JP4694379B2 - Flat light source and manufacturing method thereof - Google Patents

Description

  The present invention relates to a flat light source and a method for manufacturing the same. More specifically, the present invention relates to a high-luminance flat light source and a method for manufacturing the same.

  In recent years, liquid crystal display panels (LCD panels) have played a major role in display screens. However, since the LCD panel itself cannot emit light, a backlight module must be placed under the LCD panel to provide a light source and realize a display function. The light source of the backlight module is usually provided by a lamp. The light emitted from the lamp passes through the optical film of the backlight module, and after being scattered, constitutes a surface light source suitable for irradiation of the LCD panel.

  If a flat light source can be used directly, the light use efficiency and uniformity of the surface light source can be improved. Further, the flat light source can be used in various other fields besides the backlight source of the LCD panel. Therefore, there is an advantage in developing a flat light source.

  In general, a flat light source is a plasma light-emitting device. A high voltage is mainly applied between electrode pairs to generate high-energy electrons, and the high-energy electrons collide with an inert gas to form a so-called plasma. To do. Then, the excited atoms in the plasma release UV light to release the energy, and the emitted UV light further excites the phosphor of the flat light source to emit visible light.

  One key to the active development of existing flat light sources is how to improve brightness and improve uniformity of emitted light.

  Accordingly, an object of the present invention is to provide a flat light source having high luminance and high light emission uniformity.

  Another object of the present invention is to provide a method of manufacturing a flat light source, and the manufactured flat light source has high luminance and high light emission uniformity.

The present invention provides a flat light source having a first substrate, a second substrate, a seal portion, a plurality of sets of dielectric patterns and a phosphor layer. An electrode is provided on the first substrate. The seal portion is disposed between the first substrate and the second substrate, and a gap is formed between the first substrate, the second substrate, and the seal portion. The plurality of sets of dielectric patterns are formed in a gap between the first substrate and the second substrate. Each set of dielectric patterns has at least two dielectric strips parallel to each other, each dielectric strip covering one of the corresponding electrodes. Each dielectric strip has an upper surface and two side surfaces, and the upper surface has a convex portion and a concave portion along the longitudinal direction . The phosphor layer is disposed between the dielectric strips of each set of dielectric patterns, and the phosphor layer is disposed on the top surface of the dielectric strip.

  In one embodiment of the present invention, the phosphor layer is further disposed between two adjacent sets of dielectric patterns.

  In one embodiment of the present invention, the flat light source further includes a plurality of partition walls arranged in a gap between the first substrate and the second substrate. In one embodiment, the phosphor layer is further applied on the surface of the barrier rib. In another embodiment, the height of the dielectric strip is the same as the height of the partition. In yet another embodiment, the height of the dielectric strip is lower than the bulkhead.

  In one embodiment of the invention, the height of the dielectric strip is the same as the gap between the first substrate and the second substrate.

  In one embodiment of the present invention, the flat light source further includes a reflective layer disposed on the surface of the first substrate.

  In one embodiment of the present invention, the flat light source further includes another phosphor layer disposed on the second substrate.

The present invention further provides a method of manufacturing a flat light source. In this method, a first substrate is provided. Next, a plurality of electrodes are formed on the first substrate. Then, a plurality of sets of dielectric patterns are formed on the first substrate. Each set of dielectric patterns has at least two dielectric strips parallel to each other, each dielectric strip covering one of the corresponding electrodes, each formed dielectric strip having an upper surface and two side surfaces. The upper surface has a convex part and a concave part along the longitudinal direction . Thereafter, a phosphor layer is formed between the dielectric strips of each set of dielectric patterns and on the top surface of the dielectric strip. A second substrate is provided, a seal is formed between the first substrate and the second substrate, and the first substrate and the second substrate are connected together.

  In one embodiment of the present invention, the method of forming a dielectric strip includes a screen printing process, an etching process, or a sandblasting process.

  In one embodiment of the present invention, the step of forming the phosphor layer further applies a phosphor layer between adjacent sets of dielectric patterns.

  In one embodiment of the present invention, a plurality of partition walls are formed between the first substrate and the second substrate before the connection between the first substrate and the second substrate by the above method. In one embodiment, the phosphor layer is further applied on the surface of the barrier rib. In another embodiment, the height of the dielectric strip is the same as the height of the partition. In yet another embodiment, the height of the dielectric strip is lower than the partition.

  In one embodiment of the invention, the height of the dielectric strip is the same as the gap between the first substrate and the second substrate.

