JP5367260B2 - Light source module, illumination device, and liquid crystal display device - Google Patents

Description

  The present invention relates to a light source module in which a light-emitting body sealed with a lens is mounted on a surface of a substrate, and relates to a method for manufacturing the light source module, an illumination device to which the light source module is applied, and a liquid crystal display device.

  An image display device that employs a liquid crystal method (hereinafter referred to as a liquid crystal display (LCD)) can be made thinner for any screen size, from large to small, compared to a cathode ray tube method. Also, power saving is excellent. In recent years, televisions made up of liquid crystal display devices are expanding in the market for general users with the progress of price reduction, and further price reduction is required.

The liquid crystal display device includes a liquid crystal panel in which a liquid crystal layer is sandwiched between a pair of transparent substrates, and a backlight unit (illumination device) that transmits transmitted light that transmits the liquid crystal panel and displays an image on the surface thereof. And as an illuminating device, there exists an edge light type | mold with which the light source is provided in the edge of the light-guide plate arrange | positioned directly under a liquid crystal panel other than the direct type | mold with which the light source is arrange | positioned directly under a liquid crystal panel.
As a light source, a cold cathode fluorescent lamp (CCFL) has been conventionally used, but in recent years, a light emitting diode (LED) excellent in long life and illumination controllability has been widely used.

The illumination device using LEDs as light sources includes a light source module in which a plurality of LEDs are arranged in a one-dimensional direction or a two-dimensional direction on the surface of a substrate.
And the following manufacturing methods are conventionally implemented as a method of manufacturing such a light source module.
That is, the light emitter is mounted on a substrate on which wiring for supplying power is printed. Next, a liquid thermosetting resin (uncured liquid) is supplied to a mold surface in which recesses (cavities) for molding lenses for sealing the light emitters are provided in accordance with the arrangement of the light sources.
Then, the mold surface and the arrangement surface of the light emitters of the substrate are combined, and the light emitter is immersed in an uncured liquid filled in the cavity, and heat treatment is performed to cure the uncured liquid. Thereby, a light source module in which a light emitting body (LED) sealed with a lens is mounted on a surface of a substrate in a one-dimensional direction or a two-dimensional direction is obtained (for example, see Patent Document 1).
JP 2000-228545 A

Incidentally, the following problems have been pointed out in the above-described conventional method of manufacturing a light source module.
First, it is necessary to produce the above-described mold surface separately, which is a cost increase factor.
Furthermore, rotating the heat treatment cycle including the mold increases the lead time from injection of uncured liquid to mold release to mold the lens, and increases the man-hours for improving mold release. It becomes a cost increase factor.
Also, when the mold surface and the substrate are combined, foreign matter and voids (bubbles) are mixed in, the lens is insufficiently filled, or the uncured liquid overflowing from the cavity forms burrs around the lens. When such a defect occurs, not only does the yield decrease and the cost increases, but also the quality deteriorates.

  An object of the present invention is to provide a lighting device and a liquid crystal display device that are capable of solving such a problem, manufacturing a high-quality light source module while eliminating the above-described cost increase factors, and having high performance and cost-responsiveness. The purpose is to provide.

In order to solve the above-described problems, the present invention provides a method of manufacturing a light source module, a step of providing a resist on a surface of a substrate on which a light emitting body that emits light upon receiving power supply is mounted, and partially exposing the resist by exposure. Sensitizing the substrate to divide the surface of the substrate into a plurality of lighting regions and other regions, and removing the resist provided in the other regions and then providing a liquid repellent layer on the substrate surface; Removing the resist provided in the lighting region, mounting at least two or more light emitters in each of the lighting regions, and sealing the two or more mounted light emitters. in to the steps of respectively placed high affinity uncured liquid of a plurality of the lighting area to the surface of the substrate than the liquid repellent layer, wherein curing the uncured liquid, light emission of the light emitter By the lens for radiating the wide angle, and forming a light source having at least two or more of said emitters, characterized in that it contains.

