JP2007012978A - Dam frame for led display and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a dam frame of an LED display for forming a clear image and its manufacturing method. <P>SOLUTION: The LED display dam frame 10 composed of a base sheet 12, an adhesive layer 16(17) provided on one side of the base sheet 12, and a peel sheet 24 laminated on the adhesive layer 16(17). It has a plurality of through-holes 14. The base sheet 12 and the adhesive layer 16(17) are impermeable to the visible light in the width direction. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a dam frame material for partitioning LED chips and a method for manufacturing the same in an LED display device in which LED chips are arranged on a substrate and a liquid resin raw material forming a transparent resin is injected and cured.

  Display devices using LEDs are widely used as large displays because of their high brightness and excellent visibility.

  In such an LED display device, conventionally, a so-called bullet-type LED lamp in which the LED chip is sealed with a transparent resin and the tip is hemispherical has been used, but a high-quality display device with a higher number of pixels can be obtained. For this purpose, a COB (Chip on Board) type display device in which an LED chip is directly mounted on a circuit board and sealed with a transparent resin is also known (Non-Patent Document 1).

Tatsuo Uchida et al. “Encyclopedia of Flat Panel Display” (Industry Research Committee: 2001), page 905

  Since the above-mentioned COB type display device is formed by sealing LED chips arranged and mounted on a substrate with a transparent resin, the light of the LED chip is transmitted to the position of the adjacent LED chip, and the contour There is a problem that the display becomes unclear.

  An object of this invention is to provide the dam frame material for LED display apparatuses which forms a clear image, and its manufacturing method in view of the problem of the said well-known technique.

  The dam frame material for an LED display device of the present invention comprises a base sheet, an adhesive layer provided on one side of the base sheet, and a release sheet laminated on the adhesive layer, and has a plurality of through holes. And the said base material sheet and the said adhesive layer do not permeate | transmit visible light to the width direction, It is characterized by the above-mentioned.

  When the LED chips having a predetermined arrangement are sealed with a transparent resin using the dam frame material having such a configuration, the transmission of light emitted from one LED chip to the position of the adjacent LED chip is based on a base having a through hole. As a result of being effectively blocked by both the frame surrounding the LED chip formed by the material sheet and the pressure-sensitive adhesive layer that adheres the frame to the substrate, an LED display device that forms a clear image is formed. The "width direction" said above means the width direction of the frame which divides the LED chip of a dam frame material, ie, the plane direction of a base material sheet.

  In the above-mentioned dam frame material for an LED display device, the pressure-sensitive adhesive layer is formed of a double-sided pressure-sensitive adhesive tape having a reinforcing base material layer, and the reinforcing base material layer is a fiber material or a visible light opaque material. It is comprised with the film and it is preferable that an adhesive contains a visible light impervious coloring agent.

  In the dam frame material having such a configuration, the pressure-sensitive adhesive layer is also impermeable to visible light, and can be manufactured by a simple method.

  The pressure-sensitive adhesive layer of the dam frame material of the present invention may be formed by applying a pressure-sensitive adhesive layer to the reinforcing base material layer, but it is simple to form by sticking a double-sided pressure-sensitive adhesive tape, Preferably, the double-sided pressure-sensitive adhesive tape preferably has a reinforcing base material layer from the viewpoint of shape stability. A dam frame material that does not transmit visible light in the width direction that partitions the light of adjacent LED chips by using a pressure-sensitive adhesive containing a visible light-impermeable colorant comprising a reinforcing base material layer of a nonwoven fabric. can get.

Another aspect of the present invention includes a pressure-sensitive adhesive layer forming step in which a pressure-sensitive adhesive layer is laminated on a substrate sheet to form a laminated sheet having a release sheet layer, and a punching step in which the laminated sheet is punched to form a plurality of through holes. A method for producing a dam frame material for an LED display device having a plurality of through holes,
The base sheet and the pressure-sensitive adhesive layer do not transmit visible light in the width direction.

  According to the manufacturing method of the above configuration, a dam frame material capable of forming an LED display device that blocks the transmission of light emitted by one LED chip to the position of an adjacent LED chip and forms a clear image can be manufactured. it can.

