CN102026434A - 照明模块 - Google Patents

照明模块 Download PDF

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CN102026434A
CN102026434A CN2010102897973A CN201010289797A CN102026434A CN 102026434 A CN102026434 A CN 102026434A CN 2010102897973 A CN2010102897973 A CN 2010102897973A CN 201010289797 A CN201010289797 A CN 201010289797A CN 102026434 A CN102026434 A CN 102026434A
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emitting component
planar light
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light
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林真太郎
棚桥理
深野智
阿南真一
住山重次
斋见元洋
河地秀治
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Panasonic Holdings Corp
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Abstract

本发明涉及照明模块。照明模块(1)具备面状发光元件(2)、布线基板(3)、光学薄片(4)。布线基板(3)具有收容面状发光元件(2)的孔部(8)。光学薄片(4)以收容在布线基板(3)的孔部(8)的面状发光元件(2)和布线基板(3)在发光面侧呈一个平面的状态来保持面状发光元件(2)和布线基板(3)。照明模块(1)由于光学薄片(4)保持面状发光元件(2)和布线基板(3)并且阻止灰尘或水分侵入到模块内，因此无需具备框体或填料等，因此能够实现模块的薄型化。

Description

照明模块
技术领域
本发明涉及具备照明器具、液晶背光、各种显示器、显示装置等中使用的有机电致发光元件(以下，称为有机EL发光元件)的照明模块。
背景技术
以往，已知具备有机EL发光元件即面状发光元件的照明模块(例如，参照日本特开2007-299740号公报)。图6中表示如上述的照明模块101的构成。照明模块101具备：面状发光元件102、用于对其供电的布线基板103、在面状发光元件102的发光面上设置的光学薄片104、将面状发光元件102的元件电极和布线基板103的布线图案(未图示)电连接的供电接合部件105、收容上述各部件的框体106。
光学薄片104对从面状发光元件102照射的光的定向性和折射率进行调整。供电接合部件105由铜的引线框或柔性线路板构成。框体106具有用于向外部发射从面状发光元件102照射的光的开口部107。
就这种构成的照明模块101而言，容易在框体106的开口部107和光学薄片104的层差产生间隙，因此容易向模块内部侵入灰尘或水分。因此，若为了阻止灰尘或水分而在间隙中设置填料，便难以使模块薄型化，无法活用面状发光元件102为薄面光源这一特征。
发明内容
本发明为了解决上述问题而研发，其目的在于，提供一种能够阻止灰尘或水分侵入到模块内并且能够使模块薄型化的照明模块。
为了实现上述目的的，本发明为一种具有面状发光元件的照明模块，其特征在于，具备：布线基板，其形成有用于对上述面状发光元件供电的布线图案；防滴性的光学薄片，其设置在上述面状发光元件的发光面上，且用于对来自该发光元件的配光进行调整，并且，上述面状发光元件被收容在形成于上述布线基板的孔部，被收容在上述布线基板的孔部的面状发光元件和上述布线基板在发光面侧呈一个平面而固定于上述光学薄片上，由此上述光学薄片在发光面侧覆盖上述面状发光元件以及上述面状发光元件与布线基板之间的交界处。
由此，光学薄片保持面状发光元件和布线基板并且阻止灰尘或水分侵入到模块内，因此无需具备框体或填料等，因此能够实现模块的薄型化。
本发明为，在上述改进的发明中，上述面状发光元件的元件电极与布线基板的布线图案通过铝线电连接，上述铝线被紫外线硬化树脂被覆。
由此，借助铝线对面状发光元件供电，因此无需具备柔性线路板等供电接合部件，因此能够实现制造成本的降低。此外，由于通过紫外线硬化树脂被覆铝线，因此能够以常温、低成本来提高绝缘性、坚固性、耐湿性。因此能够保护铝线而使其避免受到力学的负荷、水分或其他气体导致的腐蚀。
本发明为，在上述改进的发明中，上述布线基板和上述光学薄片形成为外形相同。
本发明为，在上述改进的发明中，用于收容上述面状发光元件的形成于上述布线基板的孔部，通过使多个布线基板在上述光学薄片上并列而形成。
本发明为，在上述改进的发明中，上述面状发光元件和布线基板通过粘接剂粘接在上述光学薄片上。
本发明为，在上述改进的发明中，上述面状发光元件和布线基板的、配置有上述光学薄片的一侧的相反侧的面被涂装。
附图说明
图1是本发明的一实施方式涉及的照明模块的外观图。
图2是该照明模块的A-A线侧面剖视图。
图3是该照明模块的分解图。
图4是该照明模块的、涂布紫外线硬化树脂并通过紫外线使该紫外线硬化树脂硬化时的立体图。
图5是表示该照明模块的变形例的外观图。
图6是现有照明模块的侧面剖视图。
具体实施方式
图1至图4表示本发明的一实施方式涉及的照明模块1的构成。在图1和图2中，照明模块1具备面状发光元件2、用于对其供电的布线基板3、在面状发光元件2的发光面上设置的光学薄片4、在面状发光元件2及布线基板3上设置的铝线5、和密封铝线5使其绝缘的紫外线硬化树脂6。面状发光元件2具有与铝线5连接的元件电极7，布线基板3具有收容面状发光元件2的孔部8。照明模块1被组装到具有保持模块的保持构造和对模块供电的直流电源的照明器具而被使用。
