Reflective film structure and display device

Abstract

The utility model discloses a kind of reflecting film structure and display equipment, the reflecting film structure includes the reflecting film body of main part and the mounting hole for positioning lens.In the periphery of mounting hole, movable shielding portion is formed by cutting process, the shielding portion is defined by at least two separate cutting boundaries extending outward from mounting hole, so that it is connected with main film body holding portion, forming movable flip structure.The movable shielding portion can be flipped to the upper and lower two sides of reflecting film under external force, and is pressed to the lower side of reflecting film during assembly, so as to cover the suspended area formed under lens due to backboard groove.The scheme integrates movable shielding structure on reflecting film, effectively prevents light from falling into groove and being absorbed, and solves the problem of local dimming of display area.

Description

Technical Field

[0001] This utility model relates to the field of display device technology, and in particular to a reflective film structure and a display device. Background Technology

[0002] As display devices trend towards thinner, lighter, and lower-cost designs, direct-lit backlight modules are widely used due to their simple structure and ease of achieving a thinner profile. Current technological trends prioritize smaller light mixing distances, or OD values, to further reduce overall device thickness and enhance product competitiveness. To achieve a small OD design, the internal space of the module is highly compressed, placing higher demands on the layout and dimensional accuracy of each component.

[0003] Reference Figure 6 In small-displacement direct-lit backlight modules, reflective optical lenses are typically used to improve light utilization efficiency. However, due to cost considerations, the width of the printed circuit board (PCB) supporting the light source, such as LED strips, is often designed to be smaller than the overall size of the optical lens. This results in a portion of the lens, such as its corner or side, being suspended above the recesses on the backplate designed for mounting the PCB after module assembly, creating an unsupported cavity below the lens.

[0004] When an LED light source is working, the emitted light is refracted and reflected by the lens and guided in the outgoing direction. However, for the lens portion suspended above the groove, there is a lack of a surface below it that can effectively reflect light. The inner wall of the groove is usually dark or lacks reflective properties, which absorbs a large amount of light illuminating it. This localized light absorption phenomenon results in the luminous flux emitted from this area being much lower than that from other normal areas, causing a severely uneven brightness distribution of the backlight source.

[0005] Ultimately, on the display panel, the areas corresponding to these suspended recesses will exhibit noticeable dark areas or vignetting, i.e., blackening. This display defect significantly affects the uniformity of the image and the overall visual quality, becoming a key technical challenge restricting the performance improvement of small-OD, low-cost backlight module products. Utility Model Content

[0006] The embodiments of this utility model provide a reflective film structure, which aims to solve the technical problem of local darkening of the displayed image caused by the back plate groove being suspended below the reflective lens in the existing direct-lit backlight module with small mixing distance.

[0007] In a first aspect, this utility model provides a reflective film structure, comprising: a reflective film body; a mounting hole disposed on the reflective film body for aligning a lens; and a movable shielding portion formed on the reflective film body by cutting, the movable shielding portion being disposed around the mounting hole, the movable shielding portion including at least two separating cut edges, the separating cut edges connecting to the mounting hole and extending away from the mounting hole, the movable shielding portion being able to flip to both sides of the reflective film body under the action of external force, the movable shielding portion being used to cover the suspended area formed by the groove on the back plate below the reflective lens.

[0008] In one embodiment of the reflective film structure of this utility model, the movable shielding part further includes a hinged cutting edge, and the two ends of the hinged cutting edge are respectively connected to two adjacent separate cutting edges. The movable shielding part can be flipped around the hinged cutting edge to both sides of the reflective film body under the action of external force.

[0009] In one embodiment of the reflective film structure of this utility model, the hinged cutting edge includes an intermittent cutting structure, which is used to keep one side of the movable shielding part partially connected to the reflective film body.

[0010] In one embodiment of the reflective film structure of this utility model, the movable shielding part further includes a hole edge, which is disposed at the edge of the mounting hole.

[0011] In one embodiment of the reflective film structure of this utility model, the length of the hinged cutting edge is equal to the length of the hole edge, the two separate cutting edges extend in the same direction away from the mounting hole, and the movable shielding part is used to adapt to the situation where the corner of the reflective lens is suspended above the groove of the back plate.