  In one embodiment of the present invention, the reflective layer is formed on the first substrate before forming the electrode on the first substrate by the above method.

  In one embodiment of the present invention, another phosphor layer is further formed on the second substrate by the above method.

Since the upper surface of each dielectric strip is designed to have a convex portion and a concave portion along the longitudinal direction, the application area of the phosphor layer can be increased, and the luminance of the flat light source can be improved.

  FIG. 1A is a schematic cross-sectional view of a flat light source according to a preferred embodiment of the present invention. Referring to FIG. 1A, the flat light source of the present invention includes a first substrate 100, a second substrate 120, a seal portion 104, a plurality of electrodes 102, a plurality of sets of dielectric patterns 108, and a phosphor layer 110.

  The electrode 102 is disposed on the first substrate 100. Each electrode 102 has a strip shape, and these electrodes 102 are arranged on the first substrate 100 in parallel with each other. The seal portion 104 is disposed between the first substrate 100 and the second substrate 120, and a gap portion 106 is formed between the first substrate 100, the second substrate 120, and the seal portion 104. The seal portion 104 is used to connect the first substrate 100 and the second substrate 120 together and leave a gap between the two substrates 100 and 120. The dielectric pattern 108 is disposed in the gap 106 on the first substrate 100. Each set of dielectric patterns 108 has at least two dielectric strips 108 a, 108 b, and each dielectric strip 108 a, 108 b covers one of the corresponding electrodes 102. Accordingly, the two electrodes 102 covered by the two dielectric strips 108a and 108b of the set of dielectric patterns 108 are an electrode pair.

In particular, the dielectric strips 108a, 108b of the present invention have a special contour. Referring to FIG. 4, it shows a three-dimensional schematic view of multiple sets of dielectric patterns 108 on the first substrate 100. Each dielectric strip 108a, 108b has a top surface 202 and two side surfaces 204, 206, with the top surface 202 having a non-uniform contour. In other words, each dielectric strip 108a, 108b has a convex part and a concave part along the longitudinal direction, and forms a non-uniform structure or a step structure.

  Further, referring to FIG. 1A, the phosphor layer 110 is disposed between the two dielectric strips 108a, 108b of each set of dielectric patterns 108, and the phosphor layer 110 further includes the upper surface 202 of the dielectric strips 108a, 108b. Where the contour of the upper surface 202 is non-uniform. As shown in FIG. 5, it is a cross-sectional view along the extension direction of the dielectric strips 108a, 108b. The phosphor layer 110 is further applied to the upper surface 202 of the dielectric strips 108a, 108b.

  According to another embodiment of the present invention, a reflective layer 112 is further formed on the first substrate 100. The reflective layer 112 can also be disposed on the upper surface of the first substrate 100, and the electrode 102 is disposed on the reflective layer 112. The reflective layer 112 can also be disposed on the lower surface of the first substrate 100 (not shown). Whether the reflective layer 112 is disposed on the upper surface of the first substrate 100 or the lower surface of the first substrate 100, the reflective layer 112 can be made of a non-conductive material.

  According to one embodiment of the present invention, the phosphor layer 114 can be further disposed on the second substrate 120. Therefore, the coating area of the phosphor layer of the flat light source can be further increased.

The phosphor layer 110 of the flat light source of the present invention is applied not only between the two dielectric strips 108a and 108b but also on the upper surface 202 of the dielectric strips 108a and 108b, where the upper surface 202 is elongated. It has a convex part and a concave part along the direction . Therefore, compared with the existing flat light source, the coated area of the phosphor layer of the flat light source of the present invention becomes larger, and the crosstalk phenomenon occurs in the recesses of the dielectric strips 108a and 108b, and thus it cannot emit light before. The flashing part can emit light due to the crosstalk phenomenon. Therefore, the brightness of the flat light source can be improved.

  According to a preferred embodiment of the present invention, as shown in FIG. 1A, the flat light source has a plurality of partition walls 116 disposed in the gap 106 between the first substrate 100 and the second substrate 120, and The gap height between the second substrates 120 is maintained. In another preferred embodiment of the present invention, the phosphor layer 110 can be further applied to the surface of the barrier rib 116 as shown in FIG. 1B. Therefore, the coating area of the phosphor layer can be further increased, thereby improving the luminance and light emission uniformity of the flat light source.

  When the barrier rib 116 is included in the flat light source (as shown in FIGS. 1A and 1B), the height of the dielectric pattern 108 can be lower than that of the barrier rib 116. The height of the dielectric pattern 108 may be the same as the height of the partition wall 116 as shown in FIG. 1C. Therefore, the partition wall 116 and the dielectric pattern 108 support the two substrates 100 and 120 and can maintain the height of the gap between the two substrates 100 and 120.

