JP5623697B2 - Sheet member with optical lens, light emitting device, liquid crystal display device using the same, and signboard - Google Patents

Description

  The present invention relates to a sheet member with an optical lens, a method for manufacturing the same, a light emitting device, a liquid crystal display device using the same, a signboard, and a solar cell.

  An optical lens mechanism is used as a means for condensing or diffusing light emitted from a light emitting diode (hereinafter also referred to as “LED”). Such an optical lens mechanism is designed according to the application and structure of the apparatus used. However, when LED manufacturers develop LEDs having an optical lens for each device, they are in a situation where they cannot deal with them sufficiently because of the large variety of small lots. Therefore, in the production of lighting fixtures, backlight devices, and the like, means such as manufacturing optical lenses with optical designs and bonding the optical lenses to the LEDs later are used. In particular, lighting devices used as surface light sources and backlight devices for liquid crystal display panels such as liquid crystal televisions and personal computer displays use a large number of LEDs, so each lens is mounted on an LED installed on a circuit board. There is a problem that this is very time-consuming (see, for example, Patent Document 1).

  On the other hand, in recent years, LEDs having high luminance have been developed one after another, and it is known that such LEDs generate heat with light emission. Therefore, high heat resistance is required for an optical lens used for condensing or diffusing light emitted from an LED having high luminance.

  Patent Document 2 describes an optical assembly for light emission including an array of LEDs attached to a substrate and an optical sheet disposed on the LEDs. However, the optical assembly described in Patent Document 2 emits light when a part of light entering the one surface of the optical sheet from the LED is guided to the optical sheet in a direction substantially parallel to the base. Therefore, there is a problem that the brightness is inevitably reduced. In addition, since a general optical sheet as described in Patent Document 2 is melted or deformed by heating to ensure dimensional stability, it is deformed by heat generated from an LED having high brightness or There was a problem of discoloration.

In order to solve the above-mentioned problems, it has been studied that the base portion of the optical lens made of silicone resin is integrally joined with the same material and molded into a sheet shape. There have been problems such as occurrence of misalignment and cost increase due to heavy use of heat-resistant materials such as expensive silicone materials.
JP 2006-18261 A Special table 2008-503034 gazette

  One object of the present invention is that it has high heat resistance against the heat generation of LEDs, can greatly eliminate the trouble of attaching a lens to each LED one by one, and can be easily attached to a substrate having LEDs with one touch Accordingly, it is an object of the present invention to provide a sheet member with an optical lens that can prevent misalignment during mounting and can be used stably without misalignment due to thermal deformation during use.

  Another object of the present invention is to provide a method of manufacturing a sheet member with an optical lens that can be manufactured at low cost and can be continuously formed.

The sheet member with an optical lens according to the present invention,
A sheet member for mounting on a substrate provided with a light emitting diode,
The sheet member has a sheet portion and an optical lens portion,
The optical lens portion is disposed on the sheet portion only at a position facing the light emitting diode when mounted on the substrate.

  In the sheet member with an optical lens according to the present invention, the optical lens portion may be made of a silicone resin.

  In the sheet member with an optical lens according to the present invention, the optical lens portion can be obtained by curing a liquid addition reaction curable silicone resin composition.

  In the sheet member with an optical lens according to the present invention, the thermal expansion coefficient of the sheet portion may be smaller than the thermal expansion coefficient of the optical lens portion.

  In the sheet member with an optical lens according to the present invention, the sheet portion may be a polyethylene terephthalate resin sheet or a glass nonwoven fabric.

  According to the said sheet member with an optical lens, it has a high heat resistance with respect to the high heat | fever which LED emits, and can obtain the sheet | seat member which can be easily mounted | worn on a LED board. In addition, since the optical lens portion is provided only at the portion facing the LED, the positioning of the optical lens portion is facilitated, and the yield of the material can be improved. As a result, the manufacturing cost is reduced.

  A light-emitting device according to the present invention is characterized in that the sheet member with an optical lens is mounted on a substrate provided with a light-emitting diode, and the optical lens portion is disposed on the sheet portion only at a position facing the light-emitting diode. To do.

  In the light emitting device according to the present invention, the substrate may be a printed circuit board.

  In the light emitting device according to the present invention, a reflection layer can be formed on at least one surface of the sheet member with an optical lens.

  In the light emitting device according to the present invention, a diffusion plate may be formed on the side opposite to the side on which the substrate including the light emitting diode of the sheet member with the optical lens is mounted.

  A liquid crystal display device according to the present invention includes the light emitting device described above.

  The signboard according to the present invention includes the light emitting device described above.

The sheet member with an optical lens according to the present invention,
A sheet member for mounting on a substrate provided with a solar cell element part,
The sheet member has a sheet portion and an optical lens portion,
It has an optical lens portion only at a position facing the solar cell element portion when mounted on the substrate.

  The solar cell according to the present invention includes the above-described sheet member with an optical lens.

