Optical film assembly and manufacturing method, display module, and electronic device

Abstract

The present disclosure relates to an optical film assembly and a manufacturing method thereof, a display module and an electronic device. The manufacturing method of the optical film assembly comprises: providing a substrate; forming a first refractive layer on the substrate; and forming a protective film, the protective film comprising a first protective area and a second protective area, in a stacking direction, the first protective area covering a side of the first main body part away from the substrate, and the second protective area covering a sidewall of the through hole and covering an exposed surface of the substrate. In the present disclosure, the first protective area of the protective film covers a side of the first refractive layer away from the substrate, the second protective area of the protective film covers a sidewall of the through hole of the first refractive layer, and covers an exposed surface of the substrate, that is, the projection of the protective layer on the substrate can cover the entire substrate, so that the optical transmittance of each area of the optical film assembly is consistent, thereby making the display effect of each area of the optical film assembly consistent, and improving the user experience.

Description

Technical Field

[0001] This disclosure relates to the field of electronic equipment technology, and in particular to an optical film assembly and its manufacturing method, a display module, and an electronic device. Background Technology

[0002] Currently, organic light-emitting diode (OLED) displays are commonly used in electronic devices. OLEDs have advantages such as low power consumption, fast response speed, and high color contrast.

[0003] Brightness is one of the important indicators for measuring display performance. However, some technologies cannot guarantee other display effects, such as uneven display, when increasing display brightness, which affects the user experience. Summary of the Invention

[0004] To overcome the problems existing in related technologies, this disclosure provides an optical film assembly and its manufacturing method, a display module, and an electronic device.

[0005] According to a first aspect of the present disclosure, a method for manufacturing an optical film assembly is provided, comprising:

[0006] Provide substrate;

[0007] A first refractive layer is formed on the substrate. The first refractive layer includes a first main body and a through hole. The first main body is stacked with the substrate. The through hole penetrates the first main body in the stacking direction of the first main body and the substrate and exposes a portion of the surface of the substrate.

[0008] A protective film is formed, the protective film including a first protective area and a second protective area. In the stacking direction, the first protective area covers the side of the first body portion away from the substrate, and the second protective area covers the sidewall of the through hole and the exposed surface of the substrate.

[0009] In some embodiments, forming the protective film includes:

[0010] An initial protective layer is formed on the first refractive layer, and the initial protective layer is attached to the side of the first main body that is away from the substrate;

[0011] The initial protective layer is deformed, and a portion of the structure of the initial protective layer fills the through hole to form a protective layer;

[0012] A portion of the protective layer is removed, and the remaining protective layer, which is connected to the first refractive layer and the substrate, forms the protective film.

[0013] In some embodiments, deforming the initial protective layer includes:

[0014] Under a first preset condition, the initial protective layer is subjected to a pressure degassing treatment, so that a first protrusion is formed in the area of ​​the initial protective layer opposite to the through hole. The sidewall of the first protrusion is attached to the sidewall of the through hole, and the surface of the first protrusion away from the first main body is attached to the exposed surface of the substrate.

[0015] In some embodiments, the first preset condition includes a first preset temperature, a first preset pressure, and a first preset duration:

[0016] Wherein, the first preset temperature is 45℃~60℃; and / or,

[0017] The first preset pressure is 0.58 MPa to 0.62 MPa; and / or,

[0018] The first preset duration is 14 min to 16 min.

[0019] In some embodiments, after pressure degassing, the method for manufacturing the optical film assembly further includes:

[0020] The substrate, the first refractive layer, and the protective layer are left to stand still.

[0021] In some embodiments, forming a first refractive layer on the substrate includes:

[0022] A first material layer is formed on the substrate, and the first material layer covers the surface of the substrate;

[0023] A portion of the structure of the first material layer is removed to form the through-hole in the first material, the through-hole exposing a portion of the surface of the substrate, and the remaining first material layer forms the first body portion.

[0024] In some embodiments, the method for manufacturing the optical film assembly further includes:

[0025] An initial brightness enhancement layer is provided, the initial brightness enhancement layer comprising a polarizing layer and a second material layer stacked together;

[0026] The side of the second material layer facing away from the polarizing layer is connected to the first protective zone;

[0027] The second material layer is deformed, and part of the structure of the second material layer fills the through hole and adheres to the second protection zone. The deformed second material layer forms a second refractive layer, and the second refractive layer and the polarizing layer constitute a brightening layer.

[0028] In some embodiments, providing the initial brightening layer includes:

[0029] The polarizing layer and the second material layer are provided;

[0030] The second material layer is connected to the polarizing layer using a roll-to-roll process to form the initial brightening layer.

[0031] In some embodiments, deforming the second material layer includes:

[0032] The initial brightening layer is subjected to pressure degassing treatment, so that the area of ​​the second material layer opposite to the through hole extends into the through hole to form a second protrusion, and the surface of the second protrusion is in contact with the second protection zone.