  In the above-described method for producing a dam frame material for an LED display device, the pressure-sensitive adhesive layer is formed of a double-sided pressure-sensitive adhesive tape having a reinforcing base material layer, and the reinforcing base material layer is a fiber material or visible light. It is comprised by the impermeable film and it is preferable that an adhesive contains a visible light impervious coloring agent.

  According to the manufacturing method of the structure which concerns, the adhesive layer can also manufacture the dam frame material whose visible light impermeability is easy.

  As the base sheet constituting material constituting the dam frame material of the present invention, known thermoplastic resins, thermoplastic elastomers, vulcanized rubbers and the like can be used. Specifically, as the thermoplastic elastomer, known thermoplastic elastomers can be used without limitation, and specific examples include polyester elastomers, polyolefin elastomers, polyamide elastomers, ionomers, polyurethane elastomers, and the like.

  Rubber materials constituting the vulcanized rubber material include natural rubber, styrene butadiene rubber (SBR), butadiene rubber (BR), isoprene rubber (IIR), nitrile rubber (NBR), hydrogenated nitrile rubber (hydrogenated NBR). ), Synthetic rubbers such as chloroprene rubber (CR), ethylene propylene rubber (EPDM), fluorine rubber, silicon rubber, acrylic rubber, and urethane rubber. These rubber materials may be used in combination of two or more as required.

  Thermoplastic resins include polyolefin resins such as polypropylene and polyethylene, polyester resins such as PET and PBT, polyamide resins such as nylon 66, fluorine resins such as PFA and ETFE, polyvinyl chloride, polyoxymethylene, polyphenylene sulfide (PPS). ), Polyphenylene oxide (PPO), polyether sulfone (PES), PEEK, and the like. Two or more thermoplastic resins may be used in combination as required.

  As the base sheet, the material exemplified above can be used without limitation when the unevenness of the circuit board to which the dam frame material is stuck is small, but when the unevenness is large, the thermoplastic elastomer or the vulcanized rubber It is preferable to use a material having high flexibility such as the above because it can be deformed according to the unevenness and effectively prevent leakage of visible light.

  Addition to the reinforcing base layer prevents visible light transmission in the width direction of the reinforcing base layer and at the same time, the visible light impermeable colorant that sharpens the pixels of the image display device includes carbon black, bengara, Examples include dark pigments such as dark blue, calcium carbonate, magnesium carbonate, calcium sulfate, silica, alumina, titanium oxide and the like, and one or more can be used. Among these, the use of dark pigments such as carbon black, bengara, and dark blue is preferable because the effect of blocking the transmission of visible light to adjacent positions is great.

  As the material constituting the pressure-sensitive adhesive layer, a known pressure-sensitive adhesive such as a known rubber-based pressure-sensitive adhesive, acrylic resin-based pressure-sensitive adhesive, or silicon-based pressure-sensitive adhesive can be used without limitation. The pressure-sensitive adhesive layer may be formed by directly applying a pressure-sensitive adhesive to a predetermined surface of the dam frame material, but may be formed by sticking a double-sided pressure-sensitive adhesive tape as described above. The adhesive only needs to be able to fix the dam frame material to the substrate by the adhesive force, and may be one that is subsequently reaction-cured.

  As the visible light non-transparent colorant added to the pressure-sensitive adhesive layer, the visible light non-transparent colorant added to the above-mentioned base sheet constituent material can be used. When the pressure-sensitive adhesive layer is formed of a double-sided pressure-sensitive adhesive tape having a reinforcing base material layer, the reinforcing base material is preferably composed of a fiber material made of a woven fabric or a non-woven fabric or a visible light opaque film. The fiber material does not guide visible light like a film, so it does not need to contain a visible light non-transparent colorant, but the fiber constituting the fiber material also contains a visible light non-transparent colorant. More preferably. The fiber material does not transmit visible light in the width direction unlike a film. When a visible light non-transparent colorant is added to the adhesive, the adhesive impregnates the fiber material and allows the fiber material layer to transmit visible light. The effect | action which lowers further is show | played. A commercial product may be used as a double-sided pressure-sensitive adhesive tape in which a nonwoven fabric is used as a reinforcing base and carbon black is added to the pressure-sensitive adhesive.