面状发光元件2例如通过在80mm×80mm×0.7mm尺寸即长方形的无碱玻璃基板上将透明电极且作为阳极的铟锡氧化物、作为发光体的有机物、作为阴极的铝、和保护有机物的吸湿层或密封层按该顺序进行层叠而成。面状发光元件2通过在阳极和阴极之间施加电压而使有机物发光，并通过阴极的铝反射光而从发光面发射出光。
面状发光元件2的元件电极7由在面状发光元件2的阳极和阴极上溅射成膜的钼/铝/钼形成，例如由2mm×19mm的长方形垫片构成，并且在面状发光元件2的彼此对置的两边上各设有1个。另外，元件电极7可以在面状发光元件2的三边上各设有1个、或者在四边上各设有1个。面状发光元件2通过增加所设置的元件电极7的个数，使得对发光体的供电部位成为多个，防止因形成阳极的铟锡氧化物的电阻高而导致的阳极内发生的电压下降，因此能够降低光斑而均匀地发光。
布线基板3形成有用于对面状发光元件2供电的布线图案(未图示)，例如作为基板使用形成为20mm×80mm×0.5mm尺寸的FR-4，作为布线使用铜，具有电源电路的元件(component)，并且包含该元件在内的厚度为4mm。另外，布线基板3可以具有点灯控制用的IC，该点灯控制用的IC具有用于并列多个照明模块1而使用的DC/DC转换功能、用于在并列多个照明模块1而使用时进行个别点亮熄灭的地址控制功能、用于对照明模块1进行调光的PWM控制功能等。此外，也可以具有用于供电的连接器、照明器具或用于固定在墙壁、天花板等上的螺栓孔等。
布线基板3的孔部8为收纳面状发光元件2的大小，其周围排列有用于与铝线5超声波接合的作为布线图案的一部分的焊盘。焊盘例如为1mm×1mm的大小，且通过薄镀金处理形成。在焊盘周边，为了控制所涂布的紫外线硬化树脂6浸润而展开的区域而印刷有丝网图案。另外，布线基板3可以是不具有贯通通孔的加厚布线板。具有该加厚布线板的照明模块1能够通过在布线基板的与设置有光学薄片4侧相反的一侧的面进行任意的涂装来提高设计性。涂装优选使用防水性的涂料。
光学薄片4由丙烯酸树脂形成，且形成为与布线基板3相同的尺寸，被切成与螺纹孔或连接器的形状相匹配。此外，光学薄片4具有防滴、防尘性，通过控制折射率来提高光取出量并控制光的定向性。光学薄片4以收容在布线基板3的孔部8的面状发光元件2和布线基板3在发光面侧没有层差的呈一个平面的状态，通过粘接剂来保持面状发光元件2和布线基板3。此外，覆盖面状发光元件2并且也覆盖面状发光元件2和布线基板3之间的交界处。另外，光学薄片4在需要耐气候性、强度的情况下，可以由玻璃板、丙烯板等构成。此外，光学薄片4只要覆盖面状发光元件2并且也覆盖面状发光元件2和布线基板3之间的交界处，也可以形成为与布线基板3不同的尺寸。
如图6所示，在供电接合部件105为引线框的情况下，需要使引线框与面状发光元件102的元件电极稳定地接触，但是在低温下很难使引线框与面状发光元件102的元件电极接合。因此，通常通过框体106机械性地夹持引线框和面状发光元件102，而模块的薄型化变得更为困难。此外，由于引线框具有绝缘性，因此无法将用于强化面状发光元件102的散热力的金属散热板配置在引线框附近。
在供电接合部件105为柔性线路板的情况下，柔性线路板能够通过各向异性导电薄膜等与面状发光元件102的元件电极接合。但是，由于构成面状发光元件102内的发光体的有机物不耐热，因此若一边加热至150℃的高温一边进行的元件电极与柔性线路板的接合，容易使面状发光元件102内的发光体受到损伤。此外，由于柔性线路板和各向异性导电薄膜的材料费比引线框的材料费价格高，因此成本较高。
相对于此，如本实施例所示，铝线5由纯铝构成，为了提高机械强度和电流量，例如由直径200μm以上的粗线、或者厚度200μm、宽度2mm以上的带状材料构成。铝线5被设置在面状发光元件2和布线基板3的设置有光学薄片4侧的相反侧的面上，并将面状发光元件2的元件电极7和布线基板3的布线图案的一部分即焊盘电连接。铝线5与元件电极7或焊盘的连接能够通过超声波接合进行。由此能够实现常温低成本且高可靠性的电连接。
紫外线硬化树脂6例如以被膜厚度100μm以上被覆铝线5，并通过照射紫外线而硬化。另外，照明模块1被紫外线硬化树脂绝缘，而不会因与金属接触导致短路，因此可以在面状发光元件2的发光面的相反侧的面上具备对面状发光元件2的热进行散热的散热器或提高设计性的装饰板等。
参照图3和图4对照明模块1的组装进行说明。如图3所示，首先在光学薄片4的一个面上涂布粘接剂9，以该涂布面为上面，在光学薄片4的上面配置布线基板3并通过粘接剂9将其粘接。进而，使面状发光元件2的发光面朝下地插入到布线基板3的孔部8，从而配置在光学薄片4的上面并通过粘接剂9粘接。
接着如图4所示，通过使用了超声波焊线机的超声波接合，将面状发光元件2的元件电极7和布线基板3的焊盘通过铝线5电连接。然后，以被覆铝线5的方式，通过树脂涂布装置10涂布紫外线硬化树脂6。接下来，通过照射紫外线使该紫外线硬化树脂6硬化。由此，照明模块1完成。另外，在面状发光元件2内有三个以上的元件电极7的情况下，通过铝线5将同极彼此电连接。
如上述那样构成的照明模块1中，光学薄片4保持面状发光元件2和布线基板3并且阻止灰尘或水分侵入到模块内，因此无需具备框体或填料等，从而能够使模块薄型化。此外，照明模块1经由铝线5对面状发光元件2供电，因此无需具备柔性线路板等供电接合部件，从而能够实现制造成本的降低。此外，由于铝线5被紫外线硬化树脂6被覆，因此能够以常温、低成本来提高绝缘性、坚固性、耐湿性。由此，能够保护铝线5而使其避免受到力学的负荷、水分或其他气体导致的腐蚀。
图5表示本实施方式的变形例涉及的照明模块1。照明模块1的布线基板3由4个矩形状的部件3a、3b、3c、3d构成，其他构成与上述实施方式相同。照明模块1并未从布线基板3的材料基板沿着孔部8的形状切除材料基板的一部分来形成孔部8，而是通过组合4个矩形状的部件3a～3d来形成布线基板3的孔部8，因此不会产生因切除而成为废料的材料基板，因此能够消减制造成本。
本发明并不局限于上述实施方式的构成，可以在不改变发明的主题思想的范围内进行多种变形。例如，在上述实施方式中表示了在布线基板的孔部收容1个面状发光元件的构成，但是可以是在布线基板的孔部收容多个面状发光元件的构成。此外，本申请以日本专利申请2009-216557号为基础，其专利申请的内容通过参照包含于本申请。