[0033] According to a second aspect of this disclosure, an optical film assembly is provided, the optical film assembly comprising:

[0034] substrate;

[0035] The first refractive layer includes a first main body and a through hole. The first main body is stacked with the substrate. The through hole penetrates the first main body along the stacking direction of the substrate and the first refractive layer and exposes a portion of the surface of the substrate.

[0036] The protective film includes a first protective zone and a second protective zone. In the stacking direction, the first protective zone covers the side of the first body portion away from the substrate, and the second protective zone covers the sidewall of the through hole and the exposed surface of the substrate.

[0037] In some embodiments, the first protective zone and the second protective zone have uniform thickness.

[0038] In some embodiments, the brightening layer includes a polarizing layer and a second refractive layer stacked together, wherein the second refractive layer is connected to the protective layer;

[0039] The second refractive layer has a microlens structure on the side facing the substrate, and the microlens structure is attached to the second protective zone.

[0040] In some embodiments, the refractive index of the second refractive layer is greater than the refractive index of the first refractive layer.

[0041] According to a third aspect of this disclosure, a display module is provided, the display module including a light-emitting layer and an optical film assembly prepared by the manufacturing method provided in the first aspect, or an optical film assembly as described in the second aspect;

[0042] The light-emitting layer has light-emitting pixels, and in the film layer stacking direction of the optical film assembly, the light-emitting pixels are directly opposite the microlens accommodating area of ​​the optical film assembly.

[0043] According to a fourth aspect of this disclosure, an electronic device is provided, including an optical film assembly manufactured as by the manufacturing method provided in the first aspect, or an optical film assembly as described in the second aspect, or a display module as described in the third aspect.

[0044] The technical solutions provided by the embodiments of this disclosure may include the following beneficial effects: the first protected area of ​​the protective film covers the side of the first refractive layer away from the substrate, the second protected area of ​​the protective film covers the sidewall of the through hole of the first refractive layer, and covers the exposed surface of the substrate, that is, the projection of the protective layer on the substrate can cover the entire substrate, so that the optical transmittance of each area of ​​the optical film assembly is consistent, thereby making the display effect of each area of ​​the optical film assembly consistent and improving the user experience.

[0045] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this disclosure. Attached Figure Description

[0046] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments consistent with this disclosure and, together with the description, serve to explain the principles of this disclosure.

[0047] Figure 1 This is a flowchart illustrating a method for manufacturing an optical film assembly according to an exemplary embodiment.

[0048] Figure 2 This is a flowchart illustrating a method for manufacturing an optical film assembly according to an exemplary embodiment.

[0049] Figure 3 This is a flowchart illustrating a method for manufacturing an optical film assembly according to an exemplary embodiment.

[0050] Figure 4 This is a flowchart illustrating a method for manufacturing an optical film assembly according to an exemplary embodiment.

[0051] Figure 5 This is a schematic diagram of an optical film assembly having a first material layer and a light-emitting layer, according to an exemplary embodiment.

[0052] Figure 6 This is a schematic diagram of an optical film assembly having a first refractive layer and a light-emitting layer, according to an exemplary embodiment.

[0053] Figure 7This is a schematic diagram of an optical film assembly with an initial protective layer and a light-emitting layer, according to an exemplary embodiment.

[0054] Figure 8 This is a schematic diagram of an optical film assembly with a protective layer and a light-emitting layer according to an exemplary embodiment.

[0055] Figure 9 This is a schematic diagram of an optical film assembly with a protective film and a light-emitting layer according to an exemplary embodiment.

[0056] Figure 10 This is a schematic diagram of an optical film assembly with a protective film and a light-emitting layer according to an exemplary embodiment.

[0057] Figure 11 This is a schematic diagram of an optical film assembly with an initial brightening layer and a light-emitting layer, according to an exemplary embodiment.

[0058] Figure 12 This is a schematic diagram of an optical film assembly with a brightness enhancement layer and a light-emitting layer according to an exemplary embodiment.

[0059] Figure 13 This is a schematic diagram illustrating an optical film assembly with a first protected zone and a light-emitting layer according to an exemplary embodiment. Detailed Implementation

[0060] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numerals in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this disclosure. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this disclosure as detailed in the appended claims.

[0061] In related technologies, inkjet technology is commonly used to improve the luminous efficiency of displays. Inkjet technology uses inkjet equipment to spray high-refractive-index particles into a designated area (MLP HRL) of the display film. These high-refractive-index particles can form a high-refractive-index layer in the display film. The high-refractive-index layer has a different refractive index than the original structure of the display film, thus creating a high-low refractive index interface. When light passes through the high-low refractive index interface, it is refracted to change the light path and move closer to the normal of the display film, forming a light-focusing effect, thereby improving the local luminous efficiency.

