CN104183590B - 平面光源装置及其导光板的制造方法 - Google Patents
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Abstract
本发明提供了一种平面光源装置及其导光板的制造方法,该装置包括一导光板,其上下分别具有一第一表面及一第二表面;至少一光条,其上具有多个发光二极管,光条位于导光板的侧边,且发光二极管设于导光板内以发出光线;设于第二表面外侧的一反射片,将光线反射;以及设于第一表面外侧的扩散片,将反射片的反射光散射。本发明由于制造导光板时预置发光二极管于模具中,因此发光二极管与导光板一体成型,可避免光源散失,提高平面光源装置的效率。
Description
技术领域
本发明涉及一种光源模块,尤其是一种平面光源装置及其导光板的制造方法。
背景技术
目前以发光二极管为光源的侧光式平面光源模块是将多个发光二极管组装在一基板本体上,请参阅图1a及图1b,其为采用楔形导光板的一实施例的侧视图及俯视图,该侧光式光源模块包括一导光板2及多个发光二极管10,导光板一般为亚克力射出成型,于导光板2上下分别设有一扩散板22及一反射板24,基板本体为光条12,发光二极管10设在光条12的一面,接着再将该光条12的发光面对准导光板2的入光面20,光线经反射片24反射后从扩散片22处散射,转变成均匀的面光源。
图2a及图2b为现有的另一种光源模块的前视图及俯视图,其采用平板导光板4,于两侧各设有一光条12及发光二极管10。
光条通常为一条状基板本体,其上具有一正极导电轨迹与一负极导电轨迹,光条制造为依序将多个封装完成的发光二极管设置在该条状基板本体上,并将每一个封装完成的发光二极管的正负极端分别电连接于该条状基板本体的正负极导电轨迹。
发光二极管封装通常是将发光二极管芯片接合(Bonding)在含外壳的导线架上,电极则以金属打线接合(Wire Bonding)方式引出至导线架,再涂布含荧光粉的硅胶或环氧树脂等有机树脂形成封装体。
为促使光源模块获得均匀的辉度,通常在导光板的表面印刷不同于亚克力板折射率的材料,或直接在导光板表面形成不同角度的折射面。图3a至图5b为三种现有的侧光式光源模块实施例的前视图及俯视图,其中图3a及图3b是在导光板2的第二表面18上形成含有光散射粒子、由透明树脂构成的油墨层30;图4a及图4b是在导光板2的第二表面18上制造多个粗糙块40,使第二表面18成为凹凸面;图5a及图5b是在导光板2的第二表面18上挖射出多个凹痕50,使第二表面18成为锯齿面;此三种实施例皆是利用增加反射或散射面积使光线均匀,但现行技术的效率与导光板的入光面20厚度与入光面20的镜面加工平整度成正比,在成本、重量及厚度考虑下,常需牺牲效率以取得各方面的平衡,且发光二极管封装体与空气因折射率差异产生全反射及光源与导光板分离会使光线散失,致照度降低。
另因导光板厚度限制及光条制造方便性,目前侧光式光源模块通常会采用功率较小表面黏着型(SMD)发光二极管,此类发光二极管因外形及结构限制,发光效率及散热效果通常不佳,无法使用大电流驱动,故需较多数量发光二极管,且整体光源模块效率不佳,制造工艺复杂,虽然侧光式平面光源模块具有薄形化、柔和、均匀的高质量光源等优点,但成本太高,除了作为液晶显示器的背光模块外,在一般照明市场并不普及。
因此,本发明即提出一种平面光源装置及其导光板的制造方法,以克服上述所述问题,具体架构及其实施方式将详述于下。
发明内容
本发明的主要目的是在提供一种平面光源装置,其是将发光二极管与导光板一体成型,光线完全进入导光板,大幅提高平面光源装置的效率。
本发明的另一目的是在提供一种平面光源装置中导光板的制造方法,其是将发光二极管置于模具的侧边,接着注入可聚合成导光板的调和物,使发光二极管与导光板一体成型。