  The method for manufacturing a sheet member with an optical lens according to the present invention is a method for manufacturing a sheet member with an optical lens in which an optical lens portion is provided in a sheet portion so as to face a position of a light emitting diode disposed on a substrate, Preparing a mold having a lens mold in accordance with the position of the light emitting diode; injecting a lens material into the lens mold of the mold; and in the mold so as to contact the injected lens material. A step of setting a sheet portion; and a step of curing the lens material to integrate the optical lens portion and the sheet portion.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

1. 1.1. First Embodiment A sheet member with an optical lens according to a first embodiment of the present invention is a sheet member with an optical lens for mounting on a substrate having a light emitting diode, The sheet member with an optical lens has a sheet part and an optical lens part, and the optical lens part is disposed on the sheet part only at a position facing the light emitting diode when mounted on the substrate. It is characterized by that. FIG. 1 is a plan view schematically showing an example of a sheet member with an optical lens according to the first embodiment.

  The sheet member with an optical lens 100 includes an optical lens unit 10 and a sheet unit 20.

  The optical lens unit 10 is disposed on the sheet unit 20 so as to be provided only at a position facing the LED when the sheet member 100 with an optical lens is mounted on a substrate including the LED. Thereby, in the production of a lighting device used as a surface light source, a backlight for a liquid crystal display device, etc., it is possible to save the trouble of mounting an optical lens for each LED. Moreover, the optical lens part 10 can be correctly arrange | positioned in the position facing each LED by one operation | work only by positioning a sheet | seat part and a board | substrate.

  The optical lens unit 10 may be a rubber lens or the like, but is preferably an optical lens molded from a silicone resin from the viewpoint of high heat resistance. If it is an optical lens molded with a silicone resin, it is possible to prevent deterioration such as melting or deformation or discoloration caused by heat generated from the LED. The optical lens made of silicone resin is not particularly limited as long as it is a silicone resin, but is preferably obtained by curing a liquid addition reaction curable silicone resin composition into a shape suitable for the intended use. Since the liquid addition reaction curable silicone resin composition is solvent-free, the surface and the inside can be uniformly cured without foaming.

  The addition reaction curable silicone resin composition is not particularly limited as long as it forms a transparent silicone resin by heat curing. For example, an organopolysiloxane is used as a base polymer, and an organohydrogenpolysiloxane and a platinum-based catalyst are used. And those containing a heavy metal catalyst.

  Examples of the addition reaction type silicone resin composition include those represented by the following average unit formula (1).

R _a SiO _{(4-a) / 2} (1)
Wherein R is an unsubstituted or substituted monovalent hydrocarbon group, preferably having 1 to 10 carbon atoms, particularly 1 to 8. a is a positive number of 0.8 to 2, particularly 1 to 1.8. Number.)
Here, R is an alkyl group such as a methyl group, an ethyl group, a propyl group or a butyl group, an alkenyl group such as a vinyl group, an allyl group or a butenyl group, an aryl group such as a phenyl group or a tolyl group, or an aralkyl such as a benzyl group. A halogen-substituted hydrocarbon group such as a chloromethyl group, a chloropropyl group, or a 3,3,3-trifluoropropyl group in which some or all of the hydrogen atoms bonded to these carbon atoms are substituted with a halogen atom, Or a cyano group-substituted hydrocarbon group such as a 2-cyanoethyl group substituted with a cyano group, and R may be the same or different, but those containing a phenyl group as R, particularly all R Of these, those having 5 to 80 mol% of a phenyl group are preferred from the viewpoint of heat resistance and transparency of the optical lens.

  Further, those containing an alkenyl group such as a vinyl group as R, particularly those in which 1 to 20 mol% of all R are alkenyl groups are preferred, and those having two or more alkenyl groups in one molecule are preferably used. It is done. Examples of such an organopolysiloxane include terminal alkenyl group-containing diorganopolysiloxanes such as dimethylpolysiloxane having a terminal alkenyl group such as vinyl group and dimethylsiloxane / methylphenylsiloxane copolymer, particularly at room temperature. A liquid one is preferably used.

  On the other hand, the organohydrogenpolysiloxane is preferably trifunctional or higher (that is, one having three or more hydrogen atoms (Si—H groups) bonded to a silicon atom in one molecule), for example, methylhydrogenpolysiloxane, Examples thereof include methylphenyl hydrogen polysiloxane, and those that are liquid at room temperature are preferred. Examples of the catalyst include platinum, platinum compounds, organometallic compounds such as dibutyltin diacetate and dibutyltin dilaurate, and metal fatty acid salts such as tin octenoate. The types and amounts of these organohydrogenpolysiloxanes and catalysts may be appropriately determined in consideration of the degree of crosslinking and the curing rate. Moreover, you may add a filler, a heat-resistant agent, a plasticizer, etc. to such an extent that the intensity | strength and transparency of silicone resin obtained other than the said component are not impaired.

  As the silicone resin composition, commercially available products such as “KJR632” manufactured by Shin-Etsu Chemical Co., Ltd. can also be used.