[0012] In one embodiment of the reflective film structure of this utility model, the length of the hinged cutting edge is greater than the length of the hole edge, and the ends of the two separate cutting edges that are away from the mounting hole extend in different directions. The movable shielding part is used to adapt to the situation where the side of the lens is suspended above the groove on the back plate.

[0013] In one embodiment of the reflective film structure of this utility model, a protective film is further included, which covers the surfaces of the reflective film body and the movable shielding part, and the protective film is peelable.

[0014] In one embodiment of the reflective film structure of this utility model, the distance D from the hinged cutting edge to the center point of the mounting hole is: D=[(R+3mm-L) / 2]+10mm; where R is the lens diameter and L is the circuit board width of the backlight strip.

[0015] In one embodiment of the reflective film structure of this utility model, the minimum distance d from the hinged cutting edge to the edge of the hole is: d=D-(RL) / 6; where R is the lens diameter and L is the circuit board width of the backlight strip.

[0016] Secondly, this utility model discloses a display device, which includes the reflective film structure described above.

[0017] Compared with the prior art, the beneficial effects of this utility model are: In the technical solution of this utility model, the reflective film structure includes a main reflective film body and mounting holes for positioning the lens. Around the mounting holes, a movable shielding portion is formed through a cutting process. This shielding portion is defined by at least two separate cutting boundaries extending outward from the mounting holes, maintaining partial connection with the main film body to form a movable flip structure. This movable shielding portion can flip to the upper and lower surfaces of the reflective film under external force, and during assembly, it is pressed below the reflective film, thereby covering the suspended area formed by the backplate groove under the lens. This solution, by integrating a movable shielding structure onto the reflective film, effectively prevents light from falling into the groove and being absorbed, solving the problem of localized darkening in the display area. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the reflective film structure according to an embodiment of the present invention; Figure 2 This is a cross-sectional view of the reflective film structure without the movable shielding part in an embodiment of this utility model; Figure 3 This is a cross-sectional view of the movable shielding part of the reflective film structure in an embodiment of the present invention when it is not pressed down; Figure 4 This is a cross-sectional schematic diagram of the movable shielding part of the reflective film structure in an embodiment of the present invention when it is pressed down; Figure 5 This is a schematic diagram of the reflective film structure installed on the back plate according to an embodiment of the present invention; Figure 6 This is a schematic diagram showing the structural relationship between the lens and the reflective film in a small-OD direct-lit backlight module under existing technology. Figure label explanation: 10. Back panel; 11. Groove; 20. Reflective film; 21. Mounting hole; 30. Movable shielding part; 31. Separation cutting edge; 32. Hinge cutting edge; 33. Hole edge; 40. Circuit board; 50. Lens. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0021] It should be noted that all directional indicators (such as up, down, left, right, front, back, etc.) in this utility model embodiment are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0022] This invention addresses the technical problem of localized darkening of the displayed image caused by the groove 11 of the backplate 10 being suspended below the reflective lens 50 in existing direct-lit backlight modules with small mixing distances. A reflective film structure is proposed. (Refer to...) Figures 1 to 5 The reflective film structure includes: a reflective film body 20; a mounting hole 21 disposed on the reflective film body 20 for aligning the lens 50; and a movable shielding part 30 formed by cutting on the reflective film body 20. The movable shielding part 30 is disposed on the periphery of the mounting hole 21, and the movable shielding part 30 includes at least two separating cut edges 31. The separating cut edges 31 connect to the mounting hole 21 and extend away from the mounting hole 21. The movable shielding part 30 can be flipped to both sides of the reflective film body 20 under the action of external force. The movable shielding part 30 is used to cover the suspended area formed by the groove 11 on the back plate 10 below the reflective lens 50.

[0023] In the manufacturing process of a direct-lit LED backlight module, a rectangular reflective film 20 is first provided. This reflective film 20 is typically made of white PET material with high reflectivity and is used to reflect downward-emitted light back to the light-emitting surface to improve light efficiency. A through mounting hole 21 is provided at a designated position on the reflective film 20. The shape and size of the mounting hole 21 are adapted to the bottom contour of the reflective lens 50 provided above, so as to achieve precise positioning of the reflective film and optical components during assembly and avoid misalignment affecting optical performance.