Claims (6)

1.一种照明模块，其具有面状发光元件，其特征在于，
具备：布线基板，其形成有用于对上述面状发光元件供电的布线图案；防滴性的光学薄片，其设置在上述面状发光元件的发光面上，且用于对来自该发光元件的配光进行调整，并且，
上述面状发光元件被收容在形成于上述布线基板的孔部，
被收容在上述布线基板的孔部的面状发光元件和上述布线基板在发光面侧呈一个平面而固定于上述光学薄片上，由此上述光学薄片在发光面侧覆盖上述面状发光元件以及上述面状发光元件与布线基板之间的交界处。
2.根据权利要求1所述的照明模块，其特征在于，上述面状发光元件的元件电极与布线基板的布线图案通过铝线电连接，上述铝线被紫外线硬化树脂被覆。
3.根据权利要求2所述的照明模块，其特征在于，上述布线基板和上述光学薄片形成为外形相同。
4.根据权利要求3所述的照明模块，其特征在于，用于收容上述面状发光元件的形成于上述布线基板的孔部，通过使多个布线基板在上述光学薄片上并列而形成。
5.根据权利要求4所述的照明模块，其特征在于，上述面状发光元件和布线基板通过粘接剂粘接在上述光学薄片上。
6.根据权利要求5所述的照明模块，其特征在于，上述面状发光元件和布线基板的、配置有上述光学薄片的一侧的相反侧的面被涂装。
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