Display device, backlight module and assembling method of display device

Abstract

A display device, a backlight module and an assembling method of the display device are disclosed. The display device includes a backlight module and a display panel. The display panel is disposed on the backlight module. The backlight module includes a back plate, a lamp plate, a plurality of support columns and a diffusion plate. The lamp plate is disposed on a side of the back plate facing the display panel. The plurality of support columns are disposed on the lamp plate or the back plate. Each support column includes a support member and a buffer layer. The buffer layer is made of a soft material and covers at least a top portion of the support member. The diffusion plate is disposed on the lamp plate and the back plate with a light cavity distance. The diffusion plate abuts the buffer layer. In an embodiment, the periphery of each support column can have a plurality of microstructures to reflect the light emitted by the lamp plate towards the diffusion plate.

Description

Technical Field

[0001] This invention relates to a display device and a backlight module, and more particularly to a backlight module that can avoid noise generation and improve optical performance, a display device equipped with the backlight module, and a method for assembling the display device. Background Technology

[0002] In the design of direct-lit backlight modules, support pillars are placed between the diffuser plate and the lamp plate to support the diffuser plate and prevent it from deforming and affecting the light output. However, gaps usually exist between the support pillars and the diffuser plate due to manufacturing or assembly tolerances. When the backlight module is subjected to vibration or impact, the support pillars will collide with the diffuser plate, producing abnormal noise, which is particularly noticeable when used in automotive displays. In addition, the support pillars can also easily create shadows on the diffuser plate, affecting the light output. Summary of the Invention

[0003] The purpose of this invention is to provide a backlight module that can avoid noise generation and improve optical performance, a display device equipped with the backlight module, and a method for assembling the display device, so as to solve the above-mentioned problems.

[0004] According to one embodiment, the present invention provides a display device comprising a backlight module and a display panel. The display panel is disposed on the backlight module. The backlight module includes a back plate, a lamp plate, a plurality of support pillars, and a diffuser plate. The lamp plate is disposed on the side of the back plate facing the display panel. The plurality of support pillars are disposed on the lamp plate or the back plate. Each support pillar includes a support member and a buffer layer. The buffer layer is made of a soft material and at least covers the top of the support member. The diffuser plate is disposed on the lamp plate and the back plate, spaced apart by a light cavity distance. The diffuser plate abuts against the buffer layer.

[0005] In one embodiment, the buffer layer has a plurality of microstructures around it. The plurality of microstructures are made of the same material as the buffer layer, and the plurality of microstructures are spaced a first distance from the diffuser plate.

[0006] In one embodiment, multiple microstructures are arranged in multiple rings along the axial direction of the conical inclined surface of the support column. Adjacent rings are spaced apart by a second spacing, which is approximately equal to the length of one of the microstructures.

[0007] In one embodiment, each microstructure is elliptical and has an aspect ratio between 1.1 and 1.2.

[0008] In one embodiment, the surface of the support is light-reflective, and the buffer layer is light-transmitting.

[0009] In one embodiment, each support column further includes a fixing member, which is attached to the bottom of the support column via an embedded injection molding process. The support column is fixed to the lamp panel or back panel by the fixing member, and a buffer layer covers the support column above the fixing member via an encapsulation injection molding process.

[0010] According to one embodiment, the present invention provides a backlight module comprising a back panel, a lamp panel, a plurality of support pillars, and a diffuser plate. The lamp panel is disposed on one side of the back panel. The plurality of support pillars are disposed on the lamp panel. Each support pillar has a plurality of microstructures around it. The diffuser plate is disposed on the lamp panel and the back panel at a distance of an optical cavity. The top of the support pillars is made of a flexible material, the diffuser plate abuts against the top of the support pillars, and the plurality of microstructures are spaced apart from the top by a first spacing.

[0011] In one embodiment, a plurality of microstructures are arranged in a plurality of rings along the axial direction of the conical inclined surface of the support column, wherein adjacent rings are spaced apart by a second spacing, the second spacing being approximately equal to the length of one of the plurality of microstructures.

[0012] According to one embodiment, the present invention provides a method for assembling a display device, comprising: setting a back plate; setting a lamp plate on the back plate, wherein the back plate or the lamp plate has a plurality of support columns, the plurality of support columns are pre-assembled on the lamp plate or the back plate, the tops of the plurality of support columns are made of a soft material, and the plurality of support columns have a plurality of microstructures around them; setting a diffuser plate on the lamp plate and the back plate at a distance of a light cavity, the diffuser plate abutting against the tops of the support columns.

