LED floor tile and method of manufacturing the same

Abstract

The application relates to an LED floor tile screen and a manufacturing method thereof, which comprises the following steps: providing a transparent base material, forming a bottom filling layer on the transparent base material, and forming a textured layer with a textured pattern on the side of the bottom filling layer away from the transparent base material; performing hole opening treatment on the bottom filling layer and the textured layer to form a through-hole structure which is periodically arranged and penetrates through the bottom filling layer and the textured layer; forming a protective layer on the side of the textured layer away from the bottom filling layer to form a textured film material which comprises the transparent base material, the bottom filling layer, the textured layer and the protective layer; providing a first glass plate and a second glass plate, performing laminating treatment on the first glass plate, the textured film material and the second glass plate along a first direction to form a textured glass structure, and the first direction is perpendicular to the surface of the textured glass structure; and attaching the textured glass structure to the top of an LED display unit to form the LED floor tile screen. The application improves the presentation effect of the textured pattern in the LED floor tile screen, thereby improving the overall aesthetic degree of the LED floor tile screen.

Description

Technical Field

[0001] This application relates to the field of display technology, and in particular to an LED floor tile screen and its manufacturing method. Background Technology

[0002] LED floor tile screens are commonly used in stage rentals, commercial displays, exhibition halls, and film studios to create interactive and immersive experiences. The luminous surface of an LED floor tile screen needs to have strong load-bearing capacity, hardness, and wear resistance.

[0003] Generally, the surface of the LED floor tile screen can be made to resemble a natural texture by adding a textured mask, or by covering the entire surface of the LED floor tile screen with a patterned acrylic or glass plate.

[0004] However, textured masks can only fill the gaps between LED lights in LED floor tile screens, failing to cover the LED beads themselves. This results in the beads appearing hollowed out, causing a dot matrix effect when viewed up close, negatively impacting the screen's aesthetics. Furthermore, the low transmittance of patterns in patterned acrylic or glass panels significantly affects the brightness and image quality of the LED floor tile screen. Simply reducing the ink density or thickness of the pattern leads to uneven masking, resulting in water ripples, localized color blocks, and exposed LED backlight surfaces, severely affecting the overall appearance of the LED floor tile screen. Summary of the Invention

[0005] Therefore, it is necessary to provide an LED floor tile screen and its manufacturing method to improve the presentation effect of texture patterns in the LED floor tile screen and enhance the overall aesthetics of the LED floor tile screen.

[0006] In a first aspect, this application provides a method for manufacturing an LED floor tile screen, comprising:

[0007] A transparent substrate is provided, an underfill layer is formed on the transparent substrate, and a texture layer is formed on the side of the underfill layer away from the transparent substrate, wherein a texture pattern is formed in the texture layer;

[0008] The underfill layer and the texture layer are perforated to form a periodically arranged through-hole structure that penetrates the underfill layer and the texture layer;

[0009] A protective layer is formed on the side of the textured layer away from the underfill layer to form a textured film comprising the transparent substrate, the underfill layer, the textured layer, and the protective layer;

[0010] A first glass plate and a second glass plate are provided, and the first glass plate, the textured film and the second glass plate are laminated along a first direction to form a textured glass structure, wherein the first direction is perpendicular to the surface of the textured glass structure;

[0011] The textured glass structure is attached to the top of an LED display unit to form the LED floor tile screen.

[0012] In one embodiment, the process of creating openings in the underfill layer and the texture layer includes:

[0013] A carrier is provided, the surface of which is formed with a periodically arranged protrusion structure;

[0014] The ink layer, which is composed of the base filler layer and the texture layer, is roll-formed to form protrusions in the ink layer that correspond to the raised structure.

[0015] A portion of the ink layer at the location of the protrusion is removed to form a through-hole structure in the protrusion. The through-hole structure penetrates the underfill layer and the texture layer, and all the through-hole structures in the ink layer are arranged periodically.

[0016] In one embodiment, the process of forming an underfill layer on the transparent substrate and forming a textured layer on the side of the underfill layer away from the transparent substrate includes:

[0017] The underfill layer is formed on the transparent substrate by any one of the following processes: screen printing, microgravure printing, inkjet printing, and mold transfer.

[0018] Perform heat-drying treatment on the underfill layer;

[0019] The textured layer is formed on the side of the underfill layer away from the transparent substrate by any one of the following processes: screen printing, microgravure printing, inkjet printing, and mold transfer.

[0020] Perform a heat-drying process on the texture layer.

[0021] In one embodiment, the process of performing the lamination process to form a textured glass structure includes:

[0022] The textured film is cut, and the size of the cut textured film is larger than the size of the first glass plate and the second glass plate.

[0023] The first glass plate and the second glass plate are subjected to surface cleaning treatment;

[0024] The first glass plate, the first film, the textured film, the second film, and the second glass plate are stacked in that order, and the stacked components are pre-pressed using a pre-pressing machine to form a composite assembly. The dimensions of the first film and the second film are the same as those of the first glass plate and the second glass plate, respectively.

[0025] The laminated assembly is trimmed, and the trimmed laminated assembly is then pressurized to form the textured glass structure.

[0026] In one embodiment, the process of attaching the textured glass structure to the top of an LED display unit includes:

[0027] An LED display unit is provided, the LED display unit includes an LED housing, a lamp surface structure is formed on one side of the LED housing, and a cover plate support is formed on the periphery of the lamp surface structure;

[0028] The textured glass structure is installed on the side of the cover plate support away from the LED enclosure;

[0029] An adhesive is applied to the periphery of the textured glass structure and edge-wrapped. The structure is left to solidify so that the textured glass structure is attached to the top of the LED display unit.