[0062] Currently, display films manufactured using inkjet printing technology have at least the following problems:

[0063] First, the high-refractive-index particle layer formed by inkjet printing is relatively thick, resulting in a significant increase in the thickness of the display film. This increased thickness has drawbacks, such as making it unsuitable for or preventing its application in foldable screen devices. For example, the high-refractive-index particle layer formed by inkjet printing typically increases the thickness of the display film by approximately 30 micrometers.

[0064] Secondly, the high-refractive-index particle layer formed by inkjet printing requires a leveling area to be reserved at the edges to ensure uniform color at the edges of the display area. It is certain that the reserved leveling area will affect the narrow bezel design. For example, the leveling area will increase the bezel size by approximately 700 micrometers.

[0065] Third, inkjet equipment is prone to printhead clogging under high-intensity use, which affects normal operation, leading to reduced output or even failure to achieve mass production.

[0066] Fourth, inkjet equipment is expensive, and the cost of inkjet printing is also high in mass production, which reduces product profit margins.

[0067] To address the problems in related technologies, this disclosure provides an optical film assembly and its manufacturing method, a display module, and an electronic device. The manufacturing method of the optical film assembly includes: providing a substrate; forming a first refractive layer on the substrate, the first refractive layer including a first main body and a through-hole, the first main body being stacked with the substrate, and the through-hole exposing a portion of the substrate surface; forming a protective film, the protective film including a first protective zone and a second protective zone, wherein, in the stacking direction, the first protective zone covers the side of the first main body facing away from the substrate, and the second protective zone covers the sidewall of the through-hole and the exposed surface of the substrate. In this disclosure, the first protective zone of the protective film covers the side of the first refractive layer facing away from the substrate, the second protective zone covers the sidewall of the through-hole of the first refractive layer, and the exposed surface of the substrate. This means that the projection of the protective layer onto the substrate can cover the entire substrate, resulting in consistent optical transmittance across all areas of the optical film assembly, thereby ensuring consistent display performance across all areas and improving the user experience.

[0068] According to exemplary embodiments of this disclosure, such as Figure 1 As shown, this embodiment provides a method for manufacturing an optical film assembly, the method comprising the following steps:

[0069] Step S110: Provide a substrate.

[0070] In this step, refer to Figures 5-13 The substrate 10 includes a base and multiple functional layers disposed on the base. The substrate is used to support other film layers disposed thereon. The functional layers include touch layers (DOT for short). Touch electrodes can be disposed in the touch layers to respond to the user's touch operation.

[0071] Step S120: A first refractive layer is formed on the substrate. The first refractive layer includes a first main body and a through hole. The first main body is stacked with the substrate. The through hole penetrates the first main body in the stacking direction of the first main body and the substrate and exposes a portion of the substrate surface.

[0072] In this step, such as Figure 5 and Figure 6 As shown, the first refractive layer 20 is stacked with the substrate 10 and is located on the side of the substrate 10 opposite to the light-emitting layer 50. The first refractive layer 20 can refract the light emitted by the light-emitting layer 50, and improve the light utilization rate by changing the light path, thereby improving the luminous efficiency.

[0073] In one example, see Figure 5 and Figure 6 For example, a first material layer 20' can be formed on the substrate 10 using a photoresist material, and then a portion of the structure of the first material layer 20' can be removed to form a preset pattern in the first material layer 20', thereby obtaining the first refractive layer 20. One method for removing the first material layer 20' is photolithography, a process that forms a permanent pattern on a preset film layer through exposure, development, and etching steps. In this process, the area where the first material layer 20' is removed forms a through-hole 22, and the remaining first material layer 20' forms the first main body 21 of the first refractive layer 20.

[0074] See Figure 6 The first refractive layer 20 includes a first main body 21 and a through hole 22. The first main body 21 is stacked with the substrate 10. The through hole 22 penetrates the first main body 21 along its thickness direction and exposes a portion of the top surface 11 of the substrate 10. The through hole 22 has a portion of its structure for accommodating other film layers (such as the protective film 30 and the second refractive layer, which will be described in detail later) so that the sidewalls of the through hole 22 form a refractive surface. By refraction, the light path is changed, and the originally divergent light is converted into a focused state so that it is emitted more concentratedly to the outside of the device, thereby improving the luminous efficiency.

[0075] Step S130: Form a protective film. The protective film includes a first protective area and a second protective area. In the stacking direction, the first protective area covers the side of the first main body that is away from the substrate, and the second protective area covers the sidewall of the through hole and the exposed surface of the substrate.

[0076] In this step, refer to Figure 11Since the second material layer 42' (used to form the second refractive layer 42, which will be described in detail later) in this embodiment is not directly formed on the first refractive layer 20, but is first combined with the polarizing layer 41 (which will be described in detail later) to form the initial brightening layer 40', and then stacked with the first refractive layer 20, that is, in the process of manufacturing the optical film assembly, it is necessary to transfer the substrate 10 and the first refractive layer 20 between different process equipment. During the transfer process, impurities may adhere or scratch the substrate 10 and the first refractive layer 20. Therefore, after the first refractive layer 20 is formed in this embodiment, a protective film 30 can be formed on the first refractive layer 20 to protect the first refractive layer 20 from the adhesion of impurities or scratches, which would affect the product yield.

