CN111856812A - 背光装置用面光源模块及其制作方法 - Google Patents
背光装置用面光源模块及其制作方法 Download PDFInfo
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Abstract
本发明涉及反射部件形成为一体的显示装置的背光用LED模块及其制作方法,本发明的面光源模块包括:反射部件,在具有高反射率的板形成有规定间隔的多个光源孔;密封层,一边密封上述光源孔,一边浇铸于反射部件的上部面,来与上述反射部件形成为一体;遮光部件,在与上述光源孔相对应的位置形成有反射图案,并层压于上述密封层的上部面;以及光源部,在基板上以规定间隔安装多个,并与上述反射部件的下部面相结合,使得上述光源密封于上述光源孔内的上述密封层,上述密封层通过对浇铸的透明树脂得到第一次固化后插入的上述光源进行密封,并重新得到第二次固化来形成。
Description
技术领域
本发明涉及显示装置,更详细地,涉及反射部件形成为一体的显示装置的背光用LED模块及其制作方法。
背景技术
一般情况下,显示装置作为接收影像信号来进行显示的装置,包括电视机(TV)或显示器,而作为用于显示影像的机构,正在利用液晶显示装置(LCD:Liquid CrystalDisplay Device)、有机发光装置(OLED:Organic Light Emitting Display)、等离子显示装置(PDP:Plasma Display Panel)等多种装置。
不同于其他显示装置,液晶显示装置(LCD)其本身无法进行发光,因而如果想要显示高品质的图像,就必须设置额外的外部光源。因此,液晶显示装置除了液晶板之外,还包括面光源的背光装置,使得背光装置向液晶面板均匀地供给高亮度的光源,从而体现优质的图像。像这样,背光装置是指液晶显示装置之类的用于实现显示装置的图像的表面照明装置,并且,根据配置光源的位置,分为直接照明类型(Direct Lighting type)或边缘照明类型(Edge Lighting type)背光装置。作为背光装置的光源,主要使用具有小型、低耗电、高可靠性等优点的发光二极管(Light Emitting Diode,以下称之为“LED”)。
图1为表示根据现有技术来制作的LED模块的剖视图。
直接照明类型背光装置的LED模块通过如下方法制作:以在基板11上形成空腔(cavity)14的方式形成浇铸部13后,以压模粘合(Die bonding)及引线键合(Wirebonding)方式在空腔14内的基板11上安装LED元件12,并在空腔14内填充分散有荧光体的硅等树脂,从而形成密封层15。密封层15起到保护LED元件12并改变波长的功能,而树脂的填充适用点胶成型(Dispensing Molding)或丝网印刷(Screen Printing)。
这种制作方法由于可以同时对多个LED元件12浇铸树脂,因而具有有利于制作大面积的面光源模块的优点。
但是,现有的LED模块的制作方法通过在填充凝胶状态的树脂后,对此实施固化的过程来实现,而在树脂得到固化的过程中,因在浇铸部13的接触面出现的表面张力而在密封层15的表面发生回流(reflow)15a。在密封层15的上部面发生的回流15a歪曲向外部射出的光特性,最终引起显示装置的画质降低。
并且,LED模块因印刷于基板11的电路11a而在基板11和浇铸部13之间必然形成高度差。在现有的LED模块的制作方法中,在使凝胶状态的树脂之间固化为固体状态的过程中,因流入空气而容易在高度差部分产生气泡15b。在密封层15的内部产生的气泡15b使LED模块的耐久性变弱,在密封层15的内部引起光损耗,并歪曲从密封层15射出的光特性。因此,存在还要进行用于去除气泡15b的脱泡工序的问题。
并且,在现有的LED模块中,LED元件12安装于浇铸部13之间的空腔14内,从LED元件12射出的光无法容易地向侧面扩散而向上侧集中,从而具有安装有LED元件的位置及其之间的空间中出现大的亮度偏差的问题。
(现有技术文献)
(专利文献)