为达上述的目的,本发明的技术方案是,提供一种平面光源装置,包括:一导光板、至少一发光二极管光条、一反射片及一扩散片,导光板的上下分别为一第一表面及一第二表面;光条位于导光板的侧边,其上具有多个发光二极管,且发光二极管设于导光板内以发出光线;反射片设于第二表面的外侧,将光线反射,扩散片设于第一表面的外侧,将反射片的反射光散射出均匀面光源。
本发明更提供一种前述平面光源装置中导光板的制造方法,包括下列步骤:将多个发光二极管装设在至少一光条上,将光条放置于一上模具及一下模具的侧边;接着将多种材料调和成一调和物,材料包括甲基丙烯酸甲酯及聚合开始剂,并将调和物预备聚合及浆化;上模具及下模具组合成一个完整模具后,将浆化后的调和物注入模具中,利用热处理使调和物于模具内聚合,最后脱模形成一导光板。
本发明提供了平面光源装置的发光二极管光条,其除能在与导光板一体成型时易于安装在模具内,更具有能快速传导发光二极管产生的热能,无长度限制及极低制造成本。
综上所述技术方案,本发明提供的一种平面光源装置及其导光板的制造方法是将发光二极管放在模具中,产生与发光二极管一体成型的导光板,使光线几乎完全进入导光板,大幅提高平面光源装置的效率,此外本发明是将发光二极管芯片直接接合于光条上,发光二极管产生的热能可快速传导散热,故可有效降低发光二极管的工作温度,进而提高发光效率及使用寿命。下面对具体实施例详加说明,使得相关领域技术人员更容易了解本发明的目的、技术内容、特点及其所达成的功效。
附图说明
图1a及图1b分别为现有技术中采用楔形导光板的光源模块的前视图及俯视图。
图2a及图2b分别为先前技术中采用平板导光板的光源模块的前视图及俯视图。
图3a及图3b分别为先前技术中采用楔形导光板并于其上设置油墨层的光源模块的前视图及俯视图。
图4a及图4b分别为先前技术中采用楔形导光板并于其上设置粗糙块的光源模块的前视图及俯视图。
图5a及图5b分别为先前技术中采用楔形导光板并于其上设置凹痕的光源模块的前视图及俯视图。
图6a及图6b分别为本发明中采用凹型导光板且内置发光二极管的光源模块的前视图及俯视图。
图7a及图7b分别为本发明中采用楔形导光板且内置发光二极管的光源模块的前视图及俯视图。
图8a及图8b分别为本发明中采用平板导光板且内置发光二极管的光源模块的前视图及俯视图。
图9a及图9b分别为本发明中导光板内置发光二极管且设有油墨层的光源模块的一实施例的前视图及俯视图。
图10a及图10b分别为本发明中导光板内置发光二极管且设有粗糙块的光源模块的一实施例的前视图及俯视图。
图11a及图11b分别为本发明中导光板内置发光二极管且设有凹痕的光源模块的一实施例的前视图及俯视图。
图12a、图12b及图12c分别为本发明发光二极管光条的基板本体实施例的前视图、俯视图及侧视图。
图13a及图13b分别为本发明发光二极管光条实施例的俯视图及侧视图。
图14a及图14b分别为本发明发光二极管光条与导光板一体成型后实施例的俯视图及侧视图。
图15a、图15b及图15c分别为本发明发光二极管的基板本体另一实施例的前视图、俯视图及侧视图。
图16a及图16b分别为本发明发光二极管与导光板一体成型后另一实施例的前视图及俯视图。
图17为本发明平面光源装置的制造方法的流程图。
具体实施方式
本发明提供一种平面光源装置及其导光板的制造方法,其是将发光二极管内置于导光板中,图6a及图6b为本发明的一实施例的前视图及俯视图,包括一凹型导光板6、至少一光条12、一反射片24及一扩散片22,凹型导光板6可为透明亚克力板,其上下分别为一第一表面16及一第二表面18,扩散片22在第一表面16外侧,反射片24在第二表面18外侧;光条12位于凹型导光板6的两侧,其上具有多个发光二极管10,且发光二极管10设于凹型导光板6内以发出光线;反射片24将光线反射,扩散片22再将反射片24的反射光散射出均匀面光源。
图6a及图6b的实施例中导光板为凹型导光板,第二表面18为向第一表面16凹入的曲面或弧面,而反射片24与第二表面18的弧度相同。