[0030] Secondly, this application also provides an LED floor tile screen, comprising:

[0031] LED display unit;

[0032] A textured glass structure is attached to the top of the LED display unit. The textured glass structure includes a first glass plate, a textured film, and a second glass plate arranged sequentially along a first direction, wherein the first direction is perpendicular to the surface of the textured glass structure.

[0033] The textured film material includes:

[0034] A transparent substrate is located on the side of the textured glass structure closest to the LED display unit;

[0035] The underfill layer is located on the side of the transparent substrate away from the LED display unit;

[0036] A textured layer is located on the side of the underfill layer away from the transparent substrate. A textured pattern is formed in the textured layer, and periodically arranged through-hole structures are provided in the textured layer and the underfill layer.

[0037] A protective layer is located on the side of the textured layer away from the underfill layer.

[0038] In one embodiment, the through-hole width of the through-hole structure is in the range of 10μm to 100μm, the period of the through-hole structure is in the range of 50μm to 200μm, and the through-hole duty cycle of the through-hole structure is in the range of 10% to 40%.

[0039] In one embodiment, the transmittance of the underfill layer is in the range of 40% to 80%, the haze is in the range of 75% to 99%, and the underfill layer includes one of a black UV ink layer, a white UV ink layer, and a gray UV ink layer.

[0040] In one embodiment, the transmittance of the texture layer is in the range of 40% to 60%, the material of the texture layer includes UV ink, and the texture pattern includes at least one of marble pattern, wood grain pattern and cement pattern.

[0041] In one embodiment, the LED floor tile screen further includes:

[0042] A first film is located between the first glass plate and the textured film.

[0043] The second film is located between the second glass plate and the textured film;

[0044] The LED display unit includes:

[0045] LED cabinet;

[0046] The lamp surface structure is located on one side of the LED housing;

[0047] The cover plate support is located on the periphery of the lamp surface structure, and the end of the cover plate support away from the LED cabinet abuts against the textured glass structure.

[0048] In summary, this application provides an LED floor tile screen and its manufacturing method, comprising: providing a transparent substrate; forming a base layer on the transparent substrate; forming a texture layer on the side of the base layer away from the transparent substrate, wherein a textured pattern is formed within the texture layer; performing an opening process on the base layer and the texture layer to form a periodically arranged through-hole structure penetrating the base layer and the texture layer; forming a protective layer on the side of the texture layer away from the base layer to form a textured film material including the transparent substrate, the base layer, the textured layer, and the protective layer; providing a first glass plate and a second glass plate, and laminating the first glass plate, the textured film material, and the second glass plate along a first direction to form a textured glass structure, wherein the first direction is perpendicular to the surface of the textured glass structure; and attaching the textured glass structure to the top of an LED display unit to form the LED floor tile screen. This application improves the presentation effect of the textured pattern in the LED floor tile screen, thereby improving the overall aesthetics of the LED floor tile screen. Attached Figure Description

[0049] To more clearly illustrate the technical solutions in the embodiments of this application or the conventional technology, the drawings used in the description of the embodiments or the conventional technology will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0050] Figure 1 A flowchart illustrating a method for manufacturing an LED floor tile screen according to one embodiment of this application.

[0051] Figure 2 This is a structural diagram corresponding to the step of forming a textured film material in the manufacturing method of an LED floor tile screen provided in one embodiment of this application.

[0052] Figure 3 This is a structural diagram corresponding to the step of forming an LED floor tile screen in the manufacturing method of an LED floor tile screen provided in one embodiment of this application.

[0053] The reference numerals in the attached drawings include: 100-transparent substrate; 110-bottom filler layer; 120-textured layer; 130-protective layer; T-through-hole structure; 210-textured glass structure; 211-first glass plate; 211a-first film; 212-textured film material; 213-second glass plate; 213a-second film; 220-LED display unit; 221-LED cabinet; 222-lamp surface structure; 222a-LED lamp beads; 222b-PCB board; 223-cover plate support; 230-edge sealing strip. Detailed Implementation

[0054] To facilitate understanding of this application, a more complete description will be provided below with reference to the accompanying drawings, which illustrate embodiments of the present application. However, the present application can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that the disclosure of this application will be thorough and complete.

[0055] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application.

[0056] It should be understood that when an element or layer is referred to as "on," "adjacent to," "connected to," or "coupled to" other elements or layers, it may be directly on, adjacent to, connected to, or coupled to other elements or layers, or there may be intervening elements or layers. Conversely, when an element is referred to as "directly on," "directly adjacent to," "directly connected to," or "directly coupled to" other elements or layers, there are no intervening elements or layers. It should be understood that although the terms first, second, third, etc., may be used to describe various elements, parts, regions, layers, doping types, and / or portions, these elements, parts, regions, layers, doping types, and / or portions should not be limited by these terms. These terms are only used to distinguish one element, part, region, layer, doping type, or portion from another element, part, region, layer, doping type, or portion. Therefore, without departing from the teachings of this application, the first element, part, region, layer, doping type, or portion discussed below may be referred to as a second element, part, region, layer, or portion.

[0057] Spatial relation terms such as “below,” “under,” “below,” “below,” “above,” “above,” etc., are used herein to describe the relationship between one element or feature shown in the figure and other elements or features. It should be understood that, in addition to the orientation shown in the figure, spatial relation terms also include different orientations of the device in use and operation. For example, if the device in the figure is flipped, an element or feature described as “below,” “below,” or “below” will be oriented “above” the other element or feature. Therefore, the exemplary terms “below” and “under” can include both above and below orientations. Furthermore, the device may also include other orientations (e.g., rotated 90 degrees or other orientations), and the spatial descriptive terms used herein will be interpreted accordingly.