By configuring the invention in this way, the lens of the light source module can be molded by curing the uncured liquid without using the mold having the cavity. Furthermore, the interface between the molded lens and the substrate is free from air bubbles, underfilling, and burr formation, and has good adhesion.
Furthermore, the durability of the light source module is improved by providing the liquid repellent layer on the surface of the substrate.

  ADVANTAGE OF THE INVENTION According to this invention, while producing a high quality light source module at low cost, it has a price response power, and provides the illuminating device and liquid crystal display device which are high performance and excellent in durability.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
<First Embodiment>
A first embodiment of a liquid crystal display device, a lighting device and a light source module according to the present invention will be described with reference to FIGS.
As shown in the exploded perspective view of FIG. 1 (see also the longitudinal sectional view of FIG. 2 as appropriate), the liquid crystal display device 10A (10) includes a display means 20, a light diffusion means 30, and a lighting device 40A (40). (Including the light source module 50A (50)), the control means 70, and the back frame 80 are stacked in the front Z-axis direction.
Here, in the drawings, the liquid crystal display device 10 is assumed to be a general television used at home, and the longitudinal direction of the image display surface 22a is shown as the X axis and the short side direction is shown as the Y axis.
Thus, by configuring the liquid crystal display device 10, a still image or a moving image is displayed on the display surface 22a facing the viewer (not shown).

The display means 20 includes a front frame 21, a liquid crystal panel 22 having a display surface 22a, and a locking member 23 having a locking groove 23a.
With this configuration, the liquid crystal panel 22 is fixed to the front frame 21 to prevent deformation due to external force, and the positional relationship with the lighting device 40 is fixed, so that the entire display surface 22a is uniform. Illuminated.

  The front frame 21 is made of a metal such as highly rigid iron or aluminum, and has a rectangular opening 21a through which the display surface 22a of the liquid crystal panel 22 is exposed. Then, as shown in FIG. 2, the inner surface of the front frame 21 with the locking member 23 having an opening substantially coinciding with the opening 21a engaged with the outer periphery of the liquid crystal panel 22 in the locking groove 23a. Is fitted. Thereby, the liquid crystal panel 22 is fixed to the front frame 21 in a state exposed from the opening 21a.

Returning to FIG. 1, the description will be continued.
In the liquid crystal panel 22, a liquid crystal layer sandwiched between a pair of transparent electrodes changes a backlight transmittance in units of pixels constituting an image, thereby forming a still image or a moving image on the display surface 22a. is there.
In the mass-produced products that use the TFT (Thin Film Transistor) method, which is currently the mainstream, electrode elements that are arranged in a lattice pattern on a transparent substrate (glass plate) change the molecular orientation of the liquid crystal by controlling the electric field. The illumination light from the illumination device 40 is transmitted / blocked for each pixel. In addition, a color filter is provided by arranging three primary color filters and further transmitting the transmitted light.

The light diffusing unit 30 includes an optical sheet 31 and is disposed between the display unit 20 and the lighting device 40. The light diffusing unit 30 irradiates the liquid crystal panel 22 after uniformizing the luminance distribution of light from the lighting device 40. . As a result, an image with less luminance unevenness is displayed on the display surface 22a.
Then, as shown in FIG. 2, a plurality of optical sheets 31 are stacked, so that irradiation light from the illumination device 40 is repeatedly diffused / reflected and enters the liquid crystal panel 22. Thereby, the in-plane distribution of the luminance of the irradiation light is made uniform, and the directivity of the irradiation light toward the front Z-axis direction is given.

Returning to FIG. 1, the description will be continued.
The control means 70 includes a power board 71 and a signal board 72.
The signal board 72 outputs a video signal for controlling the elements of the liquid crystal panel 22.
The power supply board 71 inputs commercial AC power (AC100V to AC240V), and outputs DC power necessary for driving the display means 20, the lighting device 40, and others (audio equipment (not shown) such as a speaker). .

The back frame 80 has a deep drawing shape, and closes the opening on the back side of the display means 20 as shown in FIG. 2 and accommodates the control means 70 and the lighting device 40 inside.
Further, vent holes 21b and 81 as shown in FIG. 1 are provided on the side surfaces of the display means 20 and the back frame 80, respectively, so that the air heated inside and the outside air can be exchanged. It has become.

