Chixunjia Electronic Materials Co., Ltd. HYD2016 foaming agent, Guangyuxing Intelligent (Nantong) Technology Co., Ltd. Z201 foaming agent, Wuzhi New Materials Technology Co., Ltd., Guangzhou Benqi New Materials Co., Ltd. CE-3152C foaming agent, Xinfu Electromechanical Co., Ltd. HC-C3152E foaming agent, and Zhejiang Jieshangjie New Materials Co., Ltd. PS356 foaming agent.

[0032] The aforementioned nano-chromophore is an inorganic fluorescent material constructed based on a multi-metal oxide system, achieving spectral conversion through lattice doping and ion activation. This material can be created by doping rare earth or transition metal ions (such as Cr³⁺) into stable oxide lattices like Al₂O₃ and SiO₂, forming active centers with characteristic narrow-band luminescence capabilities. Under blue or ultraviolet light excitation, energy is transferred to the dopant ions via the lattice, causing electrons to undergo orbital transitions. Subsequently, during the relaxation process from the excited state to the ground state, the electrons radiate light of specific wavelengths; for example, the Al₂O₃·Cr³⁺ system can produce sharp emission peaks at approximately 692.9 nm and 694.3 nm.

[0033] The inventors discovered that this type of nano-chromic agent material exhibits a narrow-band linear spectral characteristic, with a full width at half maximum (FWHM) between that of quantum dots and traditional phosphors. It combines high color purity with good spectral stability, and its luminescence behavior is insensitive to slight changes in the lattice environment. Based on these characteristics, this nano-chromic agent can efficiently convert a portion of the blue light in the backlight into high-purity red and green light, thereby significantly improving the spectral composition of the backlight module and enhancing the display color gamut.

[0034] In summary, this nano-color enhancer material achieves a good balance between color performance, environmental tolerance, reliability and cost, making it suitable for display scenarios with high requirements for optical performance and reliability, including automotive displays, public displays and high-end display fields such as future Micro-LED full-color displays.

[0035] In practice, the mass percentage content of various nano-oxides in the nano-color enhancer can be determined based on the RGB peak wavelength of the LED light source in the target display. In other words, the ratio of various nano-oxides in the nano-color enhancer can be adapted and adjusted according to the spectral characteristics of the LED light source used in the target liquid crystal display (i.e., the liquid crystal display equipped with this foaming diffuser plate). The wavelengths of the RGB three primary colors emitted by different LED light sources fluctuate within a certain range (for example, red light wavelength is about 650nm-780nm, green light is about 495nm-570nm, and blue light is about 400nm-490nm). To match the target color gamut and white balance, the percentage content of various nano-oxides in the nano-color enhancer can be further optimized within the above range. It is worth noting that the inventors have found that selecting various nano-oxides in the nano-color enhancer within the above percentage range can achieve better spectral conversion effects.

[0036] In some embodiments, the surface of the first protective layer away from the foamed core layer and the surface of the second protective layer away from the foamed core layer respectively have diffusion microstructures to further enhance the diffusion effect of light and improve the uniformity of light emission.

[0037] The mass percentage of the nano-color enhancer in the foamed core layer is negatively correlated with the thickness of the foamed core layer.

[0038] The optical path length of light in the foamed core layer is directly related to the thickness of the foamed core layer. The thinner the foamed core layer, the shorter the time it takes for light to pass through it, and the shorter the time required for the nano-color enhancer to be excited. To achieve stable color gamut enhancement and optical uniformity, the content of the nano-color enhancer can be appropriately increased when the foamed core layer is thin, and appropriately reduced when the foamed core layer is thick. That is, the mass percentage of the nano-color enhancer in the foamed core layer can be set to be negatively correlated with the thickness of the foamed core layer. Table 1 below shows the color gamut enhancement level of the foamed diffuser plate (compared to the case without added nano-color enhancer) under different foamed core layer thicknesses and the contents of each component in the foamed core layer, as tested experimentally.