[0058] When used herein, the singular forms of “a,” “an,” and “the” may also include the plural forms, unless the context clearly indicates otherwise. It should also be understood that the terms “comprising / including” or “having,” etc., specify the presence of the stated features, wholes, steps, operations, components, parts, or combinations thereof, but do not preclude the possibility of the presence or addition of one or more other features, wholes, steps, operations, components, parts, or combinations thereof. Meanwhile, in this specification, the term “and / or” includes any and all combinations of the associated listed items.

[0059] Generally, LED floor tile screens are commonly used in commercial displays, stage rentals, exhibition halls, and other similar applications. They need to provide high-definition display while ensuring strong load-bearing capacity and protection on their surface. Therefore, transparent hard materials such as acrylic sheets or tempered glass are usually added to the LED surface to protect the LED chips. However, the off-screen effect of these LED floor tile screens is usually black or gray, failing to simulate the appearance of real floor tiles and making them incompatible with the environment.

[0060] To address these issues, a textured mask can be added to the surface of the LED floor tile screen to create a natural-looking pattern. However, this type of textured mask can only be used to fill the gaps between the LED lights, leaving the LED beads untouched. This results in the dot matrix effect of the LED beads affecting the screen's appearance when viewed up close, severely impacting its aesthetics.

[0061] Alternatively, a textured effect can be achieved by completely covering the surface of the LED floor tile screen with a patterned acrylic or glass plate. However, the pattern itself on the acrylic or glass plate has low transmittance, which negatively impacts the display brightness and image quality of the LED floor tile screen. While simply reducing the concentration or thickness of the pattern ink can improve light transmittance at the pattern area to some extent, it can easily lead to uneven light blocking by the pattern, resulting in problems such as water ripples, localized color blocks, and the exposure of the underlying LED light surface color, thus severely affecting the overall aesthetics of the LED floor tile screen.

[0062] Therefore, it is necessary to provide an LED floor tile screen and its manufacturing method to improve the presentation effect of texture patterns in the LED floor tile screen, thereby improving the overall aesthetics of the LED floor tile screen.

[0063] Figure 1 A flowchart illustrating a method for manufacturing an LED floor tile screen according to one embodiment of this application. See also... Figure 1 One embodiment of this application provides a method for manufacturing an LED floor tile screen, which includes the following steps S01 to S05.

[0064] Step S01: Provide a transparent substrate, form an underfill layer on the transparent substrate, and form a texture layer on the side of the underfill layer away from the transparent substrate, wherein a texture pattern is formed in the texture layer.

[0065] It should be noted that by forming a base layer and a textured layer with textured patterns on a transparent substrate to simulate the appearance effects of real tile patterns, wood grain patterns, cement patterns, etc., the LED floor tile screen can provide decorative effects while taking into account light transmittance.

[0066] Step S02: Perform hole-opening treatment on the underfill layer and the texture layer to form a periodically arranged through-hole structure that penetrates the underfill layer and the texture layer.

[0067] It should be noted that by forming a through-hole structure that penetrates the base layer and the texture layer, light can be transmitted through the through-hole structure, thereby improving the average light transmittance of the textured film. By adjusting the size and periodicity of the through-hole structure, the through-hole structure can be controlled within a range that is imperceptible to the human eye. This improves light transmittance while reducing the negative impact of the through-hole structure on the texture pattern, thus balancing the light transmittance and aesthetics of the textured film.

[0068] Step S03: A protective layer is formed on the side of the textured layer away from the underfill layer to form a textured film including the transparent substrate, the underfill layer, the textured layer and the protective layer.

[0069] It should be noted that by forming a textured film with a protective layer, the textured layer can be protected to a certain extent, thereby improving the practicality and service life of the textured film.

[0070] Step S04: Provide a first glass plate and a second glass plate, and stack the first glass plate, the textured film and the second glass plate along a first direction to form a textured glass structure, wherein the first direction is perpendicular to the surface of the textured glass structure.

[0071] It should be noted that by stacking the first glass plate and the second glass plate on both sides of the textured film, the textured film in the textured glass structure can be further protected from external damage, thus balancing the decorative effect and durability of the textured film.

[0072] Step S05: Attach the textured glass structure to the top of an LED display unit to form the LED floor tile screen.

[0073] The manufacturing method of the LED floor tile screen described above involves forming a base layer and a textured layer with a textured pattern on a transparent substrate to simulate the appearance effects of real ceramic tile patterns, wood grain patterns, cement patterns, etc. By forming a through-hole structure that penetrates the base layer and the textured layer, light can be transmitted through the through-hole structure, thereby improving the average light transmittance of the textured film. By adjusting the size and periodicity of the through-hole structure, the through-hole structure can be controlled within a range that is imperceptible to the human eye, thereby improving light transmittance while reducing the negative impact of the through-hole structure on the textured pattern, thus balancing the light transmittance and aesthetics of the textured film. By forming a protective layer on the textured layer and stacking a first glass plate and a second glass plate on both sides of the textured film, the textured film in the textured glass structure is protected from external damage, thus balancing the decorative effect and durability of the LED floor tile screen.

[0074] See Figure 2 In one embodiment, the process of forming an underfill layer 110 on a transparent substrate 100 and forming a texture layer 120 on the side of the underfill layer 110 away from the transparent substrate 100 includes: first, forming the underfill layer 110 on the transparent substrate 100 using any one of screen printing, microgravure printing, inkjet printing, and mold transfer processes; then, performing a heat drying treatment on the underfill layer 110; subsequently, forming the texture layer 120 on the side of the underfill layer 110 away from the transparent substrate 100 using any one of screen printing, microgravure printing, inkjet printing, and mold transfer processes; and then performing a heat drying treatment on the texture layer 120.