[0013] In one embodiment, each support column further includes a fastener, which is attached to the bottom of the support column via an injection molding process. The support column is pre-assembled onto the light panel or back panel via the fastener using surface bonding technology.

[0014] In summary, this invention forms a support column by covering the top of the support member with a buffer layer, wherein the buffer layer is made of a soft material. When the backlight module is subjected to vibration or impact, the buffer layer provides impact cushioning between the support column and the diffuser plate, thereby preventing noise. Furthermore, the area around the support column (e.g., around the buffer layer) may have microstructures. These microstructures can reflect light emitted from the lamp panel towards the diffuser plate, reducing shadows at the support column location and thus improving optical performance.

[0015] The advantages and spirit of the present invention can be further understood through the following detailed description of the invention and the accompanying drawings. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of a display device according to an embodiment of the present invention.

[0017] Figure 2 This is a perspective view of a support column according to an embodiment of the present invention.

[0018] Figure 3 This is a partial cross-sectional view of a backlight module according to an embodiment of the present invention.

[0019] Figure 4 This is another partial cross-sectional view of a backlight module according to an embodiment of the present invention.

[0020] Figure 5 This is another partial cross-sectional view of a backlight module according to an embodiment of the present invention.

[0021] Figure 6 This is a flowchart of an assembly method for a display device according to an embodiment of the present invention.

[0022] Explanation of reference numerals in the attached drawings: 1-Display device; 10-Backlight module; 12-Display panel; 100-Back plate; 102-Lamp board; 104-Support column; 106-Diffuser plate; 108-Optical film; 1020-Circuit board; 1022-Light-emitting unit; 1040-Support member; 1042-Buffer layer; 1044-Fixing member; 1046-Microstructure; D-Cavity distance; G1-First spacing; G2-Second spacing; L-Length; W, X-Width; Y-Distance; S10~S16-Steps. Detailed Implementation

[0023] Please see Figures 1 to 3 , Figure 1 This is a schematic diagram of a display device 1 according to an embodiment of the present invention. Figure 2 This is a perspective view of a support column 104 according to an embodiment of the present invention. Figure 3 This is a partial cross-sectional view of a backlight module 10 according to an embodiment of the present invention.

[0024] like Figure 1 As shown, the display device 1 includes a backlight module 10 and a display panel 12. The display panel 12 is disposed on the backlight module 10. In practical applications, the display panel 12 can be a liquid crystal display panel, but is not limited thereto. The display device 1 provides light to the display panel 12 through the backlight module 10 to display an image.

[0025] The backlight module 10 includes a backplate 100, a lamp board 102, multiple support pillars 104, a diffuser plate 106, and at least one optical film 108. In this embodiment, the backlight module 10 may be a direct-type backlight module, but is not limited thereto. For example, the lamp board 102 may be disposed on the side of the backplate 100 facing the display panel 12. The lamp board 102 may include a circuit board 1020 and multiple light-emitting units 1022, wherein the multiple light-emitting units 1022 are disposed on the circuit board 1020. The light-emitting units 1022 may be mini light-emitting diodes (mini LEDs), but are not limited thereto. The diffuser plate 106 is disposed on the lamp board 102 and the backplate 100, spaced apart by an optical cavity distance D, and at least one optical film 108 is disposed on the diffuser plate 106. At least one optical film 108 may include a dual brightness enhancement film (DBEF), a prism sheet, a diffuser sheet, etc., depending on the actual application. In addition, a reflective sheet (not shown), a reflective element, or a reflective coating may be provided on the circuit board 1020 to reflect light toward the diffuser plate 106.