[0039] Table 1: As can be seen from Table 1, when the thickness of the foamed core layer is 1~3mm, the mass percentage of the nano-color enhancer in the foamed core layer can be 0.5%~1.5%.

[0040] Please see Figure 2 This application also proposes a method for manufacturing a foamed diffusion plate, the method comprising: S201 provides a mixture of an optical resin substrate, a foaming agent, and a nano-colorant, which is a material used to form a foamed core layer.

[0041] Based on the above introduction, the mass percentage of the nano-color enhancer in the mixture can be 0.5%~1.5%, and the nano-color enhancer is composed of the following mass percentages of nano-oxides: 42.3%~43.3% nano-Na2O, 9.1%~9.6% nano-MgO, 3.3%~3.5% nano-Al2O3, 18.0%~18.5% nano-SiO2, 0.12%~0.20% nano-K2O, 21.5%~21.9% nano-CaO, 1.2%~1.3% nano-Fe2O3, 1.8%~2.1% nano-SO3, and 1.0%~1.1% nano-Cr2O3.

[0042] Furthermore, in step S201, the specific mass percentage of the nano-color enhancer in the mixture can be determined based on the thickness of the foamed core layer to be manufactured in the foam diffusion process. As described above, the principle for determining this mass percentage can be that the mass percentage of the nano-color enhancer in the mixture is negatively correlated with the thickness of the foamed core layer; that is, the greater the thickness of the foamed core layer, the smaller the mass percentage of the nano-color enhancer in the mixture. For example, when the thickness of the foamed core layer is 1 mm, the mass percentage of the nano-color enhancer in the mixture is determined to be 1.5%, while when the thickness of the foamed core layer is 2 mm, the mass percentage of the nano-color enhancer in the mixture is determined to be 0.5%.

[0043] In addition, based on the above introduction, in this step S201, the specific mass percentage of various nano-oxides in the nano-color enhancer can be determined according to the RGB peak wavelength of the LED light source in the target liquid crystal display. The target liquid crystal display is a foamed diffusion liquid crystal display to be manufactured.

[0044] The optical resin substrate is composed of transparent polystyrene (PS) and a diffusing agent, wherein the diffusing agent is a mixture of rutile titanium dioxide and silicon dioxide.

[0045] S202 is used to make the mixture molten, resulting in a foamed layer melt.

[0046] In some embodiments, step S202 can be achieved by feeding the mixture into a parallel twin-screw extruder with a length-to-diameter ratio of 40:1 via an automatic feeder. The parallel twin-screw extruder has eight heating zones sequentially along the material (mixture) travel direction: Zone 1, where the material in the parallel twin-screw extrusion is heated to 195-205°C; Zone 2, where the material is heated to 200-210°C; Zone 3, where the material is heated to 205-215°C; Zone 4, where the material is heated to 210-220°C; Zone 5, where the material is heated to 190-200°C; Zone 6, where the material is heated to 213-223°C; Zone 7, where the material is heated to 213-223°C; and Zone 8, where the material is heated to 213-223°C. The process involves several stages: Zones 1 and 2 for material feeding and propulsion; Zones 3 and 4 for initial plasticization; Zones 5 and 6 for removing volatiles and low-molecular-weight impurities generated during plasticization; and Zones 7 and 8 for complete melting and mixing of the material to achieve uniform dispersion and full foaming of the foaming agent. The twin-screw extruder's rotational speed can be controlled within the range of 70-295 RPM, and the total travel distance of the material within the barrel is approximately 3 meters.

[0047] S203, the first protective layer melt and the second protective layer melt are respectively stacked on both sides of the foaming layer melt to obtain a slab.

[0048] For example, the foamed layer melt obtained after step S202 can be fed together with the pre-prepared first protective layer melt and second protective layer melt into a confluencer. After being laminated and compounded in the confluencer, it is fed into a T-die and co-extruded through the T-die to form a slab with a three-layer structure of protective layer-foamed core layer-protective layer.