[0075] In one embodiment, the material of the underfill layer 110 includes any one of black UV ink, white UV ink, or gray UV ink. Optionally, the transmittance of the underfill layer 110 is in the range of 40% to 80%; the haze of the underfill layer 110 is in the range of 75% to 99%. Optionally, the wet film thickness of the underfill layer 110 (i.e., the thickness of the underfill layer 110 before the heat drying treatment) is in the range of 10 μm to 40 μm.

[0076] In one embodiment, the material of the texture layer 120 includes UV ink. Optionally, the transmittance of the texture layer 120 is in the range of 40% to 60%. Optionally, the wet film thickness of the texture layer 120 (i.e., the thickness of the texture layer 120 before heat drying) is in the range of 10 μm to 20 μm. Optionally, the texture pattern includes one of marble, wood grain, and cement patterns. In other embodiments of this application, the texture pattern can also be replaced with other commonly used decorative patterns. Those skilled in the art can adjust or replace the texture pattern according to actual needs, and this application does not limit this.

[0077] Continue reading Figure 2 In one embodiment, the process of opening the underfill layer 110 and the texture layer 120 to form a periodically arranged through-hole structure T penetrating the underfill layer 110 and the texture layer 120 includes: providing a carrier (not shown in the figure) with periodically arranged raised structures (not shown in the figure) formed on the surface of the carrier; then, rolling an ink layer composed of the underfill layer 110 and the texture layer 120 to form raised portions (not shown in the figure) in the ink layer corresponding to the raised structures; subsequently, removing a portion of the ink layer at the location of the raised portions to form through-hole structures T in the raised portions, the through-hole structures T penetrating the underfill layer 110 and the texture layer 120, and all through-hole structures T in the ink layer being periodically arranged.

[0078] In one embodiment, the carrier is a roller or a template; when the carrier is a roller, the roller can be used to roll on the ink layer to form a protrusion; when the carrier is a template, the template can be used to press on the ink layer to form a protrusion.

[0079] In one embodiment, the width of the through-hole structure T is between 10 μm and 100 μm; the period of the through-hole structure T is between 50 μm and 200 μm. Optionally, the through-hole duty cycle (i.e., the ratio of the through-hole area to the total area of ​​the ink layer) of the through-hole structure T is between 10% and 40%. Preferably, the through-hole duty cycle of the through-hole structure T is between 25% and 35%.

[0080] In other embodiments of this application, the shape, size, period, duty cycle or other parameters of the through-hole structure can be adjusted according to actual needs, as long as the through-hole structure can be kept within a range that is difficult for the human eye to observe and perceive while improving the light transmittance of the ink layer, so as to balance the light transmittance and aesthetics of the ink layer. This application does not impose any restrictions on this.

[0081] See Figure 2 In one embodiment, the process of forming a protective layer 130 on the side of the textured layer 120 away from the underfill layer 110 includes: applying a protective material to the surface of the textured layer 120 using a microgravure coating process or a slot coating process, and subjecting the protective material to a heat-drying treatment to form the protective layer 130. Optionally, the material of the protective layer 130 includes a transparent resin material. Optionally, the protective layer 130 fills the through-hole structure T.

[0082] In one embodiment, after forming the protective layer 130, the manufacturing method of the LED floor tile screen further includes: performing UV curing treatment on the underfill layer 110, the texture layer 120, and the protective layer 130 to completely cure the underfill layer 110, the texture layer 120, and the protective layer 130, and forming a textured glass structure including a transparent substrate 100, the underfill layer 110, the texture layer 120, and the protective layer 130. Optionally, an energy level of 500 mJ / cm² is used. 2 ~1000mJ / cm 2 UV curing is performed using a UV light source within the specified range.

[0083] See Figure 3 In one embodiment, a first glass plate 211 and a second glass plate 213 are provided, and the first glass plate 211, the textured film 212 and the second glass plate 213 are laminated along a first direction (i.e., direction A) to form a textured glass structure 210. The process is as follows.

[0084] First, the textured film 212 is cut, and the size of the cut textured film 212 is larger than the size of the first glass plate 211 and the second glass plate 213.

[0085] Next, the first glass plate 211 and the second glass plate 213 are subjected to surface cleaning treatment to improve the surface cleanliness of the first glass plate 211 and the second glass plate 213. Optionally, deionized water and a dedicated cleaning machine are used to perform surface cleaning treatment on the first glass plate 211 and the second glass plate 213.

[0086] Subsequently, a first film 211a and a second film 213a are provided, and the first film 211a and the second film 213a are cut according to the dimensions of the first glass plate 211 and the second glass plate 213, respectively, so that the dimensions of the first film 211a and the second film 213a correspond to the first glass plate 211 and the second glass plate 213, respectively. Optionally, the first film 211a and the second film 213a include one of PVB film and SGP film. Optionally, the first glass plate 211 and the second glass plate 213 have the same dimensions.

[0087] Next, the first glass plate 211, the first film 211a, the textured film 212, the second film 213a, and the second glass plate 213 are stacked in that order, and the assembled structural component is pre-pressed using a pre-pressing machine to form an assembled assembly. Optionally, the pre-pressing process includes: starting the pre-pressing machine, heating the rubber rollers to a set temperature, and rolling the assembled structural component at a set pressure and speed to form the assembled assembly. For example, the set temperature is, for example, 85°C.

[0088] Subsequently, the laminated assembly is trimmed. Optionally, a blade or dicing machine is used to remove the textured film 212, the first film 211a, and the second film 213a at one edge of the first glass plate 211 and the second glass plate 213 to form a laminated assembly with flush edges.