[0077] See Figure 9 and Figure 10 The protective film 30 includes a first protective zone 31 and a second protective zone 32. In the thickness direction of the first main body 21, the first protective zone 31 covers the side of the first main body 21 facing away from the substrate 10, and the second protective zone 32 covers the sidewall of the through hole 22 and the portion of the top surface 11 of the substrate 10 exposed by the through hole 22. As can be seen from the above, this embodiment provides a complete protective film 30. Therefore, the protective film 30 can effectively protect the first refractive layer 20 and ensure that the optical transmittance is the same at different positions of the optical film assembly, ensuring consistent display brightness and improving the display effect.

[0078] In this embodiment of the present disclosure, the first protected area of ​​the protective film covers the side of the first refractive layer away from the substrate, and the second protected area of ​​the protective film covers the sidewall of the through hole of the first refractive layer and the exposed surface of the substrate. That is, the projection of the protective layer on the substrate can cover the entire substrate, so that the optical transmittance of each area of ​​the optical film assembly is consistent, thereby making the display effect of each area of ​​the optical film assembly consistent and improving the user experience.

[0079] In some embodiments, this embodiment is a further explanation of step S130, forming a protective film, in the foregoing embodiments, such as... Figure 2 As shown, the protective film can be formed using the following steps:

[0080] Step S210: An initial protective layer is formed on the first refractive layer, and the initial protective layer is attached to the side of the first main body that is away from the substrate.

[0081] In this step, such as Figure 7 As shown, an initial protective layer 30” of a certain thickness can be placed flat on the first refractive layer 20, and the initial protective layer 30” is bonded to the first refractive layer 20 by its own adhesiveness.

[0082] In one example, the initial protective layer 30” can be a process protective film. Process protective films are mature existing technologies. In this embodiment, any process protective film in the relevant technology can be used to make the initial protective layer 30” and the protective film 30, which will not be elaborated further.

[0083] Step S220: Deform the initial protective layer, and fill part of the structure of the initial protective layer into the through hole to form a protective layer.

[0084] First, it should be noted that the reference Figure 13 Because the first refractive layer 20 has a through hole 22, but the structure of the initial protective layer 30” facing the through hole 22 cannot enter the through hole 22 in its natural state, but is suspended directly above the through hole 22. This suspended (suspended) setting causes this part of the structure to be completely removed when the initial protective layer 30” is peeled off, thus forming the retained initial protective layer. Figure 13 The structure shown indicates that a complete protective film layer is not formed. It is certain that this incomplete protective layer will cause differences in optical transmittance across different areas of the optical film assembly. This results in varying light loss as light passes through different areas, ultimately leading to inconsistent display brightness, reduced display quality, and a negative impact on user experience.

[0085] In this step, the initial protective layer 30” can be deformed, and part of the structure of the initial protective layer 30” extends toward the through hole 22 to form a first protrusion (described in detail later). The first protrusion fills the through hole 22 and adheres to the side wall of the through hole 22. The bottom wall of the first protrusion adheres to the exposed top surface 11 of the substrate 10, so that each area of ​​the protective layer is bonded and fixed.

[0086] Therefore, when a portion of the protective layer 30' is subsequently removed, a complete protective film 30 can be formed. The projection of the protective film 30 onto the substrate 10 covers the entire surface of the substrate 10. The first protected area 31 of the protective film 30 covers the top surface of the first refractive layer 20, and the second protected area 32 of the protective film 30 covers the sidewall of the through hole 22 of the first refractive layer 20. The second protected area 32 also covers the surface of the substrate 10 exposed by the through hole, so that the optical transmittance of each area of ​​the optical film assembly is the same, ensuring consistent display brightness and display effect.

[0087] Step S230: Remove part of the initial protective layer, and the remaining protective layer connected to the first refractive layer and the substrate forms a protective film.

[0088] In this step, refer to Figure 8 Since the top surface of the protective layer 30' is in direct contact with the external environment, impurities may adhere to the top surface of the protective layer 30' or it may be scratched. Furthermore, if the protective layer 30' is too thick, it will also affect the optical path. Therefore, it is necessary to remove a certain thickness of the protective layer 30'.

[0089] Combination Figures 8 to 10 The protective layer 30' can be removed by, for example, by directly applying an upward tearing force to the protective layer 30'. When the protective layer 30' is torn by an external force, since there is an adhesive force between the protective layer 30' and the first refractive layer 20 and the substrate 10, and the adhesive force is greater than the internal stress of the protective layer 30', a thin layer of protective film 30 will remain and adhere to the first main body 21 and the through hole 22. The remaining protective layer 30' forms the protective film 30.