图7a及图7b分别为本发明另一实施例的前视图及俯视图,其与图6a及图6b实施例的差异在于导光板为楔形导光板8,光条12只有一个,楔形导光板8有光条12端较粗,无光条12端为一薄边26,薄边26较细,发光二极管10同样内置于楔形导光板8内,由反射片24将发光二极管10发出的光线反射到第一表面16,再从扩散片22散射出去。
图8a及图8b分别为本发明再一实施例的前视图及俯视图,其与图6a及图6b实施例的差异在于导光板为平板导光板9,第一表面16及第二表面18为平行的二平面,于平板导光板9的两侧皆设有光条12及发光二极管10,发光二极管10同样内置于平板导光板9内,由反射片24将发光二极管10发出的光线反射到第一表面16,再从扩散片22散射出去。
图9a、图10a及图11a为本发明的另三种实施例的前视图,其是在导光板的第二表面设置可增加反射面积的设计,使光线更均匀且亮度更高。请参考图9a及图9b,其是以楔形导光板为例,在楔形导光板8的第二表面18上形成多个区块的含有光散射粒子、由透明树脂构成的油墨层30,光散射粒子可使光线更加均匀;图10a及图10b同样以楔形导光板为例,其是在楔形导光板8的第二表面18上制造多个粗糙块40,或是直接在第二表面18上形成粗糙面,使第二表面18成为凹凸面,增加反射面积;图11a及图11b也以楔形导光板为例,其是在楔形导光板8的第二表面18上挖射出多个凹痕50,使第二表面18成为锯齿面,增加反射面积,匀光效果佳,散射后亮度足够。
针对以上的实施例,本发明提供一种专有发光二极管光条,该光条包含有一基板本体28,多个发光二极管芯片14、内含荧光粉的封装体72及金属导线80。
图12a、图12b及图12c分别为本发明的发光二极管光条基板本体28实施例的前视图、俯视图及侧视图。光条基板本体28为中间金属板60、左金属板62及右金属板64等三片等长金属板贴合而成,三片金属板彼此互相电性绝缘,三片金属板的一端面设为出光面68,中间金属板60较厚且宽,其出光面68的中间金属板端面66为接合多个发光二极管芯片14及内含荧光粉的封装体72的基板,其为铝镀银或铜镀银制成以快速传导发光二极管所产生的热能。左金属板62及右金属板64较中间金属板60薄且窄,各为发光二极管正极及负极导电轨迹,其材质以铜镀银为佳。
图13a及图13b分别为发光二极管光条实施例的俯视图及侧视图,发光二极管芯片14是直接接合于中间金属板端面66上,左金属板62及右金属板64略突出于中间金属板60以形成突出部,该突出部向外呈一定角度倾斜,其内侧面74设置有一内含荧光粉的封装体72,以及一用以将发光二极管芯片14的光加以反射的光反射层,左金属板端面76及右金属板端面78则为发光二极管芯片14正极及负极电极引出的金属导线80的电性接点。
图14a及图14b分别为本发明发光二极管光条12与导光板8一体成型后实施例的前视图及俯视图,该光条的中间金属板60前端设有多个发光二极管芯片14及内含荧光粉的封装体72的出光面68设在导光板8之内,后端则在导光板8侧边之外以作为发光二极管散热器或外接散热器端点,正负极导电轨迹的左金属板62及右金属板64,除顶端部份在导光板8之外设为电源接点70,其余皆设在导光板8内以隔绝外部环境对发光二极管影响。
图15a、图15b及图15c分别为本发明的发光二极管光条基板本体28另一实施例的前视图、俯视图及侧视图,其与图12a、图12b及图12c实施例的差异在于左金属板62及右金属板64呈不连续状,以提供发光二极管不同的串联并联电连接方式。
图16a及图16b分别为本发明的发光二极管光条12与导光板8一体成型后另一实施例的前视图及俯视图,其与图14a及图14b实施例的差异在于正极及负极导电轨迹的电源接点70分别位于导光板8的两端。
综合以上,本发明所提供的发光二极管光条具有简洁构造及足够的机械强度,故可在与导光板一体成型时易于安装在模具内且成型后可得到稳定的外形尺寸与光学性能。