However, this invention is not limited to having to arrange | position a partition in a flat light source. In another embodiment of the present invention, the partition is not included in the flat light source as shown in FIG. Since the partition walls are not included in the flat light source, the height of the set of dielectric patterns 108 is preferably the same as the height of the partition walls 116 in order to maintain the height of the gap between the two substrates 100 and 120. To do. On the other hand, in the embodiment of FIG. 2, the phosphor layer 110 is applied between the two dielectric strips 108a and 108b of each set of dielectric patterns 108 and on the upper surface of the dielectric strips 108a and 108b having the convex and concave portions. In addition, it is applied between a pair of two adjacent dielectric patterns 108. Therefore, the application area | region of a fluorescent substance layer is further increased and the brightness | luminance of a flat light source is improved by it.

  1A to 1C and FIG. 2, each set of dielectric patterns 108 includes two dielectric strips 108a and 108b (electrode pairs), but the present invention is not limited to this. In the structure of the flat light source of the present invention, each set of dielectric patterns 108 may have three or more dielectric strips 108a, 108b and 108c (three electrodes 102) as shown in FIG. In particular, the contours of the top surfaces of the dielectric strips 108a, 108b and 108c are non-uniform, and the phosphor layer 110 not only covers between the dielectric strips 108a, 108b and 108c, but also the dielectric strips 108a, 108b and 108c. Cover the top surface of. On the other hand, when the flat plate light source further includes a partition wall 116, the phosphor layer 110 further covers the surface of the partition wall 116.

  The manufacturing method of said flat light source is shown as follows. First, referring to FIG. 1A, 1B, or 1C, a first substrate 100 is provided. Then, a plurality of electrodes 102 are formed on the first substrate 100 by a known method such as a film formation and etching process or a screen printing process. In one embodiment, the reflective layer 112 is further formed on the first substrate 100 by this method.

Next, a plurality of sets of dielectric patterns 108 are formed on the first substrate, wherein each set of dielectric patterns 108 has at least two dielectric strips 108a, 108b, each dielectric strip 108a, 108b being One of the corresponding electrodes 102 is coated. In particular, the formed dielectric strips 108a and 108b each have an upper surface 202 and two side surfaces 204 and 206, and the upper surface 202 has convex portions and concave portions along the longitudinal direction as shown in FIG. The method of forming the dielectric strips 108a and 108b includes a screen printing process, an etching process or a sand blasting process.

  Thereafter, a phosphor layer 110 is formed between the dielectric strips 108a and 108b of each set of dielectric patterns 108, and the phosphor layer 110 is further formed (as shown in FIG. 5), and the dielectric strips 108a and 108b. It is also applied to the upper surface 202. Then, a second substrate 120 is provided. In a preferred embodiment, another phosphor layer 114 is formed on the second substrate 120. The seal portion 104 is formed between the first substrate 100 and the second substrate 120, and the first substrate 100 and the second substrate 120 are connected together, and between the first substrate 100, the second substrate 120, and the seal portion 104. A gap 106 is formed. Thereafter, the void 106 is filled with an inert gas. When the power supply is turned on, high-energy electrons generated between the electrodes 102 collide with the inert gas and form plasma.

  According to a preferred embodiment, the barrier wall 116 is further formed on the first substrate 100 or the second substrate 120 in this method before the connection of the substrates 100, 120, in particular, before the phosphor layer 110 is applied. When the barrier ribs 116 are formed in a flat light source, more specifically, the phosphor layer 110 is further applied to the surface of the barrier ribs 116 during the step of applying the phosphor layer 110. When the barrier rib is not formed in the flat light source, the phosphor layer 110 is further applied between two adjacent dielectric patterns 108 during the phosphor layer 110 application step as shown in FIG.

From the above viewpoint, since the dielectric strip formed in the flat light source and the manufacturing method thereof according to the present invention has an upper surface with a convex portion and a concave portion as a non-uniform contour, the phosphor layer is formed of two dielectric strips. In addition to being applied in between, it is also applied to the protrusions and recesses on the top surface of the dielectric strip. Therefore, compared with the existing flat light source, the coating area of the phosphor layer of the flat light source of the present invention is larger, and the crosstalk phenomenon can occur in the concave portion of the dielectric strip, thereby preventing the light emission that could not be emitted before. The part can emit light due to the crosstalk phenomenon. Thus, the luminance of the flat light source can be improved.