The illumination device 40A includes a first reflection sheet 41, a second reflection sheet 42, a light guide plate 43, an intermediate frame 44, a support member 45, and a light source module 50A.
As shown in FIG. 3A, the illumination device 40A configured in this way emits light in the front Z-axis direction when the light source module 50A provided at the edge of the light guide plate 43 emits light. It is.

Returning to FIG. 1 (see FIG. 2 as appropriate), the description will be continued.
The light guide plate 43 is made of a transparent resin such as acrylic, and light incident from the incident surface 43a at the edge repeats internal reflection and propagates to the entire plane (XY plane) toward the front Z-axis direction. To irradiate. Thus, the light guide plate 43 has a function of converting the line light source of the light source module 50A into a surface light source.

The first reflection sheet 41 has a structure in which an outer peripheral portion and an inner peripheral portion are stepped. As shown in FIG. 2, the outer peripheral portion is fastened together with the front frame 21, the locking member 23, and the support member 45. The inner peripheral portion is in contact with the edge of the light guide plate 43 and functions so that the light emitted from the light source module 50A enters the incident surface 43a without leakage.
Furthermore, the 1st reflection sheet 41 provides a clearance gap between the light-guide plate 43 and the optical sheet 31, and makes it easy to irradiate the light which reflects internally the light-guide plate 43 to a front surface (Z-axis direction).

  The second reflection sheet 42 is disposed in close contact with the back surface of the light guide plate 43, and allows light to enter the incident surface 43 a in cooperation with the first reflection sheet 41. Furthermore, the second reflection sheet 42 has a function of improving incident light utilization efficiency by returning incident light that has been once incident on the incident surface 43a and is out of the total reflection condition and jumped from the lower surface to the light guide plate 43 again.

  The intermediate frame 44 has high rigidity, and supports the light guide plate 43 and the second reflection sheet 42 so as not to be warped by a plane portion thereof.

As shown in FIG. 2, the support member 45 has a substantially L-shaped structure, is connected to the display means 20 and the back frame 80 on the upper and lower end surfaces of the L shape, and supports the intermediate frame 44 in the horizontal plane. The light source module 50A is supported on the vertical inner surface.
As described above, the support member 45 is configured to connect the respective constituent elements so as to bear the integrity of the structure of the liquid crystal display device 10.
Further, the support member 45 is formed of a metal material such as copper or aluminum having excellent thermal conductivity, and has a function of conducting heat generated by the light source module 50A to the heat radiating fins 45a and efficiently radiating heat. Then, the air in the gap that receives the heat radiation from the heat radiation fin 45a is heated and released from the vent holes 21b and 81 (see FIG. 1) by natural convection.

  The light source modules 50A and 50A are arranged to face each other so that the incident surfaces 43a and 43a at both ends of the light guide plate 43 are desired as shown in FIG. 3B, a plurality of light sources 60 (light emitting diodes (LEDs)) are mounted linearly (one-dimensionally) on the lighting region 61 on the surface of the substrate 51, as shown in a partially enlarged perspective view of FIG. Has been.

The substrate 51 is made of a substrate in which a glass fiber is impregnated with a thermosetting resin such as an epoxy resin, or a ceramic substrate, and is supported on the vertical inner surface of the L-shaped support member 45.
The substrate 51 is provided with an input terminal (not shown) for inputting power from the outside (control means 70 (see FIG. 1)), and a wiring 63 for guiding the input power to the terminal electrode 62 is provided. Yes.
Further, the substrate 51 is provided with a liquid repellent layer 52 in another region outside the lighting region 61.

  The wiring 63 is formed by forming a conductive layer having a copper foil pattern on the substrate 51, and an insulating film (not shown) is further formed thereon. The electrode 62 located at the end of the wiring 63 is exposed on the surface of the substrate 51 with the insulating film peeled off, and is wire-bonded to the light emitter 65. In the drawing, the wiring 63 is provided on the surface of the substrate 51, but is not limited thereto, and may be stacked inside the substrate 51.