韩国公开专利10-2012-0086142号(2012年08月02日申请公开,LED封装件的制作方法)
发明内容
所要解决的问题
本发明的目的在于,提供可在基板上与LED元件一同设置反射部件来呈现出高的亮度,并可以使亮度偏差最小化来呈现出均匀的亮度的面光源模块及其制作方法。
并且,本发明的目的在于,提供对LED元件进行密封的密封层具有均匀的出光面,并防止在内部形成气泡,从而可以呈现出优秀的光特性的面光源模块及其制作方法。
解决问题的手段
用于实现如上所述的目的的本实施例的面光源模块包括:反射部件,在具有高反射率的板形成有规定间隔的多个光源孔;密封层,一边密封上述光源孔,一边浇铸于反射部件的上部面,来与上述反射部件形成为一体;遮光部件,在与上述光源孔相对应的位置形成有反射图案,并层压于上述密封层的上部面;以及光源部,在基板上以规定间隔安装多个,并与上述反射部件的下部面相结合,使得上述光源密封于上述光源孔内的上述密封层,上述密封层通过对浇铸的透明树脂得到第一次固化后插入的上述光源进行密封,并重新得到第二次固化来形成。
其中,上述反射部件可以包括:第一反射面,形成于上述光源孔的侧面,并呈凸出的曲面形状;以及第二反射面,在与上述第一反射面相连接的上述反射部件的上部面呈平面形状。
并且,在上述第一反射面的最下端部,曲面的切线倾斜度相对于垂直方向可形成45°至60°。
并且,上述光源和上述反射图案可一对一对应,并能够以垂直中心轴相一致的方式得到配置。
并且,本实施例的面光源模块还可以包括扩散部件,上述扩散部件结合于上述密封层和上述遮光部件之间。
并且,上述密封层可形成于上述光源孔,并具有与上述第二反射面相同的高度。
而且,用于实现如上所述的目的的本实施例的面光源模块的制作方法包括:在具有高反射率的板形成以规定间隔隔开的多个光源孔来制作反射部件,步骤(a),在包括上述光源孔的上述反射部件的上部面浇铸透明树脂来形成密封层;步骤(b),对上述密封层进行第一次固化;在基板上与上述光源孔相对应的位置安装多个光源来制作光源部,在步骤(c),上述光源部与上述反射部件的下部面相结合,使得上述光源部被密封于得到第一次浇铸的上述光源孔的内部的上述密封层;步骤(d),对上述密封层进行第二次固化。
并且,上述面光源模块的制作方法还可以包括步骤(e),在上述步骤(e)中,在上述密封层的上部面对形成有反射图案的遮光部件进行层压。
并且,面光源模块的制作方法还可以包括步骤(f),在上述步骤(f)中,在上述密封层的上部面结合扩散部件,上述遮光部件可层压于上述扩散部件的上部面。
并且,上述光源孔的侧面可呈凸出的曲面形状,且上述光源孔可以与上述板的上部面相连接。
并且,在上述步骤(b)的第一次固化中,以防止凝胶状的上述透明树脂具有流动性的方式进行固化。
发明的效果
本发明在基板上具有反射部件,从而呈现出高的亮度,并且,反射部件具有曲面的反射面,从而具有提高光均匀度的效果。
并且,本发明在对密封层进行固化的过程中不会生成回流和气泡,从而可以呈现出均匀且优秀的光特性。
附图说明
图1为表示根据现有的技术来制作的LED模块的剖视图,
图2为表示本发明的实施例的LED模块的分解立体图,
图3为表示图2的主要部分的I-I方向的剖视图,
图4为表示作为图3的主要部分的反射部件的侧面反射部的放大图,
图5为表示作为图2的主要部分的反射部件的光射出特性的剖视图,
图6为表示制作本发明的实施例的LED模块的过程的工序图,
图7为表示本发明的另一实施例的LED模块的剖视图。
附图标记的说明
100:光源部;110:基板;120:LED元件;200:反射部件;
210:光源孔;220:第一反射面;230:第二反射面;300:密封层;
400:遮光部件;410:反射图案;500:扩散部件
具体实施方式
本发明及通过实施本发明来实现的技术问题将通过以下所述的多个优选的实施例来变得明确。参照以下所附的附图来详细观察本发明的优选的实施例。