[0089] Next, the trimmed laminated assembly is pressurized to form a textured glass structure 210. Optionally, the pressurization process includes: placing the laminated assembly vertically or horizontally on a support frame, separating adjacent laminated assemblies with spacers to ensure air circulation to the surface of all laminated assemblies; then, pushing the support frame containing the laminated assemblies into an autoclave; next, closing the sealing door of the autoclave, pressurizing the autoclave to 1.0 MPa to 1.5 MPa, and heating it to 120°C to 135°C at a rate of 1°C / min, maintaining it for 1 to 3 hours; then, slowly depressurizing it to normal atmospheric pressure (i.e., standard atmospheric pressure) and allowing it to cool naturally to room temperature (i.e., within the temperature range of 20°C to 28°C) to form the textured glass structure 210, and then removing it from the autoclave.

[0090] It should be noted that the manufacturing process and method for forming textured glass structures described above are merely one example. In other embodiments of this application, those skilled in the art can flexibly adjust the manufacturing process and the process methods used in each step of the textured glass structure based on common knowledge and actual needs, and this application does not impose any limitations on this.

[0091] Continue reading Figure 3 In one embodiment, after forming the textured glass structure 210, the process of attaching the textured glass structure to the top of an LED display unit 220 to form an LED floor tile screen includes: providing an LED display unit 220, the LED display unit 220 including an LED housing 221, a lamp surface structure 222 formed on one side of the LED housing 221, and a cover plate support 223 formed on the periphery of the lamp surface structure 222; installing the textured glass structure 210 on the side of the cover plate support 223 away from the LED housing 221; applying an adhesive to the periphery of the textured glass structure 210 and performing edge binding treatment, allowing it to stand until the adhesive solidifies, thereby attaching the textured glass structure 210 to the top of the LED display unit 220. Optionally, the adhesive includes glass glue. Optionally, adhesive tape or Mylar sheet is used for edge binding treatment.

[0092] In one embodiment, after attaching the textured glass structure 210 to the top of the LED display unit 220, the manufacturing method of the LED floor tile screen further includes: assembling and calibrating the LED cabinet 221, and performing brightness and color correction on the LED beads 222a in the lamp surface structure 222 directly below the location of the textured pattern, so as to improve the consistency of the white screen of the LED floor tile screen under the normal viewing angle.

[0093] The following is combined with Figure 2 and Figure 3 This application describes in detail an exemplary application of the method for manufacturing an LED floor tile screen according to one embodiment of the present application.

[0094] First, refer to Figure 2 A transparent substrate roll film is provided. The transparent substrate roll film is placed on a roll holder, and its surface is subjected to plasma corona treatment to produce a transparent substrate 100 that meets process requirements. Optionally, the transparent substrate roll film is, for example, a PET substrate roll film, and its thickness is, for example, 120 μm, its width is, for example, 0.6 m, and its light transmittance is, for example, 94%. Optionally, the plasma corona treatment power is 1.5 kW, the frequency is 20 kHz, and the starting speed is 20 m / min. Optionally, after the plasma corona treatment, the dyne value of the transparent substrate roll film is greater than or equal to 50 dyn / cm.

[0095] Subsequently, a semi-transparent black UV ink material is provided, which is stirred evenly and subjected to vacuum degassing treatment. Then, under yellow light, the semi-transparent black UV ink material is coated onto the surface of the PET film using a micro-gravure coating process, and pre-cured at a constant temperature of 60°C for 5 minutes to form an underfill layer 110 on the transparent substrate 100.

[0096] For example, a semi-transparent black UV ink material comprises 60 parts UV acrylate resin, 20 parts dipropylene glycol diacrylate, 6 parts nano-transparent iron oxide black paste (30% solid content), 10 parts fumed silica, 2 parts photoinitiator TPO, 1 part silane coupling agent KH-570, 0.5 parts dispersant BYK-2150, and 0.5 parts leveling agent BYK-310. Optionally, the wet film thickness of the semi-transparent black UV ink material is, for example, 20 μm.

[0097] Next, a semi-transparent gold ink is provided, along with a texture transfer steel roller with a marble pattern laser-engraved on it and a silicone elastic impression roller. The transfer steel roller is immersed in the semi-transparent gold ink, and the ink on the raised parts of the transfer steel roller is scraped clean with a doctor blade, leaving only the ink in the textured grooves of the transfer steel roller. The transfer steel roller carrying the textured ink and the elastic impression roller are brought into contact under a set pressure, so that the marble pattern ink is completely transferred to the surface of the elastic impression roller. The elastic impression roller is pressed onto the surface of the underfill layer 110 and heated at a constant temperature of 60°C for 1 minute to transfer the marble pattern onto the surface of the underfill layer 110. The elastic impression roller is then smoothly separated to form a textured layer 120 with a textured pattern.

[0098] For example, the translucent gold ink contains 60 parts polyurethane acrylate resin, 20 parts dipropylene glycol diacrylate, 6 parts nano-transparent golden iron oxide pigment, 2 parts photoinitiator TPO, 8 parts fumed silica, 2 parts silane coupling agent KH-560, 1 part dispersant polyether modified polydimethylsiloxane, 0.5 parts leveling agent BYK-310 and 0.5 parts defoamer BYK-055.

[0099] Subsequently, an embossing plate with periodic cylindrical protrusions is provided; the embossing plate is used to micro-imprint the ink layer (i.e., the underfill layer 110 and the texture layer 120), and the protruding cylindrical portions completely squeeze the corresponding ink layers apart; using 80mJ / cm 2 A 365nm UV surface light source is used to pre-cur the ink layer under a nitrogen atmosphere, and the curing time is 10 seconds before demolding to form a periodically arranged through-hole structure T. For example, the diameter of the cylinders on the imprint plate is 67μm, the height is 20μm, and the distance between the centers of two adjacent cylinders is 100μm.