[0024] Around the mounting hole 21, a movable shielding part 30 is formed directly from the reflective film 20 using a precision die-cutting process. This movable shielding part 30 is not an independent component but is integrally formed with the reflective film 20. Specifically, at least two separate cutting edges 31 start from the edge of the mounting hole 21 and extend outward in a straight line for a certain length. These cutting edges limit the connection between the movable shielding part 30 and the main reflective film 20 to the non-cut area, so that the movable shielding part 30 is connected to the main body only through the uncut part, i.e., the hinge or connection area, and has the freedom to flip.

[0025] When the reflective lens 50 in the backlight module is suspended above the groove 11 of the back plate 10 due to insufficient width of the circuit board 40, the movable shielding part 30 can be subjected to vertical pressing pressure applied by fingers or automated equipment in subsequent assembly processes, causing it to flip down around the connection area to the bottom side of the reflective film 20 and enter the suspended space below the lens 50, and finally flatten out to cover the groove 11 area of ​​the back plate 10.

[0026] Through this structure, the area where light was originally lost due to light absorption by the inner wall of the groove 11 is blocked by the highly reflective movable blocking part 30, so that light can be reflected normally, thereby effectively eliminating the local blacking phenomenon in the display screen and improving the brightness uniformity.

[0027] In one embodiment, the movable shielding part 30 further includes a hinged cutting edge 32, with each end of the hinged cutting edge 32 connected to two adjacent separate cutting edges 31. The movable shielding part 30 can be flipped around the hinged cutting edge 32 to both sides of the reflective film 20 under the action of external force.

[0028] In addition to at least two separate cutting edges 31 extending outward from the mounting hole 21, the movable shielding part 30 also has a crucial hinged cutting edge 32. The two ends of this hinged cutting edge 32 are connected to the two adjacent separate cutting edges 31, thereby enclosing a relatively independent movable area on the reflective film 20. For example, when the two separate cutting edges 31, the edge 33 of the mounting hole 21, and the hinged cutting edge 32 work together, a trapezoidal or triangular movable block can be formed. The separate cutting edges 31 are completely cut, ensuring that the three sides of the movable shielding part 30 are completely separated from the main film. The hinged cutting edge 32, however, is not completely cut but partially cut, retaining certain connecting fibers or thin ribs in the material to form a flexible connection. This partially cut hinged cutting edge 32 acts as the "hinge" or rotation axis for the movable shielding part 30 to flip.

[0029] During module assembly, when the movable shielding part 30 needs to be installed in place, the operator or the pin of the automated equipment applies vertical downward pressure to the middle of the movable shielding part 30. This pressure causes the movable shielding part 30 to twist and flip around the hinged cutting edge 32 between itself and the reflective film 20, thereby rotating from an initial flat state coplanar with the reflective film 20 to a shielding state covering the bottom surface of the reflective film 20 and extending into the suspended area below the lens 50.

[0030] In one embodiment, the hinged cutting edge 32 includes an intermittent cutting structure for maintaining a partial connection between one side of the movable shielding portion 30 and the reflective film 20.

[0031] The hinged cutting edge 32 specifically employs an intermittent cutting structure, i.e., discontinuous cutting along a predetermined trajectory on the reflective film 20, forming a linear structure composed of multiple independent cut segments and uncut retained segments alternating. In this intermittent cutting structure, the total length of the cut segments occupies most of the length of the hinged edge, while the retained segments are evenly or non-uniformly distributed among them, serving as a mechanical and material link connecting the movable shielding part 30 and the main reflective film 20. Microscopically, these retained segments appear as fiber bundles or plastic ribs connecting the upper and lower material layers; macroscopically, they collectively perform the function of "anchoring" the movable shielding part 30 to the reflective film 20. Simultaneously, due to the elastic deformation capability of the material itself, the movable shielding part 30 is allowed to generate sufficient torsion and bending when subjected to external forces. It is this partially connected state that allows the movable shielding part 30 to stably rotate around the axis defined by the intermittent cutting structure.

[0032] In actual production, this intermittent cutting structure can be achieved using a high-precision die-cutting plate. For example, by adjusting the die's depth or using a dotted-line die shape, the cutting depth can be ensured to penetrate the main layer of the reflective film without completely cutting off all the material, thus achieving reliable hinge performance. During assembly, when an external force is applied to the movable shielding part 30, the retaining section undergoes elastic deformation, allowing the movable shielding part 30 to smoothly flip under the lens 50 and cover the groove 11 of the back plate 10. After flipping, the retaining section recovers part of its shape, stably holding the movable shielding part 30 in the shielding position, effectively preventing its rebound and ensuring the durability of the optical shielding effect.