The light source 60 (LED) has a configuration in which one lens 64, one or a plurality of (three in the figure) light emitters 65, and corresponding electrodes 62 are provided in the lighting region 61. By configuring the light source 60 in this way, the light of the light emitter 65 can be emitted at a wide angle by the function of the lens 64, and light is incident on the incident surface 43a of the light guide plate 43 in a state where the luminance distribution is suppressed. be able to.
Furthermore, if a plurality (three in the figure) of the light emitters 65 emit R (Red), G (Green), and B (Blue), for example, these primary colors are mixed by the scattering function of the lens 64. Various colors of light with no color unevenness can be expressed. Furthermore, by changing the brightness of the light emitters 65 of these three primary colors independently, it is possible to emit light whose color has changed over time.

The lens 64 is in close contact with the surface of the substrate 51 in the lighting region 61, and also has a function of sealing and protecting the light emitter 65 and the like disposed in the lighting region 61.
Such a lens 64 is formed by curing a low-viscosity uncured liquid 66 (see FIG. 4G) by heat treatment or light treatment, and transmits the light emitted from the light emitter 65 without being attenuated. It consists of the material which has.
Such materials include silicone resin, methacrylic resin, fluorene resin, cycloolefin resin, epoxy resin, organic / inorganic hybrid resin, polycarbonate resin, TAC resin, polystyrene resin, and fluorine resin. Type, polyethylene terephthalate resin type, MS resin type, and polyvinyl alcohol resin type.

The liquid repellent layer 52 is provided on the surface of the substrate 51 in another area that is out of the lighting area 61.
When compared with the surface of the substrate 51, the liquid repellent layer 52 has high liquid repellency with respect to the uncured liquid 66 (see FIG. 4G) before being cured by the lens 64. In other words, the uncured liquid 66 has higher affinity and better wettability on the surface of the substrate 51 than on the liquid repellent layer 52.
As the uncured liquid 66 having such properties, fluorine-based and silicone-based materials can be appropriately employed.

When the surface of the substrate 51, the liquid repellent layer 52, and the uncured liquid 66 have such a relationship in nature, the following actions are led. That is, when the liquid repellent layer 52 is provided in another region of the surface of the substrate 51 that is out of the lighting region 61, and the uncured liquid 66 is injected into this lighting region 61, it is potted into the shape of the lens 64 due to the surface tension. The In this state, the lens 64 is molded by performing a process (heating, light irradiation) for curing the uncured liquid 66.
The liquid repellent layer 52 protects the light-emitting body 65 sealed by the lens 64 in order to find a slight gap between the surface of the substrate 51 and the lens 64 and to prevent moisture from entering due to capillary action. Make it more complete.
In addition, although the lighting area | region 61 has shown the electrode 62, a part of wiring 63, and the area | region containing the light-emitting body 65 in the drawing, it is not specifically limited, Suppose that it is an area | region including the light-emitting body 65 at least. .

Next, a method for manufacturing a light source module will be described with reference to FIGS.
4A to 4H show an embodiment of a method for manufacturing a light source module.
First, in the step shown in FIG. 4A, a substrate 51 on which an electrode 62 and a wiring 63 (not shown) are mounted is manufactured.
Then, in the step shown in FIG. 4B, a resist 53A (53) is provided on the surface of the substrate 51 on which the light emitter 65 is mounted in a later step.

Next, in the step shown in FIG. 4C, the lighting region 61 divided so as to include the light emitter 65 and its peripheral portion is exposed, and the resist 53A provided in the lighting region 61 is partially applied. And is fixed on the surface of the substrate 51.
Then, in the step shown in FIG. 4D, after removing the resist 53A provided in the other region outside the lighting region 61, the surface of the substrate 51 as shown in FIG. A liquid repellent layer 52 is provided.

Next, in the step shown in FIG. 4F, the resist 53A fixed to the lighting region 61 is removed with chemicals, and then the light emitter 65 is mounted on the surface of the substrate 51. Further, as shown in FIG. 4G, an uncured liquid 66 is placed (potted) in the lighting region 61 using an injector 67 or the like.
Then, in the step shown in FIG. 4H, the uncured liquid 66 is cured by heating with the heater 91, the lens 64 is formed, and the luminous body 65 is sealed.