[0100] Next, refer to Figure 2 and Figure 3 A transparent UV ink is provided; the transparent UV ink is applied to the surface of the texture layer 120 using a slit extrusion method and pre-dried at 60°C for 1 minute to form a protective layer 130; the transparent UV ink is irradiated with a 395nm high-power UV-LED point light source at an intensity of 800mJ / cm² and subjected to overall UV deep curing to form a textured film 212; subsequently, the textured film 212 is cut into 510mm × 510mm dimensions for later use. Optionally, the wet film thickness of the transparent UV ink is, for example, 10μm.

[0101] For example, the transparent UV ink comprises 50 parts aliphatic polyurethane acrylate, 10 parts epoxy acrylate, 20 parts isobornyl acrylate, 10 parts trimethylolpropane triacrylate, 2 parts photoinitiator phenyl bis(2,4,6-trimethylbenzoyl)phosphorus oxide, 1 part photoinitiator phenyl bis(2,4,6-trimethylbenzoyl)phosphorus oxide, 4 parts fumed silica, 2 parts silane coupling agent KH-570, 0.5 parts leveling agent BYK-333, and 0.5 parts defoamer BYK-011.

[0102] Subsequently, two pieces of tempered glass (495mm×495mm×5mm) are provided (i.e., the first glass plate 211 and the second glass plate 213); the surfaces of the two tempered glass pieces are cleaned using deionized water and a glass cleaning machine; two pieces of PVB film (i.e., the first film 211a and the second film 213a) are provided; the films are stacked in the order of tempered glass-film-textured film-film-tempered glass, and the film is slowly laid down from one side to avoid air entrapment and to ensure that the edges of the tempered glass and the PVB film are aligned.

[0103] Next, the assembled structural components are fed into a pre-pressing machine (which includes three pairs of heated rubber rollers). The temperature of the first pre-pressing roller is set to 85℃, the pressure to 0.5MPa, and the rolling speed to 1m / min; the temperature of the second pre-pressing roller is set to 95℃, the pressure to 0.6MPa, and the rolling speed to 1.5m / min; and the temperature of the third pre-pressing roller is set to 105℃, the pressure to 0.8MPa, and the rolling speed to 2m / min. The assembled structural components are rolled at a uniform speed to gradually expel interlayer air from the center to the edges and to allow the PVB film to initially adhere to the steel. On tempered glass and textured film; use a blade to trim away the excess textured film and PVB film from the edges of the tempered glass, place the pre-pressed composite assembly horizontally on a support frame, and use spacers to separate adjacent composite assemblies to ensure that air can circulate to the surface of all composite assemblies; push the support frame into the autoclave and close the sealing door, gradually pressurize to 1.5MPa, heat to 120℃ at a rate of 1℃ / min, maintain for 1 hour, and then slowly depressurize to atmospheric pressure (i.e., standard atmospheric pressure), and then allow it to cool naturally to room temperature (i.e., 20℃~28℃) before removing it from the autoclave to form a textured glass structure 210.

[0104] Then continue to refer to Figure 3An LED cabinet 221 and four modules are provided and assembled in a 2×2 configuration. The textured glass structure 210 is mounted on the cover plate support 223 for support. A layer of transparent glass glue is applied to the four sides of the textured glass structure 210, and then tape is used to wrap the edges of the textured glass structure 210. Excess glass glue overflowing from the surface is scraped off, and the surface is left to stand for 24 hours until the glue is completely cured to form an edge wrapping strip 230. The LED cabinet 221 is assembled and aligned, and the brightness and color of the LED beads 222a at the texture pattern position are corrected to ensure the consistency of the white screen of the LED floor tile screen under the direct viewing angle.

[0105] Continue reading Figure 3 One embodiment of this application also provides an LED floor tile screen, including an LED display unit 220 and a textured glass structure 210; wherein, the textured glass structure 210 is attached to the top of the LED display unit 220, and the textured glass structure 210 includes a first glass plate 211, a textured film 212, and a second glass plate 213 arranged sequentially along a first direction (i.e., direction A), the first direction being perpendicular to the surface of the textured glass structure 210; see reference Figure 2 and Figure 3 The textured film material 212 includes a transparent substrate 100, a base filler layer 110, a textured layer 120, and a protective layer 130. The transparent substrate 100 is located on the side of the textured glass structure 210 closer to the LED display unit 220. The base filler layer 110 is located on the side of the transparent substrate 100 away from the LED display unit 220. The textured layer 120 is located on the side of the base filler layer 110 away from the transparent substrate 100. A textured pattern is formed in the textured layer 120, and periodically arranged through-hole structures T are provided in the textured layer 120 and the base filler layer 110. The protective layer 130 is located on the side of the textured layer 120 away from the base filler layer 110.

[0106] As described above, the LED floor tile screen simulates the appearance of real ceramic tile patterns, wood grain patterns, and cement patterns by setting a base layer and a textured layer with textured patterns on a transparent substrate. By setting a through-hole structure that penetrates the base layer and the textured layer, light can be transmitted through the through-hole structure, thereby improving the average light transmittance of the textured film. By adjusting the size and periodicity of the through-hole structure, the through-hole structure can be controlled within a range that is imperceptible to the human eye, thereby improving light transmittance while reducing the negative impact of the through-hole structure on the textured pattern, thus balancing the light transmittance and aesthetics of the textured film. By setting a protective layer on the textured layer and laying a first glass plate and a second glass plate on both sides of the textured film, the textured film in the textured glass structure is protected from external damage, thus balancing the decorative effect and durability of the LED floor tile screen.