[0026] In one embodiment of the present invention, a plurality of support columns 104 are disposed on the lamp panel 102 or the back plate 100 to support the diffuser plate 106 at intervals and to prevent local deformation or tilting of the diffuser plate 106. Figure 2 and Figure 3As shown, each support column 104 includes a support member 1040, a buffer layer 1042, and a fixing member 1044. In one embodiment of the present invention, the support member 1040 is fixed to the fixing member 1044, and the fixing member 1044 serves as the base of the support member 1040. The buffer layer 1042 is made of a soft material and at least covers the top of the support member 1040. In one embodiment of the present invention, the buffer layer 1042 can be formed around the support member 1040 via an overmolding process and completely covers the support member 1040 located above the fixing member 1044. In other words, the top of the support column 104 is made of a soft material. In one embodiment of the present invention, the soft material used to make the buffer layer 1042 can be optical-grade liquid silicone, wherein the optical-grade liquid silicone has a light transmittance of 95% and a hardness of 50A, therefore the buffer layer 1042 is transparent, soft, elastic, and light-transmitting. In other embodiments, depending on the design requirements of the backlight module 10, the soft material used to make the buffer layer 1042 can also be rubber or other soft materials, so that the buffer layer 1042 has both soft shock absorption and optical properties required for practical applications. In one embodiment of the present invention, the support member 1040 can be made of a rigid material (e.g., polycarbonate (PC), polyphthalamide (PPA), etc.) to maintain the integrity and strength of the structure, avoid lateral deformation caused by instantaneous impact, and the surface of the support member 1040 can be light reflective. In one embodiment of the present invention, the fixing member 1044 can be attached to the bottom of the support member 1040 via an insert molding process. The fixing member 1044 can be made of metal. Therefore, each support column 104 can be fixed to the back plate 100 or the lamp panel 102 by surface mount technology (SMT) via fasteners 1044 without vibrating and falling off. However, it is not limited to this. The fasteners 1044 of each support column 104 can also be glued to the lamp panel 102 or the back plate 100, locked from the outside of the back plate 100 with screws, or fixed by clamping with reflectors. In addition, two or more of the above fixing methods can be combined to fix the support column 104 at the same time to ensure that it will not fall off.

[0027] like Figure 3 As shown, since the buffer layer 1042 covers the top of the support member 1040, the diffuser plate 106 abuts against the buffer layer 1042 above the support column 104, that is, the diffuser plate 106 abuts against the top of the support column 104. When the backlight module 10 is subjected to vibration or impact, the buffer layer 1042 can act as a buffer between the support column 104 and the diffuser plate 106 to absorb the impact force, thereby preventing the generation of abnormal noise. In one embodiment of the present invention, the width X of the top of the support column 104 (e.g., Figure 1The diameter (as shown) can be less than or equal to 1 mm to avoid affecting the light output due to the support column 104 hitting the diffuser plate 106, which would cause shadows on the display screen.

[0028] like Figure 2 and Figure 3 As shown, in one embodiment of the present invention, each support column 104 may have multiple microstructures 1046 around it, such as microlens structures. In one embodiment of the present invention, the buffer layer 1042 may have multiple microstructures 1046 around the support column 104, wherein the multiple microstructures 1046 are made of the same material as the buffer layer 1042, and the multiple microstructures 1046 are spaced at a first distance G1 from the top of the support column 104 or the diffuser plate 106. The multiple microstructures 1046 are used to reflect the light emitted by the lamp plate 102 toward the diffuser plate 106 and reduce the shadow formed at the position where the support column 104 touches the diffuser plate 106, thereby improving the optical performance of the backlight module 10. In one embodiment of the present invention, each microstructure 1046 may be elliptical, such as... Figure 1 As shown, the aspect ratio L / W of each microstructure 1046 can be between 1.1 and 1.2, and multiple microstructures 1046 can be arranged into multiple rings along the axial direction of the conical inclined surface of the support column 104. Furthermore, multiple elliptical microstructures 1046 protrude on the surface of the support column 104, and the height perpendicular to the inclined surface is about half of the width, that is, the aspect ratio of the microstructure 1046 is about 2, so as to achieve better optical performance. Figure 1 In this context, L represents the length of the microstructure 1046 along the conical inclined surface of the support column 104, and... Figure 1 In this embodiment, W represents the width of the microstructure 1046. The length L of the microstructure 1046 is 0.55–0.6 mm, and the width W is 0.5 mm. Furthermore, the vertical distance Y between the center of the uppermost microstructure 1046 and the top of the support column 104 (e.g., ...) is... Figure 1 (As shown) can be 0.8 mm to avoid the microstructure 1046 being too close to or too far from the diffuser plate 106, thus achieving better optical performance. Additionally, in one embodiment of the invention, as... Figure 2 As shown, the support column 104 has a total of 5 rows of microstructures 1046. The microstructures 1046 are arranged vertically aligned on the conical inclined surface of the support column 104. The spacing between the microstructures 1046 in each row is equal, that is, the microstructures 1046 are arranged in a 5-part division on the conical inclined surface of the support column 104. However, the present invention is not limited thereto. The shape, number and arrangement of the microstructures 1046 can be determined according to the actual required optical performance, and are not limited to the embodiment shown in the figure. For example, the microstructures 1046 can be arranged in an alternating manner or not in a 5-part division on the conical inclined surface of the support column 104, or the shape and size of the microstructures 1046 can be changed according to the light pattern of the light-emitting unit 1022.