[0049] S204, the slab is fed into the roll imprinting equipment to imprint diffusion microstructures on the surface of the first protective layer melt and the surface of the second protective layer melt.

[0050] More specifically, the slab is fed into a roll forming device, where it undergoes surface forming and dimensional shaping (removing the edge material of the slab) under set temperature and pressure, and then is initially cured by cooling rollers. Since the implementation of this step S204 is well known to those skilled in the art, it will not be described in detail.

[0051] S205, after the slab with the embossed diffusion microstructure is cured, the slab is cut to obtain a foamed diffusion plate.

[0052] In some embodiments, the slab processed in step S204 can be further cooled to room temperature via a conveying system and then cut to the required size to obtain a high color gamut foamed diffusion plate.

[0053] Example 1: The foam diffusion plate in this embodiment 1 is according to Figure 2 The method shown is used to prepare the foamed core layer, wherein the mass percentage of the nano-color enhancer in the foamed core layer is 1.5%, and the mass percentage of each nano-oxide in the nano-color enhancer is shown in Table 2 below.

[0054] Table 2: The peak wavelengths of the LED light source in the target LCD are: 700nm for red light, 550nm for green light, and 480nm for blue light.

[0055] Comparative Example 1-1: The board material of Comparative Example 1-1 uses a similar Figure 2 The method used to prepare this material differs from Example 1 only in that no nano-color enhancer or foaming agent is added; that is, the mixture in step S201 contains only an optical resin substrate. The material in Comparative Example 1-1 is a conventional diffusion plate.

[0056] Comparative Examples 1-2: The boards used in Comparative Examples 1-2 are similar. Figure 2 The method used to prepare this board differs from Example 1 only in that no nano-color enhancer is added; that is, the mixture in step S201 contains only an optical resin substrate and a foaming agent. The boards used in Comparative Examples 1-2 are conventional foamed diffusion boards.

[0057] Comparative Examples 1-3: The boards used in Comparative Examples 1-3 are similar. Figure 2The method used in Comparative Examples 1-3 differs from Example 1 only in that the nano-color enhancer is replaced with a quantum dot masterbatch composed of low-concentration quantum dots and photosensitive polymers at a mass percentage of 1%. Specifically, step S201 is adjusted to provide a mixture of an optical resin substrate, a foaming agent, and quantum dot masterbatch, wherein the quantum dot masterbatch is composed of low-concentration quantum dots and photosensitive polymers, and the mass percentage of the quantum dot masterbatch in the mixture is 1%. Therefore, the boards of Comparative Examples 1-3 are quantum dot + foamed diffusion boards.

[0058] Comparative Examples 1-4: The boards used in Comparative Examples 1-4 also employ a similar method. Figure 2 The method used to prepare this board differs from Example 1 only in that no foaming agent is added; that is, the mixture in step S201 contains only an optical resin substrate and a nano-color enhancer in the same proportions as in Example 1. The boards in Comparative Examples 1-4 are nano-color enhancers combined with conventional diffusion boards.

[0059] In Example 1 and Comparative Examples 1-1 to 1-4, the thickness of each board was 1 mm. One square meter of each board was taken as the test object, and brightness and color gamut tests were performed. The specific data are shown in Table 3 below.

[0060] Table 3: The performance parameters mentioned in Table 1 are all standard technical indicators in this field, and their meanings and functions are clearly defined: Light transmittance and haze: These respectively characterize a material's ability to retain luminous flux and its light scattering intensity. High light transmittance is fundamental to luminous efficiency, while high haze is key to achieving uniform light output.

[0061] NTSC color gamut: The coverage of a display device's color space relative to the NTSC standard. This value directly reflects the device's color reproduction range and saturation.

[0062] DCI-P3 color gamut: The coverage of the digital cinema P3 color space by a display device. This standard emphasizes the performance of deep reds and cyans, which can enhance visual impact and contrast.