[0107] In one embodiment, the transparent substrate 100 is, for example, a PET film. In one embodiment, the transmittance of the underfill layer 110 is in the range of 40% to 80%, the haze is in the range of 75% to 99%, and the underfill layer 110 includes one of a black UV ink layer, a white UV ink layer, and a gray UV ink layer.

[0108] In other embodiments of this application, the underfill layer 110 may also be a pure black, pure white, pure gray, or other semi-transparent solid color layer. Optionally, the underfill layer 110 comprises, by weight, 45-65 parts of high-transparency UV resin, 15-30 parts of reactive diluent, 2-8 parts of semi-transparent black or white pigment, 5-10 parts of matte filler, 1-4 parts of photoinitiator, 0.1-2 parts of adhesion promoter, 0.1-2 parts of dispersant, and 0.1-2 parts of leveling agent.

[0109] In one embodiment, the transmittance of the texture layer 120 is in the range of 40% to 60%, and the material of the texture layer 120 includes UV ink. Optionally, the texture pattern includes at least one of marble pattern, wood grain pattern, and cement pattern. In other embodiments of this application, the texture pattern may also include patterns of stainless steel, mirror, or other imitation decorative materials. Optionally, the texture layer 120 comprises, by weight, 50-70 parts of high-transparency UV resin, 20-30 parts of reactive diluent, 2-10 parts of nano-scale transparent pigment, 5-10 parts of filler, 1-5 parts of photoinitiator, 0.1-2 parts of adhesion promoter, 0.1-2 parts of dispersant, and 0.1-2 parts of leveling agent.

[0110] The high-transparency UV resin is one or more of acrylic resin, epoxy acrylate, polyurethane acrylate, and polyester acrylate; the reactive diluent is one or more of caprolactone acrylate, isoborneol acrylate, lauryl acrylate, tripropylene glycol diacrylate, ethoxylated phenolic acrylate, and trimethylolpropane triacrylate; the translucent black pigment is one of nano carbon black or nano iron oxide black; the translucent white pigment is one of nano titanium dioxide, barium sulfate, zinc oxide, or fumed silica; the matting filler is one or more of fumed silica, PE wax, PP wax, PTFE wax, kaolin, talc, or barium sulfate; and the photoinitiator is phenylbis(2,4,6-trimethylbenzoyl)phosphorus oxide or 1-hydroxy-cyclohexyl-phenyl One or more of the following: methyl ketone, 2,4,6-trimethylbenzoyl-diphenylphosphine oxide, 2-hydroxy-2-methyl-1-phenyl-1-propanone, 2-dimethylamino-2-benzyl-1-[4-(4-morpholino)phenyl]-1-butanone, and 2-isopropylthioxanthone; the adhesion promoter is one of the following: silane coupling agent KH-550, KH-560, KH-570, A151, mono(meth)acryloyloxyethyl phosphate, ethoxylated diacrylate phosphate, (meth)acryloyloxyalkyl phosphate, and bis((meth)acryloyloxyethyl) phosphate; the dispersant is one of the following: BYK-2150, BYK-2163, and BYK-110; and the leveling agent is one of the following: BYK-306, BYK-310, and BYK-333.

[0111] In one embodiment, the through-hole shape of the through-hole structure T includes any one of a circle, square, regular hexagon, cross, or other centrally symmetrical shape; the through-hole width of the through-hole structure T is in the range of 10μm to 100μm; the period is in the range of 50μm to 200μm; and the through-hole duty cycle of the through-hole structure T is in the range of 10% to 40%.

[0112] Continue reading Figure 3 In one embodiment, the LED floor tile screen further includes a first film 211a and a second film 213a; the first film 211a is located between the first glass plate 211 and the textured film 212, and the second film 213a is located between the second glass plate 213 and the textured film 212. Optionally, the materials of the first film 211a and the second film 213a include one of PVB and SGP.

[0113] In one embodiment, the LED display unit 220 includes an LED housing 221, a lamp surface structure 222 (including multiple LED beads 222a disposed on a PCB board 222b) located on one side of the LED housing 221, and a cover plate support 223 located around the lamp surface structure 222, with one end of the cover plate support 223 away from the LED housing 221 abutting against the textured glass structure 210. Optionally, the periphery of the textured glass structure 210 is fixed with an edge-sealing adhesive strip 230 (i.e., an adhesive strip formed by applying glass glue to the edge).

[0114] In one embodiment, the manufacturing method for the LED floor tile screen described above can be used to manufacture the LED floor tile screen as described above. It should be noted that the textured glass structure in the LED floor tile screen can achieve a light transmittance of 50%-70%, thereby enabling the brightness of the LED floor tile screen to reach 600 nits~1500 nits. Furthermore, by using two pieces of tempered glass to sandwich the textured film material in the middle to prepare the textured glass structure, the problem of poor adhesion and difficulty in protecting the ink on the glass surface is solved, thus protecting the textured pattern from damage caused by external forces or disassembly of the enclosure. Further, in the future, the textured glass structure can be reused by replacing the textured film material to save production costs.

[0115] In summary, this application provides an LED floor tile screen and its manufacturing method, comprising: providing a transparent substrate; forming a base layer on the transparent substrate; forming a texture layer on the side of the base layer away from the transparent substrate, wherein a textured pattern is formed within the texture layer; performing an opening process on the base layer and the texture layer to form a periodically arranged through-hole structure penetrating the base layer and the texture layer; forming a protective layer on the side of the texture layer away from the base layer to form a textured film material including the transparent substrate, the base layer, the textured layer, and the protective layer; providing a first glass plate and a second glass plate, and laminating the first glass plate, the textured film material, and the second glass plate along a first direction to form a textured glass structure, wherein the first direction is perpendicular to the surface of the textured glass structure; and attaching the textured glass structure to the top of an LED display unit to form the LED floor tile screen. This application improves the presentation effect of the textured pattern in the LED floor tile screen, thereby improving the overall aesthetics of the LED floor tile screen.