  Furthermore, the phosphor layer is also applied to other portions where the phosphor layer was not applied in the prior art, such as between the surface of the barrier ribs or between two sets of adjacent dielectric patterns. In this way, the coating area of the phosphor layer can be increased, thereby improving the luminance of the flat light source. Furthermore, the overall light emission uniformity of the flat light source is improved.

  While this invention has been disclosed in the above preferred embodiments, it is not limited thereto. It will be apparent to those skilled in the art that several modifications and innovations can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention should be defined by the appended claims.

  The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the disclosure, serve to explain the principles of the invention.

It is a schematic sectional drawing of the flat light source by several Example of this invention. It is a schematic sectional drawing of the flat light source by several Example of this invention. It is a schematic sectional drawing of the flat light source by several Example of this invention. It is a schematic sectional drawing of the flat light source by another Example of this invention. It is a schematic sectional drawing of the flat light source by another Example of this invention. FIG. 3 is a three-dimensional schematic diagram of a dielectric pattern of a flat light source according to a preferred embodiment of the present invention. FIG. 3 is a cross-sectional view along one extension direction of a dielectric strip of a flat light source according to a preferred embodiment of the present invention.

DESCRIPTION OF SYMBOLS 100 1st board | substrate 102 Electrode 104 Sealing part 106 Space | gap part 108 Dielectric pattern 108a-108c Dielectric strip 110 Phosphor layer 112 Reflecting layer 114 Phosphor layer 116 Partition 120 Second board 202 Upper surface 204 Side surface

Claims (13)

A first substrate having an electrode disposed thereon;
A second substrate;
A seal portion disposed between the first substrate and the second substrate, and forming a gap between the first substrate and the second substrate;
Forming a gap between the first substrate and the second substrate, each set comprising at least two dielectric strips parallel to each other, each dielectric strip covering one of the corresponding electrodes, Each of the strips has an upper surface and two side surfaces, and the upper surface has a plurality of sets of dielectric patterns having protrusions and recesses along the longitudinal direction ;
It is installed in a gap portion between the first substrate and the second substrate, holding the height of the first substrate and the gap of the second substrate, a plurality of partition walls located between two adjacent dielectric pattern set ,
A flat plate light source having a phosphor layer arranged between dielectric strips of each set of dielectric patterns, and further arranging a phosphor layer on the convex and concave portions of the dielectric strip.   The flat light source according to claim 1, wherein a phosphor layer is further arranged between adjacent sets of dielectric patterns.   The flat light source according to claim 1, wherein a phosphor layer is further applied to the surface of the partition wall.   The flat light source according to claim 1, wherein the height of the dielectric strip is lower than that of the partition wall.   The flat light source according to claim 1, further comprising a reflective layer disposed on the surface of the first substrate.   Furthermore, the flat light source of Claim 1 which has another fluorescent substance layer arrange | positioned on the 2nd board | substrate. Providing the first substrate,
Forming a plurality of electrodes on the first substrate;
Forming a plurality of sets of dielectric patterns on the first substrate, each set of dielectric patterns comprising at least two dielectric strips parallel to each other, each dielectric strip covering and forming one of the corresponding electrodes The dielectric strips each have an upper surface and two side surfaces, the upper surface has a convex part and a concave part along the longitudinal direction ,
Forming a phosphor layer between the dielectric strips of each set of dielectric patterns and on the convex and concave portions of the dielectric strip;
Providing a second substrate,
In the gap portion between the first substrate and the second substrate, holding the height of the first substrate and the gap of the second substrate, and installing a plurality of partition walls located between two adjacent dielectric pattern set ,
A method of manufacturing a flat light source, wherein a seal portion is formed between a first substrate and a second substrate, and the first substrate and the second substrate are connected together. The method of manufacturing a flat light source according to claim 7 , wherein the formation of the dielectric strip includes performing a screen printing process, an etching process, or a sandblasting process. 8. The method of manufacturing a flat light source according to claim 7 , further comprising applying a phosphor layer between adjacent pairs of dielectric patterns in the step of forming the phosphor layer. Furthermore, the manufacturing method of the flat light source of Claim 7 which apply | coats a fluorescent substance layer on the surface of a partition. The method of manufacturing a flat light source according to claim 7 , wherein the height of the dielectric strip is lower than that of the partition wall. Furthermore, the manufacturing method of the flat light source of Claim 7 which forms a reflection layer on a 1st board | substrate. Furthermore, the manufacturing method of the flat light source of Claim 7 which forms another fluorescent substance layer on a 2nd board | substrate.

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