  As a release sheet, a material used as a release sheet of an adhesive tape can be used without limitation, and examples include kraft paper, polyolefin resin film, and PET film that have been subjected to release treatment.

  In the method for producing a dam frame material of the present invention, a base sheet layer constituting material such as a thermoplastic resin or unvulcanized rubber is processed and formed into a sheet shape, and the unvulcanized rubber is further subjected to heating, electron beam irradiation, or the like. A base sheet original fabric is produced by vulcanization, and a pressure-sensitive adhesive layer is formed thereon to form a laminated sheet (pressure-sensitive adhesive layer forming step), which is manufactured by a manufacturing method having a punching step of punching through holes.

  In the punching step, the through hole can be formed using a known punching means such as a Thomson blade. However, if the shape of the through hole is small and punching with a Thomson blade is not possible, it has a plate-like portion that stands vertically from the base and a blade edge portion that is formed at the tip of the plate-like portion. It is preferable to use an integral punching blade having a thickness of 0.6 mm or less and a blade depth of 1 to 3 mm. With such a punching blade, a small through-hole that cannot be punched with a Thomson blade can be formed.

  FIG. 1 is a partial cross-sectional view illustrating the configuration of a dam frame member. In the dam frame member 10 shown in FIG. 1A, an adhesive layer 16 is laminated on a base material sheet layer 12, and a release sheet 24 is laminated on one side of the adhesive layer 16. A plurality of through holes 14 are formed in the dam frame member 10. In the dam frame member 10 shown in FIG. 1B, the pressure-sensitive adhesive layer 17 is composed of a base material sheet-side pressure-sensitive adhesive 20, a reinforcing base material layer 18, and a substrate fixing pressure-sensitive adhesive layer 22. A release sheet 24 is laminated on the agent layer 22. The dam frame member 10 illustrated in FIG. 1B can be easily manufactured by sticking a double-sided pressure-sensitive adhesive tape having a reinforcing base material layer 18 to a base material sheet.

  The dam frame member 10 is peeled and removed from the release sheet 24 and attached to a predetermined position of the substrate on which the LED chips are mounted in a predetermined arrangement. In the outer peripheral frame of the dam frame member 10, it is a preferable aspect to form a hole or notch for alignment when adhering to the substrate.

  The thickness of the base material sheet and the thickness of the adhesive material layer are appropriately set according to the size of the LED chip used, etc., but the thickness excluding the release sheet of the dam frame material is 0.3. The thickness of the adhesive layer is preferably 0.1 to 0.6 mm.

  FIG. 2 is a partial plan view showing a state in which a dam frame material is attached to a substrate on which LED chips are arranged and mounted. A dam frame member 10 is attached to a substrate on which the LED chips 30 are regularly arranged and mounted vertically and horizontally so that each LED chip 30 is positioned in the through hole. A cutout 31 is formed in the dam frame member 10 for accuracy of alignment. The shape, arrangement and number of the through holes of the dam frame member 10 and the frame widths w1 and w2 are appropriately set according to the LED display device to be manufactured. For example, when the through-hole is circular and the transparent resin is cast into a hemisphere or a partial sphere by using surface tension and cured, an LED display device with further excellent visibility can be formed.

  FIG. 3 is a diagram illustrating a cross section of the substrate to which the dam frame member 10 shown in FIG. 2 is attached. The circuit board 46 is formed with circuits 40 and 44 constituting an anode electrode and a cathode electrode, and an LED chip 36 is fixed on the circuit using a conductive paste such as a silver paste, and an upper electrode of the LED chip. 34 is connected to the substrate circuit 44 by wire bonding 42. The dam frame member 10 is fixed by the adhesive layer 16, and the LED chip is partitioned and sealed by casting and curing a resin raw material forming a transparent resin in a portion surrounded by the dam frame member 10. LED display devices are formed.

  1 to 3 show an example using a single color LED chip, FIG. 4 shows an example using a multicolor light emitting LED chip. 4A is an enlarged plan view showing one of the rectangular through holes formed in the dam frame member, and FIG. 4B is a cross-sectional view thereof. A red LED chip, a blue LED chip, and a green LED chip 52, 54, and 56 are disposed on the circuit 62 of the substrate, and the upper electrode of each LED chip is connected to the circuit 60, 63, and 64 of the substrate by wire bonding, respectively. Connected to form a multicolor light emitting LED chip. A full-color LED display device is obtained by supplying and curing a resin raw material for forming a transparent resin in the recess formed by the frame of the dam frame material 10.