后述的本实施例的差异应被理解为互不排斥的事项。即,需要理解的是,在不脱离本发明的技术思想及范围的情况下,所记载的特征形状、结构及特性可以涉及一实施例来体现为其他实施例,各个所公开的实施例内的个别结构要素的位置或配置可以发生变更,并且,在附图中,类似的附图标记在多个方面指称相同或类似的功能,长度、面积、厚度等以及其形态可以为了便于说明而以夸张的方式表达。
图2为表示本发明的实施例的LED模块的分解立体图,图3为表示图2的主要部分的I-I方向的剖视图,图4为表示作为图3的主要部分的反射部件的侧面反射部的A部分的放大图,图5为表示作为图2的主要部分的反射部件的光射出特性的剖视图。
如这些附图所示,本实施例的LED模块包括:光源部100,在基板110上安装有多个LED元件120;反射部件200,具有用于露出LED元件120的光源孔210,并与基板110相结合;密封层300,填充于反射部件200的光源孔210;以及遮光部件400,与密封层300的上部面相结合。
具体观察如下,构成光源部100的基板110作为安装LED元件120来向LED元件120施加电源及控制信号的结构,可以由印刷电路板(PCB)或柔性印刷电路板(FPCB)构成。并且,LED元件120作为LED模块的光源,以压模粘合及引线键合方式安装于基板110,并实现电连接。LED元件120形成规定的间隔,并向横向、竖向及任意方向安装多个。LED元件120可以由朝向上侧发光的顶视图(top view)方式的元件或包括上侧出光面的多面发光元件构成。
反射部件200一边使LED元件120露出,一边与基板110的上部面相结合,并扩散及反射从LED元件120射出的光。用于此的反射部件200由具有高反射率的薄片或板构成,并在与各LED元件120相对应的位置形成多个光源孔210。其中,高反射率是指通常可以在面光源装置中用作反射材料的具有优秀反射率的程度。反射部件200具有形成于光源孔210的第一反射面220和形成于反射部件200的上部面的第二反射面230。
第一反射面220作为光源孔210的侧面,在本实施例中,呈凸出的曲面形状。即,相对于反射部件200的厚度方向,光源孔210的下端部的直径相对变窄,并且,越靠近上侧,直径越增加。
第一反射面220呈凸出的曲面形状,从而在形成密封层300的树脂得到固化时,缓解表面张力。因此,在第一反射面220中,不会在树脂固化过程中发生回流(参照图1的15a),从而可以提高密封层300的厚度的均匀度和上部面的扁平度。
并且,第一反射面220向第二反射面230的上部扩散从LED元件120射出的光。即,第一反射面220向第二反射面230的上部分散可以集中于LED元件120的上部的光,从而提高光均匀度。
参照图5具体观察光行进路径如下,如图5的(a)部分,在第一反射面220垂直的情况下,从LED元件120向斜线方向射出的光L1在第一反射面220得到反射,并重新在LED元件120的上部集光。但如图5的(b)部分,在第一反射面220形成凸出的曲面的倾斜的情况下,从LED元件120向斜线方向射出的光L2在第一反射面220得到反射,并向第二反射面230的上部分散。因此,呈现出通过曲面形状的第一反射面220来分散光的效果。
此时,第一反射面220应呈切线具有规定的倾斜度的曲面形状,而在本实施例中,从下端部越靠近上侧,切线方向的倾斜越减少。参照图4,在第一反射面220中,以垂直方向为基准,最下端部的切线方向的倾斜θ形成45°至60°。在第一反射面220的切线倾斜θ小于45°的情况下,在树脂固化过程中显著降低缓解表面张力的效果,在第一反射面220的切线倾斜θ大于60°的情况下,无法控制从LED元件120向斜线方向射出的光,从而使光均匀度的改善效果减少至小于50%。
第二反射面230形成于反射部件200的上部面,从而向上侧反射分布于反射部件200和遮光部件400之间的光,由此提高LED模块的亮度。第二反射面230从第一反射面220延伸,并构成平面形状的反射面。
密封层300浇铸于包括光源孔210的反射部件200的上部面来保护LED元件120,并起到扩散从LED元件120射出的光的功能。用于此的密封层300可以由高透明度的树脂材质构成,作为一例,可以由包含PS、PC、PMMA、PE、PET、PP、MMA-styrene中的一种以上的透明材料构成,只要是具有高透明度的材料,其种类不受限制。