The process diagrams of FIGS. 5A to 5F show another embodiment of the method for manufacturing the light source module.
First, in the step shown in FIG. 5A, a substrate 51 on which an electrode 62 and a wiring 63 (not shown) are mounted is manufactured.
5B, a resist 53B (53) is provided on the surface of the substrate 51 on which the light emitter 65 is mounted.

Next, in the step shown in FIG. 5C, another region outside the lighting region 61 divided so as to include the light emitter 65 and its peripheral portion is exposed to be provided in this other region. The resist 53B is partially exposed and fixed on the surface of the substrate 51 to form the liquid repellent layer 52.
That is, in the present embodiment, the fixed resist 53B is made of a material that is more excellent in liquid repellency with respect to the uncured liquid 66 than the surface of the substrate 51.

5D, the light emitter 65 is mounted on the surface of the substrate 51 after removing the resist 53B provided in the lighting region 61. In the step shown in FIG. Further, as shown in FIG. 5 (e), the uncured liquid 66 is placed (potted) in the lighting region 61 using the injector 67.
Then, in the step shown in FIG. 5 (f), the luminous body 65 is sealed by heating the heater 91 to cure the uncured liquid 66 to form the lens 64.

By the way, as the resist 53 that is exposed to light (ultraviolet rays), various types of resists can be applied, and a liquid type or a film type can be applied to the substrate 51. It can be provided on the surface.
Further, in the description, the type in which the portion where the resist 53 is fixed to the surface of the substrate 51 is exposed and exposed is exemplified, but conversely, the type in which the portion to be removed first is exposed can also be applied. .
In the case of applying these various types of resists 53, detailed explanations are omitted as they are understood by appropriately replacing the terms with the above explanation.

  By manufacturing the light source module 50 by such a manufacturing method, it is not necessary to use a conventional mold having a cavity, and foreign substances and voids (bubbles) are prevented from being mixed. Furthermore, the adhesiveness at the interface between the molded lens 64 and the substrate 51 is also good, so that the lens 64 is not insufficiently filled and burrs are not formed. Further, the liquid repellent layer 52 remaining on the surface of the substrate 51 tightly plugs the joint portion between the surface of the substrate 51 and the lens 64, so that moisture that penetrates from the joint portion and moves toward the light emitter 65 can be obtained. Block effectively. Thereby, while being able to aim at the reduction of the manufacturing cost of a light source module, the durability and quality can be improved.

Second Embodiment
Next, a second embodiment of the liquid crystal display device according to the present invention will be described with reference to FIGS.
In addition, about the component of the liquid crystal display device 10B of 2nd Embodiment which is common or corresponding to 1st Embodiment (FIGS. 1-3), attach the same code | symbol and use corresponding description. The description is omitted.

As shown in the exploded perspective view of FIG. 6 (see also the longitudinal sectional view of FIG. 7 as appropriate), the liquid crystal display device 10B (10) of the second embodiment includes a light diffusing means 30B (30) and an illumination device 40B. (40) (including the light source module 50B (50)).
With this configuration, the liquid crystal display device 10B transmits light emitted from the light source module 50B provided in a planar shape (XY plane) to the liquid crystal panel 22 and displays an image on the display surface 22a.

The light diffusing unit 30B includes an optical sheet 31 and a diffusion plate 32, and is disposed between the display unit 20 and the illuminating device 40B, and uniformizes the luminance distribution of light emitted from the illuminating device 40B. is there. Thereby, the luminance distribution of the light applied to the display means 20 is made uniform, and an image with little luminance unevenness is displayed on the display surface 22a.
The diffusion plate 32 also has a function of preventing the optical sheet 31 from bending due to its own weight or aging by supporting the optical sheet 31 in a planar shape as shown in FIG.

Returning to FIG. 6, the description will be continued.
The illumination device 40B (40) includes a light source module 50B, a container 46, and a support member 45. By configuring the illumination device 40B as described above, the light source module 50B is provided in a planar shape with respect to the display means 20, and when the light source module 50B emits light, the light is emitted toward the front surface (Z-axis direction).