[0033] In one embodiment, the movable shielding part 30 further includes a hole edge 33, which is disposed at the edge of the mounting hole 21.

[0034] The hole edge 33 is not formed by additional cutting, but refers to one or more segments of the outline of the mounting hole 21 itself, serving as the starting boundary of the movable shielding part 30. Specifically, when the mounting hole 21 is formed on the reflective film 20 by die-cutting, the edge of the hole naturally forms the hole edge 33. When designing the movable shielding part 30, its root is directly connected to this hole edge 33, and the separating cut edge 31 starts from a specific point on the hole edge 33 and extends outward. For example, in a corner-suspended application scenario, the two separating cut edges 31 of the movable shielding part 30 start from the endpoints of the two hole edge edges 33 at one corner of the mounting hole 21, extending outward at an angle, and the portion of the hole edge 33 connected to the vertex of the corner becomes a boundary of the movable shielding part 30. Therefore, the hole edge 33, the separating cut edge 31, and the hinged cut edge 32 together enclose and form the complete outline of the movable shielding part 30.

[0035] This design utilizes the existing edge of the mounting hole 21 as the structural boundary, which not only simplifies the die-cutting process and avoids the material waste and structural instability caused by completely cutting the closed contour inside the reflective film 20, but also makes the relative positional relationship between the movable shielding part 30 and the mounting hole 21 more precise and stable, ensuring that its shielding position is precisely aligned with the suspended groove 11 below the lens 50 after flipping.

[0036] In actual assembly, since the hole edge 33 is part of the rigid connection, it provides a stable force transmission base for the movable shielding part 30. When the external force is transmitted to the separating cutting edge 31 and the hinged cutting edge 32 by pressing the movable shielding part 30, the hole edge 33 can effectively support the entire flipping action, preventing the movable shielding part 30 from twisting or tearing during the pressing process, thus ensuring the reliability of the operation and the yield rate.

[0037] In one embodiment, the length of the hinged cutting edge 32 is equal to the length of the hole edge 33, and the two separate cutting edges 31 extend in the same direction from the end away from the mounting hole 21. The movable shielding part 30 is used to adapt to the situation where the corner of the reflective lens 50 is suspended above the groove 11 of the back plate 10.

[0038] The length of the hinged cut edge 32 connecting the geometric configuration of the movable shielding part 30 to the main reflective film 20 is set to be equal to the length of a section of the hole edge 33 at the corresponding corner of the mounting hole 21. Specifically, when the mounting hole 21 is square or rectangular to accommodate the corresponding square-angle lens 50, a section between two adjacent sides at the corner is selected as the hole edge 33, and the straight length of this section is the set length of the hinged cut edge 32. Two separate cut edges 31 starting from both ends of the hole edge 33 extend outward at a certain angle, and their ends away from the mounting hole 21 point in the same approximate direction. For example, both separate cut edges 31 extend outward and upward or outward and downward, thereby forming a trapezoidal or approximately right-angled triangular cantilever structure together with the hinged cut edge 32 and the hole edge 33 of equal length.

[0039] This structure is specifically designed to address scenarios where one corner of the reflective lens 50 is suspended above the recess 11 of the back plate 10. During assembly, an operator or automated equipment identifies the corner position and applies downward pressure to the center of the movable shield 30. Because the two separating cut edges 31 are completely severed, the free end of the movable shield 30 can flip downwards without obstruction, while its root rotates around the hinged cut edge 32 of equal length, closely conforming to the geometry of the mounting hole 21. After flipping, this trapezoidal movable shield 30 completely covers the area of ​​the recess 11 of the back plate 10 located diagonally below the lens 50, effectively preventing light from entering and being absorbed.

[0040] In one embodiment, the length of the hinged cutting edge 32 is greater than the length of the hole edge 33, and the ends of the two separate cutting edges 31 that are away from the mounting hole 21 extend in different directions. The movable shielding part 30 is used to accommodate the situation where the side of the lens 50 is suspended above the groove 11 on the back plate 10.