密封层300可以从包括光源孔210的内部的第二反射面230形成至规定间隔的高度。因此,从LED元件120射出的光在第二反射面230的上部的密封层300区域得到充分扩散,从而可以提高光均匀度。可在密封层300分散有用于光扩散的光散射材料,并且,根据LED元件120的种类,还可以分散有用于改变从LED元件120射出的光的波长的荧光体。
密封层300可以由凝胶状的透明树脂通过点胶成型(Dispensing Molding)等工序来得到浇铸后固化而成。尤其,本实施例的密封层300通过在反射部件200浇铸透明树脂,并在以第一次固化过程(假固化)去除树脂的流动性的状态下,与光源部100相结合,之后重新实现第二次固化(本固化)来形成。因此,本实施例的密封层300在去除树脂的流动性的状态下,与基板110相结合,因此,即使是在形成高度差的基板110的电极部分,也不会产生气泡(参照图1的15b)
遮光部件400控制向LED元件120的垂直上部射出的光的行进方向,来防止热点,从而提高光均匀度。这种遮光部件400可以由具有高透明度的薄片或膜构成,并具有用于发射LED元件120的光的反射图案410。遮光部件400层压于密封层300的上部面,并实现结合。此时,反射图案410与各LED元件120以1:1的比例对应,并在与垂直中心轴相一致的位置形成于遮光部件400的某一面。
如上所述的本实施例的LED模块在收容LED元件120的光源孔210形成有曲面形状的第一反射面220,从而向LED元件120之间的第二反射面230的上部分散集中于LED元件120的上部的光,由此可以提高光均匀度。并且,本实施例的LED模块在第一反射面220和第二反射面230的连接部缓解表面张力,因此,因不会在形成密封层300时发生回流而能够呈现出优秀的光特性。并且,在本实施例的LED模块中,浇铸于反射部件200的密封层300得到第一次固化后,与基板110相结合来实现第二次固化,从而不会在基板110和密封层300之间产生气泡而能够提高耐久性和光特性。
图6为表示制作本发明的实施例的LED模块的过程的工序图。
参照图6,在形成有光源孔210的反射部件200以规定的高度浇铸透明树脂来形成密封层300,并对透明树脂进行第一次固化。此时,可通过点胶成型或丝网印刷工序等进行透明树脂的浇铸。并且,在进行第一次固化的过程中,利用固化器来以去除流动性的程度固化凝胶状的透明树脂。
在浇铸工序之前通过额外的工序来制作反射部件200,而形成光源孔210的侧面具有曲面形状的第一反射面220。因此,在对透明树脂进行固化的过程中不会发生回流。
而且,在通过第一次固化来形成的密封层300上层压通过额外的工序来制作的遮光部件400来实现附着。遮光部件400应以各反射图案410与光源孔210的垂直中心轴相一致的方式得到层压。
在遮光部件400得到层压后,在基板110安装有LED元件120的光源部100与形成有密封层300的反射部件200相结合。此时,LED元件120位于光源孔210的中心,使得垂直中心轴与反射图案410相一致。由于在密封层300得到第一次固化的状态下结合光源部100,因此,在固化过程中不会在基板110和密封层300之间产生气泡。在光源部100和反射部件200相贴合后,对实现第一次固化的密封层300进行第二次固化,从而完全实现固化。
在本实施例的LED模块的制作过程中,对遮光部件400进行层压的步骤例示了在贴合光源部100之前实现的结构,但也可以由光源部100首先与反射部件200的下部面相结合,之后由遮光部件400层压于密封层300的上部面的结构。
图7为表示本发明的另一实施例的LED模块的剖视图。
参照附图,在本实施例的LED模块中,密封层300仅形成于光源孔210的内部。即,密封层300的高度与第二反射面230相同。因此,为了确保从LED元件120射出的光得到充分扩散的空间,在密封层300的上部面,即,在反射部件200的上部面还结合有扩散部件500。扩散部件500由规定厚度的透明树脂材料构成,作为一例,可以利用PC、PS、PMMA等透明板。