[0063] Color temperature and color coordinates: Together they define the chromaticity and color coordinates of white light, used to accurately evaluate color quality and white balance.

[0064] Light emission uniformity: Characterizes the consistency of brightness distribution on the light-emitting surface; the higher the value, the more uniform and comfortable the visual effect.

[0065] Example 2: The foam diffusion plate in this embodiment 2 is according to Figure 2 The method shown is used to prepare the foamed core layer, wherein the mass percentage of the nano-color enhancer in the foamed core layer is 0.75%, and the mass percentage of each nano-oxide in the nano-color enhancer is shown in Table 4 below.

[0066] Table 4: The peak wavelengths of the LED light source in the target LCD are: 670 nm for red light, 510 nm for green light, and 450 nm for blue light.

[0067] Comparative Example 2-1: The board material of Comparative Example 2-1 uses a similar Figure 2 The method used in Comparative Example 2-1 differs from Example 2 only in that no nano-color enhancer or foaming agent is added to the plate; that is, the mixture in step S201 contains only an optical resin substrate. The plate in Comparative Example 2-1 is a conventional diffusion plate.

[0068] Comparative Example 2-2: The board material used in Comparative Example 2-2 is similar. Figure 2 The method used in Comparative Example 2-2 differs from Example 2 only in that no nano-color enhancer is added to this board; that is, the mixture in step S201 contains only an optical resin substrate and a foaming agent. The board in Comparative Example 2-2 is a conventional foamed diffusion board.

[0069] Comparative Examples 2-3: The boards used in Comparative Examples 2-3 are similar. Figure 2 The method used in Comparative Examples 2-3 differs from Example 2 only in that the nano-color enhancer is replaced with a quantum dot masterbatch composed of low-concentration quantum dots and photosensitive polymer at a mass percentage of 3%. Specifically, step S201 is adjusted to provide a mixture composed of an optical resin substrate, a foaming agent, and quantum dot masterbatch, wherein the quantum dot masterbatch accounts for 3% of the mass percentage of the mixture. Therefore, the board material of Comparative Examples 2-3 is a quantum dot + foamed diffusion board.

[0070] Comparative Examples 2-4: The boards used in Comparative Examples 2-4 also employ a similar method. Figure 2 The method used in this example differs from Example 2 only in that no foaming agent is added; that is, the mixture in step S201 contains only an optical resin substrate and a nano-color enhancer with the same component ratio as in Example 1. The boards in Comparative Examples 2-4 are nano-color enhancers combined with conventional diffusion plates. In Example 2 and Comparative Examples 2-1 to 2-4, the thickness of each board was 2 mm. One square meter of each board was taken as the test object, and brightness and color gamut tests were performed. The specific data are shown in Table 5 below.

[0071] Table 5: Example 3: The foam diffusion plate in this embodiment 3 is according to Figure 2The method shown is used to prepare the foamed core layer, wherein the mass percentage of the nano-color enhancer in the foamed core layer is 0.5%, and the mass percentage of each nano-oxide in the nano-color enhancer is shown in Figure 6 below.

[0072] Table 6: The peak wavelengths of the LED light source in the target LCD are: 670 nm for red light, 510 nm for green light, and 450 nm for blue light.

[0073] Comparative Example 3-1: The board material in Comparative Example 3-1 uses a similar... Figure 2 The method used in this example differs from that in Example 2 only in that no nano-color enhancer or foaming agent is added to the plate; that is, the mixture in step S201 contains only an optical resin substrate composed of a highly transparent optical resin and a diffusing agent. The plate in Comparative Example 3-1 is a conventional diffusing plate.

[0074] Comparative Example 3-2: The board material in Comparative Example 3-2 uses a similar Figure 2 The method used in Comparative Example 3-2 differs from Example 2 only in that no nano-color enhancer is added to this board; that is, the mixture in step S201 contains only an optical resin substrate and a foaming agent. The board used in Comparative Example 3-2 is a conventional foamed diffusion board.