[0041] The length of the hinged cut edge 32 is designed to be significantly greater than the length of the corresponding section of the hole edge 33 on the mounting hole 21 to which it is connected. Specifically, the hole edge 33 of the mounting hole 21 is relatively short, while the hinged cut edge 32 is a straight line or approximately straight line extending beyond the hole edge 33. Two separate cut edges 31 start from the two ends of the hole edge 33 and extend in different directions, for example, one extends outward and upward, and the other extends outward and downward, forming a "T" or "I" shaped base that is approximately perpendicular to or at an angle to the edge of the mounting hole 21, and then connects to a hinged cut edge 32 that is longer than the hole edge 33. As a result, the main body of the movable shielding part 30 is offset outward relative to the mounting hole 21 and forms a rectangular or rectangular movable plate, which is flexibly connected to the reflective film 20 by the long, narrow hinged cut edge 32. This structure is specifically adapted to situations where an entire side of the reflective lens 50 is suspended above the groove 11 of the back plate 10. During module assembly, the elongated movable shielding part 30 can cover the entire suspended area.

[0042] When an external force is applied to the middle of the elongated shielding part, it can rotate downwards around the hinged cutting edge 32, which is longer than the edge 33 of the aperture, and smoothly spread out on the groove 11 of the back plate 10 corresponding to the entire side of the lens 50. The increased length of the hinged cutting edge 32 ensures the structural stability of the elongated movable shielding part 30 during the rotation process, preventing warping or breakage caused by uneven torsion. On the other hand, it also makes its rotation smoother and can more completely cover the wider groove 11 area. After rotating into place, this structure can effectively shield the entire linear dark risk area, significantly improve the brightness uniformity of the backlight module along the side direction, and solve the problem of linear or strip-shaped blackening caused by the entire edge being suspended.

[0043] In one embodiment, the reflective film structure further includes a protective coating covering the surfaces of the reflective film body 20 and the movable shielding portion 30, and the protective coating is peelable.

[0044] To address the issue of warping, deformation, or accidental overturning and damage to the movable shielding part 30 during manufacturing, transportation, and storage, a protective film is further added to the surface of the reflective film 20. This protective film is a continuous sheet of film that completely covers the upper surface of the reflective film 20 and extends to cover the surfaces of all movable shielding parts 30, ensuring they remain flat and fixed during manufacturing and transportation. Specifically, because the movable shielding part 30 forms a cantilever or door-like structure with the main film body through the separating cut edge 31, its free end is easily curled or broken by external force during stacking or handling, leading to product scrap. The protective film, through its own tension and slight adsorption force on the reflective film surface, applies a uniform downward constraint force to the movable shielding part 30, effectively "flattening" it and fixing it in an initial position coplanar with the main reflective film 20, thereby preventing premature movement or damage during non-assembly stages. The protective coating is made of a lightweight material that is easy to peel off (such as PE or PP film) and does not form a permanent bond with the reflective film 20.

[0045] On the automated production line for backlight modules, after the reflective film structure is fed into the workstation, the peeling mechanism first performs the peeling operation: the suction cup of the peeling mechanism adheres to the back of the reflective film 20 to keep it stable, while a robotic arm or clamp holds a corner of the protective film and applies an appropriate peeling force. Since the adsorption force between the protective film and the reflective film 20 is controlled at a low level, when the peeling force is greater than the adsorption force, the protective film is completely peeled off from the surface of the reflective film 20 and the movable shielding part 30, while the reflective film 20 itself remains stationary. After peeling is completed, the movable shielding part 30 returns to its free state and then enters the next assembly process. The ejector pin driven by the robotic arm is positioned in the predetermined pressing area of ​​the movable shielding part 30, and a downward force is applied to make it rotate around the hinged cutting edge 32, finally snapping it into the position of the suspended groove 11 below the lens 50.

[0046] In one embodiment, the distance D from the hinged cutting edge 32 to the center point of the mounting hole 21 is: D=[(R+3mm-L) / 2]+10mm; where R is the diameter of the lens 50 and L is the width of the circuit board 40 of the backlight strip.

[0047] To ensure that the movable shielding part 30 accurately covers the suspended groove 11 area below the lens 50, this embodiment has a quantitatively designed position for the hinged cutting edge 32. Specifically, the distance D from the hinged cutting edge 32 to the center point of the mounting hole 21 is set to satisfy the formula: D = [(R + 3mm - L) / 2] + 10mm; Where R represents the diameter of the reflective lens 50, and for the non-circular lens 50, it refers to its effective width in the corresponding suspended direction. L represents the width of the circuit board 40 used for the backlight strip, i.e., the width of the strip.