[0029] Please see Figure 4 as well as Figure 5 , Figure 4 This is another partial cross-sectional view of a backlight module 10 according to an embodiment of the present invention. Figure 5 This is another partial cross-sectional view of a backlight module 10 according to an embodiment of the present invention.

[0030] Please refer to Table 1 below, such as Figure 4 As shown, the lower the optical cavity height, the shorter the support pillar 104, resulting in fewer microstructures 1046, and a closer distance between the support pillar 104 and the adjacent light-emitting unit 1022. Conversely, as... Figure 5 As shown, the longer the support column 104 is designed, the more microstructures 1046 it will have, and the farther the distance between the support column 104 and the adjacent light-emitting unit 1022 will be. Furthermore, in one embodiment of the present invention, the spacing between the microstructures 1046 in the same row on the buffer layer 1042 arranged along the conical inclined surface of the support column 104 is equal. The height of the optical cavity and the length of the support column 104 can be slightly adjusted to increase the number of microstructures 1046 in a single row. Taking Table 1 as an example, with a total of 5 rows of microstructures 1046, the number of microstructures 1046 in a single row can be 2 to 4. In one embodiment of the present invention, the number of microstructures 1046 in a single row is also the number of microstructure layers 1046 formed on the surface of the support column 104. Figure 2 For example, the number of microstructures 1046 in a single row is 3, so there are 3 layers of microstructures 1046 arranged in an equal-division manner around the support column 104. In one embodiment of the present invention, the center spacing between two adjacent microstructures 1046 in the same row is approximately equal to or slightly greater than twice the length of the microstructure 1046. That is, the edge spacing between two adjacent microstructures 1046 in the same row is approximately the length of one microstructure 1046. Taking Table 1 below as an example, the center spacing between two adjacent microstructures 1046 is approximately between 1.1 mm and 1.2 mm. That is, in the multiple rings formed by the microstructures 1046, the spacing between two adjacent sets of rings is approximately equal to the length L of one microstructure 1046. In other words, there is a second spacing G2 between adjacent rings, and the second spacing G2 is approximately equal to the length L of one of the multiple microstructures 1046. However, the present invention is not limited to this. The present invention can adjust the length of the support column 104, the number of multiple microstructures 1046 and / or the distance between the support column 104 and the adjacent light-emitting unit 1022 according to the actual required optical performance.

[0031] Table 1

[0032]

[0033] In one embodiment of the present invention, the fixing member 1044 is first attached to the bottom of the support member 1040 via an embedded injection molding process, and then a buffer layer 1042 is formed around the support member 1040 via an injection molding process covering the fixing member 1044. At the same time, a plurality of microstructures 1046 are formed on the buffer layer 1042 by a mold to complete the fabrication of the support column 104. In one embodiment of the present invention, during the manufacturing of the back plate 100 or the lamp plate 102, the support column 104 can be pre-assembled on the back plate 100 or the lamp plate 102 via the fastener 1044 using surface adhesive technology. Thus, when assembling the backlight module 10 of the display device 1, it is only necessary to sequentially set the back plate 100, the lamp plate 102 and the diffuser plate 106, without having to spend time assembling the support column 104. For example, the lamp plate 102 can have openings to allow the pre-assembled support column 104 on the back plate 100 to pass through, or the lamp plate 102 with the support column 104 can be directly assembled onto the back plate 100, and then the diffuser plate 106 can be abutted against the top of the support column 104 to be disposed on the backlight module 10.

[0034] Please see Figure 6 , Figure 6 This is a flowchart of an assembly method for a display device 1 according to an embodiment of the present invention.