[0116] In the description of this specification, the references to terms such as "some embodiments," "other embodiments," "ideal embodiments," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example that are included in at least one embodiment or example of this application. In this specification, the illustrative descriptions of the above terms do not necessarily refer to the same embodiments or examples.

[0117] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features of the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0118] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A method for manufacturing an LED floor tile screen, characterized in that, include: A transparent substrate is provided, an underfill layer is formed on the transparent substrate, and a texture layer is formed on the side of the underfill layer away from the transparent substrate, wherein a texture pattern is formed in the texture layer; The underfill layer and the texture layer are perforated to form a periodically arranged through-hole structure that penetrates the underfill layer and the texture layer; A protective layer is formed on the side of the textured layer away from the underfill layer to form a textured film comprising the transparent substrate, the underfill layer, the textured layer, and the protective layer; A first glass plate and a second glass plate are provided, and the first glass plate, the textured film and the second glass plate are laminated along a first direction to form a textured glass structure, wherein the first direction is perpendicular to the surface of the textured glass structure; The textured glass structure is attached to the top of an LED display unit to form the LED floor tile screen.

2. The manufacturing method of the LED floor tile screen according to claim 1, characterized in that, The process of creating openings in the base fill layer and the texture layer includes: A carrier is provided, the surface of which is formed with a periodically arranged protrusion structure; The ink layer, which is composed of the base filler layer and the texture layer, is roll-formed to form protrusions in the ink layer that correspond to the raised structure. A portion of the ink layer at the location of the protrusion is removed to form a through-hole structure in the protrusion. The through-hole structure penetrates the underfill layer and the texture layer, and all the through-hole structures in the ink layer are arranged periodically.

3. The manufacturing method of the LED floor tile screen according to claim 1, characterized in that, The process of forming an underfill layer on the transparent substrate and forming a textured layer on the side of the underfill layer away from the transparent substrate includes: The underfill layer is formed on the transparent substrate by any one of the following processes: screen printing, microgravure printing, inkjet printing, and mold transfer. Perform heat treatment and surface drying on the underfill layer; The textured layer is formed on the side of the underfill layer away from the transparent substrate by any one of the following processes: screen printing, microgravure printing, inkjet printing, and mold transfer. Perform a heat-drying process on the texture layer.

4. The manufacturing method of the LED floor tile screen according to claim 1, characterized in that, The process of performing the lamination and stacking process to form a textured glass structure includes: The textured film is cut, and the size of the cut textured film is larger than the size of the first glass plate and the second glass plate. The first glass plate and the second glass plate are subjected to surface cleaning treatment; The first glass plate, the first film, the textured film, the second film, and the second glass plate are stacked in that order, and the stacked components are pre-pressed using a pre-pressing machine to form a composite assembly. The dimensions of the first film and the second film are the same as those of the first glass plate and the second glass plate, respectively. The laminated assembly is trimmed, and the trimmed laminated assembly is then pressurized to form the textured glass structure.

5. The method for manufacturing an LED floor tile screen according to claim 1, characterized in that, The process of attaching the textured glass structure to the top of an LED display unit includes: An LED display unit is provided, the LED display unit includes an LED housing, a lamp surface structure is formed on one side of the LED housing, and a cover plate support is formed on the periphery of the lamp surface structure; The textured glass structure is installed on the side of the cover plate support away from the LED enclosure; An adhesive is applied to the periphery of the textured glass structure and edge-wrapped. The structure is left to solidify so that the textured glass structure is attached to the top of the LED display unit.

6. An LED floor tile screen, characterized in that, include: LED display unit; A textured glass structure is attached to the top of the LED display unit. The textured glass structure includes a first glass plate, a textured film, and a second glass plate arranged sequentially along a first direction, wherein the first direction is perpendicular to the surface of the textured glass structure. The textured film material includes: A transparent substrate is located on the side of the textured glass structure closest to the LED display unit; The underfill layer is located on the side of the transparent substrate away from the LED display unit; A textured layer is located on the side of the underfill layer away from the transparent substrate. A textured pattern is formed in the textured layer, and periodically arranged through-hole structures are provided in the textured layer and the underfill layer. A protective layer is located on the side of the textured layer away from the underfill layer.

7. The LED floor tile screen according to claim 6, characterized in that, The through-hole width of the through-hole structure is in the range of 10μm to 100μm, the period of the through-hole structure is in the range of 50μm to 200μm, and the through-hole duty cycle of the through-hole structure is in the range of 10% to 40%.

8. The LED floor tile screen according to claim 6, characterized in that, The transmittance of the underfill layer is in the range of 40% to 80%, and the haze is in the range of 75% to 99%. The underfill layer includes one of a black UV ink layer, a white UV ink layer, and a gray UV ink layer.

9. The LED floor tile screen according to claim 6, characterized in that, The transmittance of the texture layer is in the range of 40% to 60%, the material of the texture layer includes UV ink, and the texture pattern includes at least one of marble pattern, wood grain pattern and cement pattern.

10. The LED floor tile screen according to claim 6, characterized in that, The LED floor tile screen also includes: A first film is located between the first glass plate and the textured film. The second film is located between the second glass plate and the textured film; The LED display unit includes: LED cabinet; The lamp surface structure is located on one side of the LED housing; The cover plate support is located on the periphery of the lamp surface structure, and the end of the cover plate support away from the LED cabinet abuts against the textured glass structure.

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