[0048] The derivation of this formula is based on the actual assembly relationship of the optical components: In a direct-lit backlight module, when the width L of the circuit board 40 is less than the diameter R of the lens 50, the overhang width on both sides of the lens 50 is (R - L) / 2. The "(R + 3mm - L) / 2" part in the formula is a compensation calculation for the overhang area, where the added 3mm margin is to account for the extra space caused by the lens 50 bracket or tolerance. The calculated value represents the horizontal distance from the center of the LED to the starting point of the overhang area. Adding another 10mm on this basis is to ensure that the hinge position of the movable shielding part 30 can be arranged in a position that is reasonably stressed and does not affect the main reflection area, while allowing the effective shielding part of the movable shielding part 30 to extend sufficiently and completely cover the entire groove 11 area. Therefore, the precise setting of distance D ensures that after the movable shielding part 30 is flipped, its shielding range can completely cover the light-absorbing area of ​​the groove 11 where light is most likely to leak, and will not be limited by the die-cutting space due to being too close, or cause insufficient structural strength or interference with adjacent components due to being too far.

[0049] In actual production, the corresponding D value can be calculated based on the specific lens 50 used, such as 15mm, 17mm, 18mm, etc., and the design width of the circuit board 40. This allows for the precise definition of the position of the hinged cutting edge 32 on the die-cutting drawing, ensuring the versatility and assembly reliability of the reflective film structure.

[0050] Furthermore, the minimum distance d from the hinged cutting edge 32 to the hole edge 33 is: d=D-(RL) / 6; where R is the diameter of the lens 50 and L is the width of the circuit board 40 of the backlight strip.

[0051] Based on the determined distance between the hinged cutting edge 32 and the center point of the mounting hole 21, the structural dimensions of the movable shielding part 30 are further optimized to ensure sufficient shielding area and good flipping mechanical performance. Specifically, the minimum distance d from the hinged cutting edge 32 to the edge 33 of its adjacent mounting hole 21 is defined as d, and this distance is set to satisfy the formula: d = D - (R - L) / 6; In this context, R and L represent the diameter of the lens 50 and the width of the circuit board 40, respectively.

[0052] The correction term (R - L) / 6 in the formula is used to calculate the length by which the movable shield 30 needs to retract towards the mounting hole 21. Since (R - L) represents the total clearance between the lens 50 and the circuit board 40, 1 / 6 is an empirical proportionality coefficient designed to reasonably allocate the length of the movable shield 30. By subtracting this correction from the D value, the final distance d is the actual distance from the hole edge 33 to the hinged cut edge 32. This d value directly determines the initial length of the movable shield 30 before flipping.

[0053] This design ensures that after flipping, the front end of the movable shield 30 can extend sufficiently below the lens 50 to stably cover the groove 11, while its length is not excessive, preventing breakage or excessive deformation during flipping. The setting of the d-value dynamically correlates the size of the movable shield 30 with the (R - L) clearance of a specific model, ensuring the universality of this structural design. For models with a larger clearance, the d-value is increased accordingly, and the movable shield 30 is longer to cover a larger area; for models with a smaller clearance, the d-value is decreased, resulting in a more compact structure.

[0054] In one embodiment, to meet the needs of automated assembly lines and improve assembly accuracy and efficiency, a mechanical identification press mark is provided on the surface of the movable shield 30. This press mark is not a mark for manual observation, but rather a feature structure or pattern that can be identified by automated equipment. Specifically, the mark can be a tiny indentation, a raised dot, a cut of a specific shape formed on the surface of the movable shield 30, or a high-contrast optical mark printed / etched on the reflective film surface. The position of the mark is precisely designed, typically located at the geometric center of the movable shield 30 or in the optimal pressing force area thereon.

[0055] In the automated production process, after the reflective film structure is transported to the assembly station and initially positioned, the image acquisition device on the assembly equipment scans the surface of the reflective film. The system quickly locates the mechanical identification pressing mark using an image recognition algorithm, thereby accurately calculating the actual spatial coordinates of the movable blocking part 30 and any possible slight offsets. Subsequently, based on the recognition results, the control system adjusts the movement trajectory of the robotic arm's end effector, such as the cylindrical ejector pin, to ensure that the ejector pin is accurately aligned with the center of the pressing area.