  In the light source module 50B, as shown in FIG. 8A, light sources 60 (see FIG. 8B) are mounted on the surface of the substrate 51 in a regular (two-dimensional) arrangement. .

  The container 46 has a bottomed shape having an opening substantially coinciding with the optical sheet 31, and an inner surface thereof is inclined to reflect light emitted from the light source 60 toward the front surface (Z-axis direction). Then, as shown in FIG. 7, the periphery of the container 46 abuts on the outer periphery of the optical sheet 31 and the diffusion plate 32, and holds them between the locking member 23 and the front frame 21.

In the above description, the light source 60 is exemplified as an LED. However, the light source 60 is not limited to the light emission mechanism, and any light source 50 that is sealed by the lens 64 is included.
Moreover, although the light source module 50 illustrated what was applied to the illuminating device 40, it is not limited to this, As long as the several light source 60 is provided in the surface of the board | substrate 51, it employ | adopts suitably. For example, it can be employed as an indicator (display device).
Moreover, although the illuminating device 40 illustrated what was applied as a backlight module of the liquid crystal display device 10, it is not limited to this, It can employ | adopt suitably as a plane body which light-emits with uniform brightness | luminance, for example, It can be employed as a signboard, indoor or outdoor lighting device 40.

1 is an exploded perspective view showing a first embodiment of a liquid crystal display device according to the present invention. It is a longitudinal cross-sectional view of the liquid crystal display device in 1st Embodiment. (A) is a perspective view of the illuminating device in 1st Embodiment, (b) is the elements on larger scale of a light source module. (A)-(h) is process drawing which shows embodiment of the manufacturing method of the light source module which concerns on this invention. (A)-(f) is process drawing which shows other embodiment of the manufacturing method of the light source module which concerns on this invention. It is a disassembled perspective view which shows 2nd Embodiment of the liquid crystal display device which concerns on this invention. It is a longitudinal cross-sectional view of the liquid crystal display device in 2nd Embodiment. (A) is a perspective view of the illuminating device in 2nd Embodiment, (b) is an expansion perspective view of the light source part of a light source module.

Explanation of symbols

10, 10A, 10B Liquid crystal display device 20 Display means 22 Liquid crystal panel 22a Display surface 30 Light diffusing means 40, 40A, 40B Illuminating device 43 Light guide plate 43a Incident surface 45 Support member 46 Container 50, 50A, 50B Light source module 51 Substrate 52 Repellent Liquid layer 53, 53A, 53B Resist 60 Light source 61 Lighting area 62 Electrode 63 Wiring 64 Lens 65 Light emitter 66 Uncured liquid 80 Back frame Z Front

Claims (2)

A step of providing a resist on the surface of a substrate on which a light-emitting body that emits light upon receiving power supply is mounted;
Partially exposing the resist by exposure to divide the surface of the substrate into a plurality of lighting regions and other regions;
Providing a liquid repellent layer on the surface of the substrate after removing the resist provided in the other region;
Removing the resist provided in the lighting region;
Mounting at least two or more of the light emitters in each of the lighting regions;
Placing each uncured liquid has high affinity with a plurality of the lighting area to the surface of the substrate than the liquid-repellent layer implemented two or more of the light emitters so as to seal,
Forming a light source having at least two of the light emitters by curing the uncured liquid to form a lens that emits light emitted from the light emitter at a wide angle. Manufacturing method. A step of providing a resist on the surface of a substrate on which a light-emitting body that emits light by receiving power is mounted;
Partially exposing the resist by exposure to divide the surface of the substrate into a plurality of lighting regions and liquid repellent layer regions;
Removing the resist provided in the lighting region;
Mounting at least two or more of the light emitters in each of the lighting regions;
Placing each uncured liquid has high affinity with a plurality of the lighting area to the surface of the substrate than the liquid-repellent layer implemented two or more of the light emitters so as to seal,
Forming a light source having at least two of the light emitters by curing the uncured liquid to form a lens that emits light emitted from the light emitter at a wide angle. Manufacturing method.

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