[0035] like Figure 1 and Figure 6 As shown, the assembly method of the display device 1 may include the following steps. First, a back plate 100 is set (step S10). Next, a lamp plate 102 is set on the back plate 100 (step S12), wherein a plurality of support pillars 104 are pre-assembled on the lamp plate 102 or the back plate 100, the tops of the plurality of support pillars 104 are made of a soft material, and the plurality of microstructures 1046 are present around the plurality of support pillars 104. Next, a diffuser plate 106 is set on the lamp plate 102 and the back plate 100 at a distance D from the optical cavity, such that the diffuser plate 106 abuts against the tops of the support pillars 104 (step S14). Next, the display panel 12 is set on the backlight module 10 (step S16). It should be noted that the detailed embodiments of the backlight module 10 of the present invention are as described above, and will not be repeated here.

[0036] In summary, this invention forms a support column by covering the top of the support member with a buffer layer, wherein the buffer layer is made of a soft material. When the backlight module is subjected to vibration or impact, the buffer layer provides impact cushioning between the support column and the diffuser plate, thereby preventing noise. Furthermore, the area around the support column (e.g., around the buffer layer) may have microstructures. These microstructures can reflect light emitted from the lamp panel towards the diffuser plate, reducing shadows at the support column location and thus improving optical performance.

[0037] The above description is only a preferred embodiment of the present invention. All equivalent changes and modifications made in accordance with the claims of the present invention should be included within the scope of the present invention.

Claims

1. A display device, characterized in that, Include: A display panel; and A backlight module, the display panel being disposed on the backlight module, the backlight module comprising: One back panel; A light panel is disposed on the side of the back panel facing the display panel; Multiple support columns are disposed on the light panel or the back panel, each support column comprising a support member and a buffer layer, the buffer layer being made of a soft material and at least covering the top of the support member; and A diffuser plate is disposed on the lamp plate and the back plate at a distance of one optical cavity, and the diffuser plate abuts against the buffer layer.

2. The display device as claimed in claim 1, characterized in that, The buffer layer is surrounded by multiple microstructures made of the same material as the buffer layer, and the multiple microstructures are spaced a first distance from the diffuser plate.

3. The display device as claimed in claim 2, characterized in that, The multiple microstructures are arranged in multiple rings along the axial direction of the conical inclined surface of the support column, wherein adjacent rings are spaced by a second spacing equal to the length of one of the multiple microstructures.

4. The display device as claimed in claim 2, characterized in that, Each of these microstructures is elliptical in shape and has an aspect ratio between 1.1 and 1.

2.

5. The display device as claimed in claim 1, characterized in that, The surface of the support is light reflective, while the buffer layer is light transmittable.

6. The display device as claimed in claim 1, characterized in that, Each of the support columns further includes a fastener attached to the bottom of the support column via an embedded injection molding process. The support column is fixed to the light panel or the back panel by the fastener, and the buffer layer covers the support column above the fastener via an encapsulation injection molding process.

7. A backlight module, characterized in that, Include: One back panel; A light panel is installed on one side of the back panel; Multiple support columns are set on the lamp panel, and each support column has multiple microstructures around it; as well as A diffuser plate is disposed on the lamp plate and the back plate, separated by a light cavity distance; The top of the support column is made of a soft material, the diffuser plate abuts against the top of the support column, and the plurality of microstructures are spaced a first distance from the top.

8. The backlight module as described in claim 7, characterized in that, The multiple microstructures are arranged in multiple rings along the axial direction of the conical inclined surface of the support column, wherein adjacent rings are spaced by a second spacing equal to the length of one of the multiple microstructures.

9. A method for assembling a display device, characterized in that, Include: Set a back panel; A light panel is mounted on the back panel, wherein the back panel or the light panel has multiple support columns, which are pre-assembled onto the light panel or the back panel. The tops of the multiple support columns are made of a soft material, and multiple microstructures are present around the multiple support columns; and A diffuser plate is placed between the lamp plate and the back plate at a distance equal to the distance of a light cavity, and the diffuser plate abuts against the top of the support column.

10. The assembly method of the display device as described in claim 9, characterized in that, Each of the support columns further includes a fastener attached to the bottom of the support column via an embedded injection molding process. The support column is pre-assembled to the light panel or the back panel via the fastener using surface bonding technology.

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