[0056] This design solves the problem of misalignment during pressing caused by slight material deformation, transmission errors, or initial positioning deviations in high-speed automated production. Precise pressing position ensures that external force is applied evenly to the movable shielding part 30, allowing it to smoothly and completely flip around the hinged cutting edge 32 to below the lens 50, effectively avoiding defects such as structural tearing, incomplete flipping, or springback caused by eccentric pressing. Furthermore, the introduction of mechanically recognized pressing marks allows the reflective film structure to achieve high-precision assembly without relying on complex external positioning fixtures, improving the flexibility and efficiency of the production line and providing crucial support for the large-scale mass production of this low-cost optimization solution.

[0057] In one embodiment, a positioning mark is provided on the main reflective film 20.

[0058] The positioning marks are set on a specific area of ​​the main reflective film 20 away from the movable blocking part 30. They usually appear in pairs, such as located diagonally on the film. Their position design has a precise geometric correspondence with the LED array on the LED light strip in the backlight module. For example, the midpoint or geometric center of the line connecting the positioning marks is aligned with the midpoint of the line connecting the centers of the first and last LEDs, ensuring the global positioning of the reflective film 20 in the X and Y directions and rotation angles.

[0059] During automated assembly, the image acquisition device of the installation equipment first scans the entire surface of the reflective film 20, while simultaneously identifying and locating the positioning marks on the main reflective film 20. By analyzing the coordinates of the positioning marks, the system can perform a first-level correction to the initial position of the reflective film 20, achieving a rough alignment of the film and ensuring that the mounting holes 21 on the reflective film roughly match the approximate positions of the lower light strip and lens 50. After completing this step, the system then focuses on the area of ​​the movable shielding part 30, identifying the mechanical identification pressing marks on its surface. At this point, because the main film has been precisely calibrated using the positioning marks, the relative positional error of the pressing marks is extremely small, allowing the image acquisition system to lock the pressing point with higher precision.

[0060] This utility model also discloses a display device, which includes the reflective film structure described in the above embodiments.

[0061] Reference Figure 5 The display device can be a backlit flat panel display product such as an LCD TV, monitor, tablet computer, or laptop computer, which includes a backlight module as a light source unit. The backlight module is a direct-lit structure, including a backplate 10, LED strips mounted on the backplate 10, a reflective lens 50 above the LED strips, a diffuser plate, and a display panel at the top. The backlight module employs the reflective film structure described in the foregoing embodiments of this invention.

[0062] During assembly, the reflective film structure is laid between the back plate 10 and the LED strip. The mounting hole 21 of the reflective film body 20 is precisely aligned with the contour of the upper reflective lens 50 to ensure the concentricity of the optical components. When a narrow-width circuit board 40 (circuit board 40) is used in the design to reduce costs, a portion of the reflective lens 50 (such as the corner or side) is suspended above the groove 11 provided by the back plate 10 to accommodate the circuit board 40. In this case, the movable shielding part 30 located around the mounting hole 21 plays a key role: during the module assembly process, pressure is applied to the movable shielding part 30 manually or automatically, causing it to flip downward around the hinged cutting edge 32 and extend into the suspended space below the lens 50, ultimately covering the groove 11 area of ​​the back plate 10. The active shielding part 30 is made of a high reflectivity material of the same material as the reflective film 20. After it is covered, it effectively blocks the path of light entering the groove 11 and being absorbed by the dark inner wall, so that the area that would originally be dark can reflect light, thereby significantly improving the uniformity of backlight brightness and solving the technical problem of local darkening of the screen.

[0063] This reflective film structure requires no additional material costs or complex manufacturing processes, and is fully compatible with existing module manufacturing processes. It optimizes display quality solely through structural innovation. Therefore, display devices incorporating this reflective film structure offer a superior visual experience while maintaining low-cost design advantages, giving them significant market competitiveness.

[0064] In addition, this utility model also discloses a method for manufacturing the aforementioned display device.

[0065] This method is specifically designed for manufacturing display devices incorporating the reflective film structure of this invention. The production process begins on the backlight module assembly line, where LED strips are precisely installed at designated positions on the backplate 10, with the LED chips (light beads) on the strips arranged in an array. Subsequently, the reflective film structure is transported to the assembly station. The reflective film structure is covered with a peelable protective film at the factory to prevent warping or damage to the movable shielding portion 30 during transportation.