[0090] In this embodiment, the initial protective layer 30” is deformed by pressing and degassing. Part of the deformed initial protective layer 30” adheres to the sidewalls of the substrate 10 and the through-hole 22, enabling the formation of a complete protective film 30 in subsequent steps. This ensures uniform optical transmittance across all areas of the optical film assembly, improving the display effect. Furthermore, the pressurized degassing process also removes air bubbles between the protective layer 30” and the substrate 10 and the sidewalls of the through-hole 22, preventing air gaps 33 and ensuring uniform residue of the protective layer 30” without texture, resulting in a protective film 30 of consistent thickness across all areas.

[0091] In some embodiments, this embodiment is a further explanation of step S220 in the foregoing embodiments, such as... Figure 3 As shown, the initial protective layer can be deformed to form a protective layer in the following way:

[0092] Step S310: Under the first preset conditions, the initial protective layer is subjected to pressure degassing treatment, so that the area of ​​the initial protective layer opposite to the through hole forms a first protrusion, the sidewall of the first protrusion is attached to the sidewall of the through hole, and the surface of the first protrusion away from the first main body is attached to the exposed surface of the substrate.

[0093] See Figures 6 to 10 The pressure degassing process is a technique that increases the solubility of gas in a liquid by applying pressure, and then reducing the pressure to allow the gas to precipitate, thus achieving degassing. In this step, pressure degassing of the initial protective layer allows the gas dissolved in the initial protective layer 30” to be released, preventing air bubbles from existing in the subsequently formed protective layers 30' and 30 film. This avoids air bubbles between the protective layers 30' and 30 and other film layers, thereby preventing uneven textures. In addition, the pressure degassing treatment also enhances the adhesion reliability of the protective layer and film to other film layers, preventing the formation of a complete protective film when removing parts of the protective layer.

[0094] The first preset conditions include a first preset temperature, a first preset pressure, and a first preset duration. It is understood that during the pressurized degassing process, temperature, pressure, and duration all affect the deformation. The temperature during pressurized degassing affects the flowability, smoothness, and viscosity of the initial protective layer 30”. The pressure during pressurized degassing accelerates the flow of the initial protective layer 30”, and the duration of pressurized degassing ensures continuous flow of the initial protective layer 30”, facilitating the removal of air bubbles. In one example, the first preset temperature is 45℃~60℃, the first preset pressure is 0.58Mpa~0.62Mpa, and the first preset duration is 14min~16min.

[0095] It is understood that this does not limit the technical solution disclosed herein, and any other extrusion method can be used to process the initial protective layer, as long as the initial protective layer can enter the through hole.

[0096] In some embodiments, after the initial protective layer is subjected to pressure degassing to form the second protrusion, step S220 may further include the following steps:

[0097] Step S320: Set the substrate, first refractive layer, and protective layer.

[0098] In this step, refer to Figure 8 Allowing the protective layer 30' to remain still provides sufficient wetting time with the first refractive layer 20 and the substrate 10, ensuring a tight bond between the protective layer 30' and the substrate 10 and the first refractive layer 20. This prevents the protective layer 30' from failing to adhere properly and form a complete protective film 30. In one example, the substrate, the first refractive layer 20, and the protective layer can be kept at 23°C to 25°C for a second preset time, where the second preset time is longer than the first preset time.

[0099] In one example embodiment, the optical film assembly fabricated by the method provided in this embodiment further includes a brightness enhancement layer, such as... Figure 4 As shown, the method for manufacturing the optical film assembly provided in this embodiment includes:

[0100] Step S410: Provide a substrate.

[0101] Step S410 is implemented in the same way and in the same principle as step S110 in the previous embodiment, and will not be described again.

[0102] Step S420: A first refractive layer is formed on the substrate. The first refractive layer includes a first main body and a through hole. The first main body is stacked with the substrate. The through hole penetrates the first main body in the stacking direction of the first main body and the substrate and exposes a portion of the substrate surface.

[0103] Step S420 is implemented in the same way and in the same principle as step S120 in the previous embodiment, and will not be described again.

[0104] Step S430: Form a protective film. The protective film includes a first protective area and a second protective area. In the stacking direction, the first protective area covers the side of the first main body that is away from the substrate, and the second protective area covers the sidewall of the through hole and the exposed surface of the substrate.

[0105] Step S430 is implemented in the same way and in the same principle as step S130 in the previous embodiment, and will not be described again.

[0106] Step S440: Provide an initial brightening layer, which includes a polarizing layer and a second material layer stacked together, with the second material layer bonded to the top surface of the first protected area.

[0107] First, it should be noted that the initial brightening layer can be produced simultaneously with any of steps S410 to S430. That is, the initial brightening layer and the protective film can be produced in two different process equipment. After the protective film and the initial brightening film are produced, they can be spliced ​​together, which helps to improve production efficiency.