[0075] Comparative Example 3-3: The board material in Comparative Example 3-3 uses a similar Figure 2 The method used in Comparative Example 3-3 differs from Example 2 only in that the nano-color enhancer is replaced with a quantum dot masterbatch composed of low-concentration quantum dots and photosensitive polymer at a mass percentage of 5%. Specifically, step S201 is adjusted to provide a mixture composed of an optical resin substrate, a foaming agent, and quantum dot masterbatch, wherein the quantum dot masterbatch accounts for 5% of the mass percentage of the mixture. Therefore, the board material of Comparative Example 3-3 is a quantum dot + foamed diffusion board.

[0076] Comparative Examples 3-4: The boards used in Comparative Examples 3-4 also employ a similar method. Figure 2 The method used to prepare this board differs from Example 2 only in that no foaming agent is added; that is, the mixture in step S201 contains only an optical resin substrate and a nano-color enhancer with the same component ratio as in Example 1. The boards in Comparative Examples 3-4 are nano-color enhancers combined with conventional diffusion boards.

[0077] In Example 3 and Comparative Examples 3-1 to 3-4, the thickness of each board was 3 mm. One square meter of each board was taken as the test object, and brightness and color gamut tests were performed. The specific data are shown in Table 7 below.

[0078] Table 7: The technical effects of this application have been clearly verified through systematic experiments of comparative examples and embodiments, and the conclusions are as follows: 1. Comparative Examples 1-1, 2-1, and 3-1 (conventional diffuser plates) show that substrates without spectral conversion function and foaming structure cannot achieve color gamut enhancement.

[0079] 2. Comparative Examples 1-2, 2-2, and 3-2 (conventional foamed diffuser plates) confirm that introducing a foaming structure alone can improve light emission uniformity to some extent, but cannot produce substantial gains in color gamut indicators, thus confirming the traditional understanding that diffusion function and spectral conversion function are independent of each other.

[0080] 3. Comparative Examples 1-3, 2-3, and 3-3 (low-concentration quantum dot foamed diffusion plates) show that although quantum dot materials can provide limited spectral conversion capabilities, their color gamut enhancement effect at low addition levels is significantly weaker than that of the present invention, and they still face fundamental limitations in material stability, environmental compliance, and cost control.

[0081] 4. Comparative Examples 1-4, 2-4, and 3-4 (conventional diffusion plates containing nano-color enhancers) verified that the specific nano-oxide composition used in this invention possesses significant spectral conversion efficiency, with a color gamut improvement exceeding 4 percentage points, superior to low-concentration quantum dot schemes under the same process conditions. However, while achieving color gamut improvement, this structure exhibits observable color coordinate shifts, indicating that without incorporating the specific foaming structure of this invention, it is difficult to maintain color stability.

[0082] 5. Examples 1, 2, and 3 of this application (foamed diffusion plates containing nano-color enhancers) have achieved unexpected technical effects: 1) Synergy: The specific nano-chromic agent and the controllable foamed microstructure do not simply add up their functions, but rather produce a synergistic optimization effect. The foamed structure not only contributes to the expected light diffusion effect to improve uniformity, but more importantly, its interaction with the nano-chromic agent effectively suppresses color shift, stabilizing the color temperature at approximately 7600K and the color coordinates approaching (0.300, 0.310), achieving a balance between high color gamut and high color purity in a single device.

[0083] 2) Comprehensiveness: This invention simultaneously achieves high light transmittance (up to 52.5%), high haze (up to 97.5%), excellent light emission uniformity (up to 82.3%), and significant color gamut improvement (NTSC improvement > 4 percentage points). Its comprehensive optical performance surpasses all comparative examples.

[0084] This invention solves the technical defects of existing quantum dot solutions and traditional diffuser plates by creatively combining a specific composition of nano-color enhancer with a foaming structure, and provides an environmentally friendly, process-stable diffuser plate solution that can simultaneously meet the requirements of high color gamut, high uniformity, high luminous efficacy and low color deviation.