[0066] On the automated production line, the protective film is first peeled off by a film-peeling mechanism: the lower vacuum adsorption platform fixes the reflective film 20, while the upper clamp holds one end of the protective film, peeling it off completely under precisely controlled tension, allowing the movable shielding part 30 to return to its free state. Next, the system uses an image acquisition device to perform initial positioning through preset positioning holes or positioning marks on the reflective film 20, roughly aligning the reflective film 20 with the positions of the light strip and lens 50 on the back plate 10 and placing it in place.

[0067] The crucial snap-fit ​​installation process then begins: the image acquisition device of the installation equipment scans the surface of the reflective film, first identifying the positioning marks on the main reflective film 20 to complete global calibration, and then focusing on the periphery of the mounting hole 21 to identify the mechanical identification pressing marks on the movable shielding part 30, precisely locking the pressing point coordinates. The control system guides the robotic arm accordingly, moving its cylindrical ejector pin at its end to a designated position. This ejector pin, preferably 2mm in diameter with a flat end face, is driven by the robotic arm to press the ejector pin vertically downwards at a preset pressure and speed, causing it to flip downwards around the hinged cutting edge 32 until the movable shielding part 30 falls into and covers the groove 11 area of ​​the back plate 10 below the lens 50.

[0068] After the movable shielding parts 30 are flipped over at all necessary positions, the diffuser plate, optical film, and other components are installed sequentially upwards, finally merging with the liquid crystal display panel to form a complete display module. This production method integrates the reflective film structure of this invention into a standard process, adding only an automatic pressing step. Without changing the bill of materials or significantly adjusting the production line, it can efficiently and reliably manufacture display devices with excellent display uniformity, balancing the dual requirements of cost control and product quality.

[0069] The above description is merely a specific embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this utility model, and these modifications or substitutions should all be covered within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the scope of the claims.

Claims

1. A reflective film structure, characterized in that, include: Reflective film; Mounting holes are provided in the reflective film for aligning the lens; A movable shielding portion is formed on the reflective film by cutting. The movable shielding portion is located around the mounting hole. The movable shielding portion includes at least two separate cutting edges that connect to the mounting hole and extend away from the mounting hole. The movable shielding portion can be flipped to both sides of the reflective film under the action of external force. The movable shielding portion is used to cover the suspended area formed by the groove on the back plate below the reflective lens.

2. The reflective film structure according to claim 1, characterized in that, The movable shielding part also includes a hinged cutting edge, with each end of the hinged cutting edge connected to two adjacent separate cutting edges. The movable shielding part can be flipped around the hinged cutting edge to both sides of the reflective film under the action of external force.

3. The reflective film structure according to claim 2, characterized in that, The hinged cutting edge includes an intermittent cutting structure, which is used to keep one side of the movable shielding part partially connected to the reflective film.

4. The reflective film structure according to claim 2, characterized in that, The movable shielding part also includes a hole edge, which is located at the edge of the mounting hole.

5. The reflective film structure according to claim 4, characterized in that, The length of the hinged cutting edge is equal to the length of the hole edge edge, and the two separate cutting edges extend in the same direction from the end away from the mounting hole. The movable shielding part is used to adapt to the situation where the corner of the reflective lens is suspended above the groove of the back plate.

6. The reflective film structure according to claim 4, characterized in that, The length of the hinged cutting edge is greater than the length of the hole edge, and the ends of the two separate cutting edges that are away from the mounting hole extend in different directions. The movable shielding part is used to accommodate the situation where the side of the lens is suspended above the groove on the back plate.

7. The reflective film structure according to claim 1, characterized in that, It also includes a protective coating covering the surfaces of the reflective film and the movable shielding portion, the protective coating being peelable.

8. The reflective film structure according to claim 4, characterized in that, The distance D from the hinged cutting edge to the center point of the mounting hole is: D=[(R+3mm-L) / 2]+10mm; Wherein, R is the lens diameter, and L is the circuit board width of the backlight strip.

9. The reflective film structure according to claim 8, characterized in that, The minimum distance d from the hinged cutting edge to the edge of the hole is: d = D - (RL) / 6; Wherein, R is the lens diameter, and L is the circuit board width of the backlight strip.

10. A display device, characterized in that, It includes a reflective film structure as described in any one of claims 1 to 9.

Images