本发明所提供的平面光源装置本身即可作为照明用的平面光源,也可作为液晶显示器的背光模块。
图17为本发明的平面光源装置中导光板的制造方法的流程图,首先将多个发光二极管芯片接合在至少一光条基板本体的中间金属板端面上,再将发光二极管芯片的正负极端以打线方式依电路需求串联及并联电连接于光条基板本体的正负极导电轨迹,再涂布内含荧光粉的封装体完成步骤S10将发光二极管组装在光条上,接着步骤S12将光条放置于一上模具及一下模具的侧边,而依据模具形状可选择放置不同数量的光条,例如楔形导光板仅有一光条,但凹型导光板及平板导光板皆设有二光条;步骤S14将多种材料调和成一调和物,材料包括甲基丙烯酸甲酯及聚合开始剂,步骤S16另调和物预备聚合,此为让调和的单体(monomer)发生初步的聚合,可施加热处理,并接着将调和物浆化;步骤S18为上模具及下模具组合成一个完整模具后,将浆化后的调和物注入模具中的注模步骤,步骤S20利用热处理使调和物于模具内聚合,此步骤需施以热处理以增进聚合的速度及效果;最后脱模形成一与发光二极管一体成型的导光板,如步骤S22所述。
由于注入聚合法是将流体的甲基丙烯酸甲酯(MMA)经数小时缓慢聚合成固体亚克力(PMMA),过程中工作温度在110℃以下且压力极低,故可将已装设有多个发光二极管的光条先预置于上下模具之间,依图17所述流程即可得到与发光二极管一体成型的导光板。
综上所述,本发明所提供的平面光源装置及其导光板的制造方法是在制作工艺中预先将发光二极管放在模具中,产生与发光二极管一体成型的导光板,使光线几乎完全进入导光板,大幅提高平面光源装置的效率,此外本发明是将发光二极管芯片直接接合于光条上,无导线架热阻,且发光二极管产生的热能可由本发明光条的中间金属板快速传导散热,故可有效降低发光二极管的工作温度,进而提高发光效率及使用寿命。
另本发明所提供的发光二极管光条的基板本体,只需简单电镀、贴合及折弯即可由卷状原材料转变而成,故无长度限制且在后续发光二极管芯片设置、接合、打线、封装体涂布等制作工艺依然保持连续状,直至光条完成品。故本发明无论在发光效率、使用寿命、材料成本、制造费用、设备投资及生产效率皆较先前技术有大幅进步。
唯以上所述者,仅为本发明的较佳实施例而已,并非用来限定本发明实施的范围。故即凡依本发明申请范围所述的特征及精神所为的均等变化或修饰,均应包括于本发明的申请专利范围内。
Claims (17)
1.一种平面光源装置,其特征在于,该平面光源装置包括:
一导光板,其具有至少一侧边;且其上下分别具有一第一表面及一第二表面;
至少一光条,其上具有多个发光二极管,该光条位于该导光板的该侧边,且所述发光二极管设于该导光板内,用以发出光线;
一反射片,设于该第二表面的外侧,将光线反射;以及
一扩散片,设于该第一表面的外侧,将该反射片的反射光散射;
其中,该光条更包含一基板本体、一内含荧光粉的封装体及多数条金属导线;
该基板本体包含彼此相互电性绝缘的一中间金属板、一第一金属板及一第二金属板,该第一金属板及第二金属板分别贴合于该中间金属板的两个侧边,且该第一金属板及该第二金属板分别突出于该中间金属板,以形成向外倾斜的一第一突出部及一第二突出部,以使该中间金属板、该第一金属板及该第二金属板界定出一出光面;
且所述发光二极管及该封装体设于该出光面的该中间金属板的一端面上,而且该导光板与所述发光二极管为一体成型。
2.根据权利要求1所述的平面光源装置,其特征在于,该导光板为透明亚克力板且与所述发光二极管为一体成型。
3.根据权利要求1所述的平面光源装置,其特征在于,该基板本体呈连续长条状。
4.根据权利要求3所述的平面光源装置,其特征在于,所述发光二极管直接接合在该基板本体上。
5.根据权利要求3所述的平面光源装置,其特征在于,所述三片金属板的该中间金属板较该第一金属板及该第二金属板厚且宽,其为出光面的端面接合有所述发光二极管及所述内含荧光粉的封装体。