[0108] In this step, refer to Figure 11 The initial brightening layer 40' includes a polarizing layer 41 and a second material layer 42' stacked together. Both the polarizing layer 41 and the second material layer 42' are flat film layers. Therefore, when the second material layer 42' is stacked together with the first refractive layer 20, the part of the initial brightening layer 40' that is directly opposite the through hole 22 is in a suspended state.

[0109] In one embodiment, the second material layer 42' and the polarizing layer 41 can be composited together by a roll-to-roll process, which has the advantages of inexpensive equipment, low cost, high output, and cleanliness.

[0110] Step S450: Connect the side of the second material layer away from the polarizing layer to the first protection zone.

[0111] In this step, both the second material layer and the protective film are adhesive structures. Therefore, the side of the second material layer away from the polarizing layer can be placed facing the protective film, and then placed on the protective film and a certain pressure can be applied to bond the second material layer to the protective film.

[0112] Step S460: Deform the second material layer. Part of the structure of the second material layer fills the through hole and adheres to the second protection zone. The deformed second material layer forms the second refractive layer. The second refractive layer and the polarizing layer constitute the brightening layer.

[0113] In this step, the second material layer can be extruded to force a portion of its structure into the through-hole. The extrusion method can be physical extrusion or a pressure degassing process.

[0114] Specifically, under a second preset condition, the initial brightening layer can be subjected to pressure degassing treatment, causing the area of ​​the second material layer opposite to the through hole to extend into the through hole, forming a second protrusion. The surface of the second protrusion adheres to the second protected area. The second preset condition includes temperature, pressure, and time, and the second preset condition can use the same parameters as the first preset condition.

[0115] In this embodiment, see Figure 11 When an air gap 33 is formed between the second protection zone 32 of the protective film 30 and the sidewall of the substrate 10 or the through hole 22, a pressure degassing process can be used to extrude the second material layer 42' so that the second refractive layer 42 forms a second protrusion. The second protrusion is used to extrude the second protection zone 32 of the protective film 30 a second time to remove the air gap 33 present in the second protection zone 32.

[0116] According to an exemplary embodiment of this disclosure, such as Figures 9 to 12 As shown in the embodiments of this disclosure, an optical film assembly is also provided. This optical film assembly is applied to the display module of an electronic device to enable the electronic device to display image information. Examples of electronic devices include smartphones, tablets, laptops, televisions, and smart wearable devices.

[0117] like Figure 9 As shown, the optical film assembly includes a substrate 10, which supports other optical film layers disposed thereon. The substrate 10 includes a base and various optical functional layers disposed on the base, such as a touch layer (not shown in the figure). The touch layer is bonded to the first refractive layer 20 and the second protective zone 32 of the protective film 30. Touch electrodes can be disposed in the touch layer to respond to the user's touch operation.

[0118] like Figure 9 As shown, the optical film assembly also includes a first refractive layer 20. The first refractive layer 20 includes a first main body portion 21 and a plurality of through holes 22. The first main body portion 21 is stacked with the substrate 10. The plurality of through holes 22 penetrate the first main body portion 21 along the thickness direction to expose a portion of the top surface 11 of the substrate 10. Other film layers (such as a second refractive layer 42) can be formed in the through holes 22, thereby enabling light to be refracted and its path changed when passing through the optical film assembly, thus achieving a brightening effect. For example, see [reference needed]. Figure 9In the direction where the light is emitted perpendicularly, the inner diameter of the through hole 22 gradually increases. The axial section of the through hole 22 is a trapezoid with the top side dimension larger than the bottom side dimension. The spatial shape defined by the through hole 22 is, for example, an inverted frustum or a pyramid. In this embodiment, the specific shape and size of the through hole 22 are not limited too much.

[0119] like Figure 9 As shown, the optical film assembly also includes a protective film 30, which is disposed between the first refractive layer 20 and the second refractive layer 42. The protective film 30 is used to protect the first refractive layer 20 to prevent impurities from adhering to it or scratches. The protective film 30 is formed from the residual adhesive adhering to the first refractive layer 20 and the substrate 10 after the process protective film is removed. In this embodiment, any process protective film in the related art can be used to form the protective film 30. Therefore, the composition and structure of the protective film 30 will not be described in detail in this disclosure.

[0120] See Figure 9 It can be determined that in the optical film assembly provided in this embodiment, the projection of the protective film 30 on the substrate 10 covers the substrate 10, that is, the protective film 30 is a whole layer film, so that the optical transmittance of each area of ​​the optical film assembly is consistent and the display effect is consistent.

[0121] In this embodiment, the first protected area of ​​the protective film covers the side of the first refractive layer away from the substrate, and the second protected area of ​​the protective film covers the sidewall of the through hole of the first refractive layer and the exposed surface of the substrate. That is, the projection of the protective layer on the substrate can cover the entire substrate, so that the optical transmittance of each area of ​​the optical film assembly is consistent, thereby making the display effect of each area of ​​the optical film assembly consistent and improving the user experience.