并且,可以在扩散部件500的上部面层压具有反射图案410的遮光部件400。反射图案410可直接形成于扩散部件500的上部面,在这种情况下,可以不会层压额外的遮光部件400。
如上所述,虽然示出本发明的例示性的实施例进行了说明,但本发明所属技术领域的普通技术人员可以实施多种变形和其他实施例。这种变形和其他实施例均被发明要求保护范围所考虑和包含,从而视为不脱离本发明的真正的宗旨和范围。
Claims (11)
1.一种背光装置用面光源模块,其特征在于,包括:
反射部件,在具有高反射率的板形成有规定间隔的多个光源孔;
密封层,一边密封上述光源孔,一边浇铸于反射部件的上部面,来与上述反射部件形成为一体;
遮光部件,在与上述光源孔相对应的位置形成有反射图案,并层压于上述密封层的上部面;以及
光源部,在基板上以规定间隔安装多个,并与上述反射部件的下部面相结合,使得上述光源密封于上述光源孔内的上述密封层,
上述密封层通过对浇铸的透明树脂得到第一次固化后插入的上述光源进行密封,并重新得到第二次固化来形成。
2.根据权利要求1所述的背光装置用面光源模块,其特征在于,上述反射部件包括:
第一反射面,形成于上述光源孔的侧面,并呈凸出的曲面形状;以及
第二反射面,在与上述第一反射面相连接的上述反射部件的上部面呈平面形状。
3.根据权利要求2所述的背光装置用面光源模块,其特征在于,在上述第一反射面的最下端部,曲面的切线倾斜度相对于垂直方向形成45°至60°。
4.根据权利要求1所述的背光装置用面光源模块,其特征在于,上述光源和上述反射图案一对一对应,并以垂直中心轴相一致的方式得到配置。
5.根据权利要求1所述的背光装置用面光源模块,其特征在于,还包括扩散部件,上述扩散部件结合于上述密封层和上述遮光部件之间。
6.根据权利要求5所述的背光装置用面光源模块,其特征在于,上述密封层形成于上述光源孔,并具有与上述第二反射面相同的高度。
7.一种背光装置用面光源模块的制作方法,其特征在于,包括:
在具有高反射率的板形成以规定间隔隔开的多个光源孔来制作反射部件,
步骤(a),在包括上述光源孔的上述反射部件的上部面浇铸透明树脂来形成密封层;
步骤(b),对上述密封层进行第一次固化;
在基板上与上述光源孔相对应的位置安装多个光源来制作光源部,
在步骤(c),上述光源部与上述反射部件的下部面相结合,使得上述光源部被密封于得到第一次浇铸的上述光源孔的内部的上述密封层;
步骤(d),对上述密封层进行第二次固化。
8.根据权利要求7所述的背光装置用面光源模块的制作方法,其特征在于,还包括步骤(e),在上述步骤(e)中,在上述密封层的上部面对形成有反射图案的遮光部件进行层压。
9.根据权利要求8所述的背光装置用面光源模块的制作方法,其特征在于,
还包括步骤(f),在上述步骤(f)中,在上述密封层的上部面结合扩散部件,
上述遮光部件层压于上述扩散部件的上部面。
10.根据权利要求7所述的背光装置用面光源模块的制作方法,其特征在于,上述光源孔的侧面呈凸出的曲面形状,且上述光源孔与上述板的上部面相连接。
11.根据权利要求7所述的背光装置用面光源模块的制作方法,其特征在于,在上述步骤(b)的第一次固化中,以防止凝胶状的上述透明树脂具有流动性的方式进行固化。
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- 2019-07-24 WO PCT/KR2019/009183 patent/WO2020222357A1/ko active Application Filing
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WO2020222357A1 (ko) | 2020-11-05 |
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TW202042414A (zh) | 2020-11-16 |
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