6.根据权利要求3所述的平面光源装置,其特征在于,该第一金属板及该第二金属板较该中间金属板薄且窄,各为所述发光二极管正极及负极导电轨迹,其为出光面的端面则为所述发光二极管正极及负极引出的金属导线的电性接点。
7.根据权利要求3所述的平面光源装置,其特征在于,该第一金属板及该第二金属板各为该等发光二极管正极及负极导电轨迹,其为出光面的端面则为该等发光二极管正极及负极引出的金属导线的电性接点。
8.根据权利要求3所述的平面光源装置,其特征在于,该中间金属板的前端设有所述多个发光二极管的部分设在该导光板之内,后端则在该导光板侧边之外,以作为所述发光二极管的散热器或外接散热器端点。
9.根据权利要求3所述的平面光源装置,其特征在于,该第一金属板及该第二金属板除顶端部分设在该导光板外部作为电源接点,其余部分皆设在该导光板内。
10.根据权利要求3所述的平面光源装置,其特征在于,该中间金属板是由铝镀银或铜镀银的金属材质构成。
11.根据权利要求3所述的平面光源装置,其特征在于,该第一金属板及该第二金属板,是由铜镀银金属材质构成。
12.根据权利要求1所述的平面光源装置,其特征在于,该导光板为凹形导光板,该第一表面为平面,所述光条设于该导光板的两侧,且该第二表面为向该第一表面凹入的曲面。
13.根据权利要求12所述的平面光源装置,其特征在于,该第二表面为向该第一表面凹入的弧面。
14.根据权利要求1所述的平面光源装置,其特征在于,该导光板为楔形导光板,设有该光条的一侧较宽,远离该光条的另一侧较窄。
15.根据权利要求1所述的平面光源装置,其特征在于,该第一表面与该第二表面平行,两侧中至少有一侧设有一该光条。
16.一种根据权利要求1所述的平面光源装置中导光板的制造方法,其特征在于,该导光板制造方法包括下列步骤:
将多个发光二极管装设在至少一光条上;
将该光条放置于一上模具及一下模具的侧边;
将包括甲基丙烯酸甲酯及聚合开始剂的多种材料调和成一调和物;
该上模具及该下模具压合,将该调和物注入该上、下模具中,使该调和物利用热处理于该上、下模具内聚合;以及脱模形成一导光板;
其中,该光条包含一基板本体、一内含荧光粉的封装体及多数条金属导线;
该基板本体包含彼此相互电性绝缘的一中间金属板、一第一金属板及一第二金属板,该第一金属板及第二金属板分别贴合于该中间金属板的两个侧边,且该第一金属板及该第二金属板分别突出于该中间金属板,以形成向外倾斜的一第一突出部及一第二突出部,以使该中间金属板、该第一金属板及该第二金属板界定出一出光面;
且所述发光二极管及该封装体设于该出光面的该中间金属板的一端面上,而且该导光板与所述发光二极管为一体成型。
17.根据权利要求16所述的制造方法,其特征在于,该调和物是利用热处理将该调和物预备聚合及浆化。
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- 2014-05-23 US US14/285,936 patent/US9217823B2/en active Active
- 2014-05-26 CN CN201410225877.0A patent/CN104183590B/zh active Active
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US20140347880A1 (en) | 2014-11-27 |
CN104183590A (zh) | 2014-12-03 |
TW201445072A (zh) | 2014-12-01 |
US9217823B2 (en) | 2015-12-22 |
TWI585333B (zh) | 2017-06-01 |
IN2014DE01337A (zh) | 2015-06-12 |
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