[0122] In some embodiments, see Figure 9 In the film layer stacking direction of the optical film assembly, the first protection zone 31 and the second protection zone 32 of the protective film 30 have uniform and identical thicknesses. It can be understood that the uniform and identical thickness of the first protection zone 31 and the second protection zone 32 ensures that the light loss is the same when passing through various areas of the protective film 30, thereby facilitating the achievement of consistent display brightness in different areas.

[0123] In some embodiments, such as Figure 12 As shown, the optical film assembly also includes a brightness enhancement layer 40, which comprises a stacked polarizing layer 41 and a second refractive layer 42. The polarizing layer 41 selectively filters light, improving image display clarity by controlling the polarization state of the light; for example, the polarizing layer 41 is a circular polarizer. See also... Figure 8The second refractive layer 42 has a second protrusion on the side facing the first refractive layer 20. The second protrusion extends into and fills the through hole 22 of the first refractive layer 20. That is, the sidewall of the second protrusion covers the sidewall of the second protection zone 32 of the protective film 30, and the bottom wall of the second protrusion covers the top surface of the second protection zone 32 of the protective film 30.

[0124] In one example, see Figure 12 The second protrusion of the second refractive layer 42 can form a microlens structure. The microlens structure is a structure in microlens panel (MLP) technology. The microlens structure can change the light path of light, so that the originally divergent light becomes a converged state and is emitted more concentratedly from the light-emitting surface, thereby improving the luminous efficiency.

[0125] Compared to optical film assemblies fabricated using inkjet technology in related technologies, this method eliminates the need for a pressure-sensitive adhesive (PSA) bonded to the polarizing layer and uses the second refractive layer 42 to occupy the PSA's position, thus improving luminous efficiency without increasing the thickness of the optical film assembly. Furthermore, the second refractive layer 42 and the polarizing layer 41 are bonded together using a roll-to-roll process. Additionally, since the high-refractive-index particle region is not formed using inkjet technology, the edge leveling problem inherent in inkjet technology is eliminated, facilitating narrow bezel designs and increasing the screen-to-body ratio of electronic devices using the optical film assembly provided in this embodiment. Moreover, the roll-to-roll process facilitates mass production and solves the problem of reduced production efficiency and decreased output caused by inkjet head clogging in inkjet technology.

[0126] Among them, see Figure 12 The refractive index of the second refractive layer 42 is greater than that of the first refractive layer 20. The first refractive layer 20 is made of a photoresist material, and the second refractive layer 42 is made of a high-refractive-index polymer with a refractive index greater than 1.6. In one example, the optical film assembly provided in this disclosure can improve luminous efficiency by 8% to 12% compared to ordinary optical film layers in related technologies.

[0127] Among them, such as Figure 12 As shown, the protective film 30 includes a first protective zone 31 and a second protective zone 32, which are integrally formed. In the thickness direction of the first main body 21, the first protective zone 31 covers the side of the first main body 21 facing away from the substrate 10, and the second protective zone 32 covers the sidewall of the through hole 22 and a portion of the top surface 11 of the substrate 10.

[0128] According to exemplary embodiments of this disclosure, an embodiment of this disclosure provides a display module that can serve as a display screen for an electronic device. See also... Figure 12The display module includes a light-emitting layer 50 and an optical film assembly provided in any of the foregoing embodiments of this disclosure. The light-emitting layer 50 and the optical film assembly are stacked and disposed on the side of the substrate 10 of the optical film assembly opposite to the first refractive layer 20. The light-emitting layer 50 provided in this embodiment is, for example, an organic light-emitting diode (OLED) display. The light-emitting layer 50 has light-emitting pixels 51. In the film stacking direction of the optical film assembly, the light-emitting pixels 51 are directly opposite the through hole 22 and the second protrusion. When the divergent light emitted by the light-emitting pixels 51 passes through the side wall of the second protrusion, it can be refracted and changed to change the light path, becoming a converged form for continued transmission.

[0129] The display module provided in this embodiment has all the technical features and effects of optical film components, which will not be described in detail here.

[0130] According to exemplary embodiments of this disclosure, an electronic device is also provided, which applies the optical film assembly or display module provided in any of the foregoing embodiments of this disclosure. Examples of such electronic devices include smartphones, televisions, tablets, laptops, and smart wearable devices. The electronic device provided in this embodiment can possess all the technical effects of the optical film assembly and display module provided in this disclosure, and will not be elaborated further.

[0131] Other embodiments of this disclosure will readily occur to those skilled in the art upon consideration of the specification and practice of the embodiments disclosed herein. This disclosure is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of this disclosure are indicated by the following claims.

[0132] It should be understood that this disclosure is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this disclosure is limited only by the appended claims.