  In FIG. 5, the example which laminated | stacked the shape retention sheet | seat on the surface of the base material sheet | seat 12 of the dam frame material 10 was shown with sectional drawing. When the base sheet 12 is composed of vulcanized rubber or thermoplastic elastomer, if many through holes are formed, the shape of the dam frame material becomes unstable in a state where the release sheet 24 is removed before being attached to the substrate. Become. By sticking the shape-retaining sheet before the release sheet 24 is peeled and removed, the shape can be stabilized and the sticking operation can be easily performed. The sticking sheet has a certain degree of flexibility, and has an adhesive layer 32 on one side of the base material layer 30 that is difficult to stretch and deform. Specifically, the base material layer 30 is preferably made of a thermoplastic resin film such as a polyester resin such as PET or a polyolefin resin such as polypropylene. The pressure-sensitive adhesive layer 32 is formed of a pressure-sensitive adhesive that has low adhesive force and can be easily peeled off after the dam frame material 10 is attached to the substrate.

(Example)
A base sheet with a square of 80 mm on a side and a thickness of 0.4 mm is made by extrusion molding and cutting process using Santoprene 101-55 (AES Japan), a polyolefin elastomer colored with black by adding carbon black. Then, a commercially available double-sided pressure-sensitive adhesive tape # 8103D Black (Dainippon Ink & Chemicals) with a non-woven fabric as a reinforcing base material and carbon black added to the pressure-sensitive adhesive was adhered to one side of the base material sheet to obtain a laminated sheet. This laminated sheet was punched using a punching blade so that a square through-hole with a side of 2.5 mm was 16 in length and 16 in width with a frame width of 1 mm, thereby producing a dam frame material.

  The LED chips were mounted on a glass epoxy wiring board having a thickness of 1 mm in an arrangement of 16 rows × 16 rows, and were stuck so that the LED chips were positioned in the through holes of the dam frame material. Next, a commercially available reaction-curing transparent resin raw material for sealing was poured into the through-hole portion, and was cured by heating at 150 ° C. for 2 hours to produce an LED display device.

  Regarding the obtained LED display device, even when one LED was turned on, no light leaked to the pixels (cells) of other LEDs. Further, when an image was actually displayed, a good image was formed in which the contrast of each pixel was large, the contour was clear.

Partial sectional view illustrating the configuration of the dam frame material of the present invention Partial plan view showing a state where a dam frame material is attached to a substrate on which LED chips are arranged and mounted The figure which illustrated the section of the substrate which stuck the dam frame material shown in FIG. Example of using multi-color LED chips and forming pixels with dam frame material

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Dam frame material 12 Base material sheet 14 Through-hole 16 (17) Adhesive layer 24 Release sheet

Claims (4)

It consists of a base sheet, an adhesive layer provided on one side of the base sheet, and a release sheet laminated on the adhesive layer, and has a plurality of through holes, and the base sheet and the adhesive layer are A dam frame material for an LED display device, characterized by not allowing visible light to transmit in the width direction. The pressure-sensitive adhesive layer is formed of a double-sided pressure-sensitive adhesive tape having a reinforced base material layer, and the reinforced base material layer is composed of a fiber material or a visible light impermeable film. The dam frame material for an LED display device according to claim 1, which contains a visible light opaque colorant. It has a plurality of through-holes, including a pressure-sensitive adhesive layer forming step of laminating a pressure-sensitive adhesive layer on a base sheet and forming a release sheet layer, and a punching step of punching out the laminated sheet to form a plurality of through-holes. A method for manufacturing a dam frame material,
The said base material sheet and the said adhesive layer do not permeate | transmit visible light to the width direction, The manufacturing method of the dam frame material for LED display apparatuses characterized by the above-mentioned. The pressure-sensitive adhesive layer is formed of a double-sided pressure-sensitive adhesive tape having a reinforced base material layer, and the reinforced base material layer is composed of a fiber material or a visible light impermeable film. The method for producing a dam frame material for an LED display device according to claim 3, which contains a visible light opaque colorant.

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