Claims

1. A foamed diffuser panel comprising a foamed core layer, characterized in that, The foamed core layer has nanometer color enhancer dispersed therein, the nanometer color enhancer is composed of nanometer oxides with the following mass percentages: 42.3%-43.3% nanometer Na2O, 9.1%-9.6% nanometer MgO, 3.3%-3.5% nanometer Al2O3, 18.0%-18.5% nanometer SiO2, 0.12%-0.20% nanometer K2O, 21.5%-21.9% nanometer CaO, 1.2%-1.3% nanometer Fe2O3, 1.8%-2.1% nanometer SO3, and 1.0%-1.1% nanometer Cr2O3.

2. The foamed diffuser plate of claim 1, wherein, The mass percentage of the nanometer color enhancer in the foamed core layer is 0.5%-1.5%.

3. The foamed diffuser plate according to claim 1 or 2, characterized in that The mass percentage of the nanometer color enhancer in the foamed core layer is negatively correlated with the thickness of the foamed core layer.

4. The foamed diffuser plate of claim 3, wherein, When the thickness of the foamed core layer is 1-3 mm, the mass percentage of the nanometer color enhancer in the foamed core layer is 0.5%-1.5%.

5. The foamed diffuser plate of claim 2, wherein, The foamed core layer is composed of the following components with the following mass percentages: 98%-99% optical resin base material, 0.15%-0.55% foaming agent, and 0.5%-1.5% nanometer color enhancer.

6. The foamed diffuser plate of claim 1, wherein, Two protective layers are further included and are respectively laminated on the opposite sides of the foamed core layer.

7. The foamed diffuser plate of claim 6, wherein, The surface of the protective layer away from the foamed core layer has a diffusion microstructure; The protective layer is composed of the following components with the following mass percentages: 96%-99% optical resin base material, 0.2%-1% light diffuser, 0.2%-1% antioxidant, 0.02%-1% weather resistant agent, 0-0.5% lubricant, and 0.2%-1% ultraviolet resistant agent.

8. A method of manufacturing a foamed diffuser plate, characterized by, It comprises: Providing a mixture composed of optical resin base material, foaming agent, and nanometer color enhancer, wherein the mass percentage of the nanometer color enhancer in the mixture is 0.5%-1.5%, and the nanometer color enhancer is composed of nanometer oxides with the following mass percentages: 42.3%-43.3% nanometer Na2O, 9.1%-9.6% nanometer MgO, 3.3%-3.5% nanometer Al2O3, 18.0%-18.5% nanometer SiO2, 0.12%-0.20% nanometer K2O, 21.5%-21.9% nanometer CaO, 1.2%-1.3% nanometer Fe2O3, 1.8%-2.1% SO3, and 1.0%-1.1% nanometer Cr2O3; Making the mixture into a molten state to obtain a foamed layer melt; Laminating and combining a first protective layer melt and a second protective layer melt on the opposite sides of the foamed layer melt respectively to obtain a slab; After the slab is solidified, the slab is cut to obtain the foamed diffusion plate.

9. The method of claim 8, wherein, The providing of the mixture composed of optical resin base material, foaming agent, and nanometer color enhancer comprises: determining the mass percentage of the nanometer color enhancer in the mixture according to the thickness of the foamed core layer in the foamed diffusion plate to be manufactured, and the mass percentage of the nanometer color enhancer in the mixture is negatively correlated with the thickness of the foamed core layer. After the slab is obtained, and before the slab is solidified, the method includes: introducing the slab into a roll imprinting device to imprint diffusion microstructures on the surface of the first protective layer melt and on the surface of the second protective layer melt.

10. The method of claim 8, wherein, The providing of the mixture composed of an optical resin base material, a foaming agent, and a nano color enhancer includes: The mass percentage content of various nano oxides in the nano color enhancer is determined according to the RGB peak wavelength of the LED light source in the target liquid crystal display, and the target liquid crystal display is the foamed and diffused liquid crystal display to be manufactured.

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