Claims

1. A method for manufacturing an optical film assembly, characterized in that, include: Provide substrate; A first refractive layer is formed on the substrate. The first refractive layer includes a first main body and a through hole. The first main body is stacked with the substrate. The through hole penetrates the first main body in the stacking direction of the first main body and the substrate and exposes a portion of the surface of the substrate. A protective film is formed, the protective film including a first protective area and a second protective area. In the stacking direction, the first protective area covers the side of the first body portion away from the substrate, and the second protective area covers the sidewall of the through hole and the exposed surface of the substrate.

2. The method for manufacturing an optical film assembly according to claim 1, characterized in that, The formation of the protective film includes: An initial protective layer is formed on the first refractive layer, and the initial protective layer is attached to the side of the first main body that is away from the substrate; The initial protective layer is deformed, and a portion of the structure of the initial protective layer fills the through hole to form a protective layer; A portion of the protective layer is removed, and the remaining protective layer, which is connected to the first refractive layer and the substrate, forms the protective film.

3. The method for manufacturing an optical film assembly according to claim 2, characterized in that, The deformation of the initial protective layer includes: Under a first preset condition, the initial protective layer is subjected to a pressure degassing treatment, so that a first protrusion is formed in the area of ​​the initial protective layer opposite to the through hole. The sidewall of the first protrusion is attached to the sidewall of the through hole, and the surface of the first protrusion away from the first main body is attached to the exposed surface of the substrate.

4. The method for manufacturing an optical film assembly according to claim 3, characterized in that, The first preset conditions include a first preset temperature, a first preset pressure, and a first preset duration: Wherein, the first preset temperature is 45℃~60℃; and / or, The first preset pressure is 0.58 MPa to 0.62 MPa; and / or, The first preset duration is 14 min to 16 min.

5. The method for manufacturing an optical film assembly according to claim 3, characterized in that, After undergoing pressure degassing, the method for manufacturing the optical film assembly further includes: The substrate, the first refractive layer, and the protective layer are left to stand still.

6. The method for manufacturing an optical film assembly according to claim 1, characterized in that, The formation of the first refractive layer on the substrate includes: A first material layer is formed on the substrate, and the first material layer covers the top surface of the substrate; A portion of the structure of the first material layer is removed to form the through-hole in the first material, the through-hole exposing a portion of the surface of the substrate, and the remaining first material layer forms the first body portion.

7. The method for manufacturing an optical film assembly according to claim 1, characterized in that, The method for manufacturing the optical film assembly further includes: An initial brightness enhancement layer is provided, the initial brightness enhancement layer comprising a polarizing layer and a second material layer stacked together; The side of the second material layer facing away from the polarizing layer is connected to the first protective zone; The second material layer is deformed, and part of the structure of the second material layer fills the through hole and adheres to the second protection zone. The deformed second material layer forms a second refractive layer, and the second refractive layer and the polarizing layer constitute a brightening layer.

8. The method for manufacturing an optical film assembly according to claim 7, characterized in that, The provision of the initial brightening layer includes: The polarizing layer and the second material layer are provided; The second material layer is connected to the polarizing layer using a roll-to-roll process to form the initial brightening layer.

9. The method for manufacturing an optical film assembly according to claim 7, characterized in that, The deformation of the second material layer includes: The initial brightening layer is subjected to pressure degassing treatment, so that the area of ​​the second material layer opposite to the through hole extends into the through hole to form a second protrusion, and the surface of the second protrusion is in contact with the second protection zone.

10. An optical film assembly, characterized in that, The optical film assembly includes: substrate; The first refractive layer includes a first main body and a through hole. The first main body is stacked with the substrate. The through hole penetrates the first main body along the stacking direction of the substrate and the first refractive layer and exposes a portion of the surface of the substrate. The protective film includes a first protective zone and a second protective zone. In the stacking direction, the first protective zone covers the side of the first body portion away from the substrate, and the second protective zone covers the sidewall of the through hole and the exposed surface of the substrate.

11. The optical film assembly according to claim 10, characterized in that, The first and second protected areas have uniform thickness.

12. The optical film assembly according to claim 10, characterized in that, The brightening layer includes a polarizing layer and a second refractive layer stacked together, and the second refractive layer is connected to the protective layer; The second refractive layer has a second protrusion on the side facing the substrate, and the second protrusion is attached to the second protective zone.

13. The optical film assembly according to claim 12, characterized in that, The refractive index of the second refractive layer is greater than that of the first refractive layer.

14. A display module, characterized in that, The display module includes a light-emitting layer and an optical film assembly prepared by any one of the manufacturing methods of claims 1-9, or an optical film assembly as described in any one of claims 10-13; The light-emitting layer has light-emitting pixels, and in the film layer stacking direction of the optical film assembly, the light-emitting pixels are directly opposite the through holes of the optical film assembly.

15. An electronic device, characterized in that, This includes optical film assemblies manufactured by any one of the manufacturing methods of claims 1-9, or optical film assemblies as described in claims 10-13, or display modules as described in claim 14.

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