  The optical lens portion 10 can be obtained by a known method by molding the silicone resin composition into a silicone resin molded product, and can be molded by, for example, injection molding, extrusion molding, cast molding, or the like. The optical lens unit 10 can be optically designed in accordance with uses such as side light emission, diffuse light emission, and light collection, and is formed into lenses having various shapes such as convex lenses, concave lenses, cylindrical lenses, and Fresnel lenses. be able to. The dimensions of the optical lens unit 10 can be appropriately designed according to the application, but at least a size that can be opposed to the entire light emitting surface of the LED is required, the thickness is about 1 mm to 5 mm, and the pitch of the lens unit. Is preferably about 5 mm to 50 mm. In addition, the hardness of a lens is Shore hardness measured by the method of JISK7215 (plastic durometer hardness test method), Preferably it is 20-90, More preferably, it is 50-80. When a rubber lens is used as the lens material, the hardness of the lens is preferably 30 to 90 in Shore A hardness.

  A phosphor layer, a color filter layer, or a light diffusion layer may be further provided in or on the surface of the optical lens unit 10. When the phosphor layer and the light diffusion layer are provided on the lens portion and / or the LED side, it is preferable to provide a fitting portion that matches the outer shape of the LED so as to cover the entire light emitting surface of the LED. By providing this fitting portion, it is possible to prevent displacement during mounting, and it can be used stably without displacement due to thermal deformation during use.

Examples of the phosphor used in the phosphor layer include inorganic phosphors, pigments, organic fluorescent dyes, pseudo pigments, and the like. For example, (Ca, Sr, Ba) ₅ (PO ₄ ) ₃ Cl having a blue emission color: Eu ²⁺ , ZnS: Ag, CaS: Bi, etc., green light emission BaMg ₂ Al ₁₆ O ₂₇ : Eu ²⁺ , Mn ²⁺ , ZnS: Cu, Al, Au, SrAl ₂ O ₄ : Eu ²⁺ , Zn ₂ Si ( Ge) O ₄ : Eu ^2+, etc. Y ₂ O ₂ S: Eu ³⁺ whose emission color is red, 3.5MgO · 0.5MgF ₂ · GeO ₂ : Mn, LiEuW ₂ O ₈ , BaO · Gd ₂ O ₃ · Ta ₂ O ₅ : Mn, K ₅ Eu _2.5 (WO ₄ ) _6.25, or the like can be used, and the color can be adjusted so as to obtain a color closer to the desired color. By providing the phosphor layer, for example, a sheet member with an optical lens having a function of converting the wavelength of light emitted from an LED can be produced.

  Examples of the light diffusing layer include those obtained by adjusting the light diffusivity in advance by adjusting the type and amount of inorganic white pigments such as glass powder, calcium carbonate, titanium oxide, and zinc oxide. By providing the light diffusion layer, for example, when the light source is an LED having three colors of red, green, and blue, a sheet member with an optical lens capable of mixing light can be produced.

  The material of the seat part 20 is (1) has a stiffness that does not impair the installation workability and installation stability, (2) has a small thermal expansion coefficient, and (3) has excellent heat resistance. However, if there are a light guide property, a light diffusion layer, a light reflection layer, etc. in addition to these, the use is further expanded.

  If the seat portion 20 does not have a stiffness that does not impair the installation workability and the installation stability, the handling becomes worse, and the pitch may be shifted due to a decrease in productivity or a looseness of the seat portion.

When the thermal expansion coefficient of the material of the sheet portion 20 is small, the shift of the pitch can be suppressed, and a lens-attached sheet member that is optically more stable than a single molded body made of a lens material is obtained. Moreover, it is preferable that the material of the sheet part 20 is excellent in heat resistance. If the heat resistance is insufficient, the sheet part 20 may be melted or deformed or discolored by high heat emitted from the LED. . Therefore, when a silicone resin (coefficient of thermal expansion: 200 × 10 ⁻⁶ / K) is used as the material of the optical lens unit 10, for example, a polyethylene terephthalate (PET) resin (coefficient of thermal expansion: 20 × 10 ⁻⁶ / K), polyphenylene sulfide (PPS) resin (25 × 10 ⁻⁶ / K), polycarbonate resin (65 × 10 ⁻⁶ / K), polyethylene naphthalate (PEN) resin, polyetherimide (PEI) ) Resins such as resin, polyamide resin, liquid crystal polymer (LCP); hard glass (8.5 × 10 ⁻⁶ / K), Pyrex (registered trademark) glass (8.5 × 10 ⁻⁶ / K), glass paper , glass such as glass nonwoven fabric; aluminum ^{(23 × 10 -6 / K)} , stainless steel (10.4 × ¹⁰ -6 / K), etc. Metals, preferably a silicone rubber. The sheet portion 20 made of these materials may be a composite material. Further, the sheet portion 20 may be a film, a plate-like material, a nonwoven fabric, or a net-like material. Of these, polyethylene terephthalate resin or glass nonwoven fabric is particularly preferable. Since the polyethylene terephthalate resin has a strength higher than that of the silicone resin, the sheet portion 20 can be made thinner than the optical lens portion 10, and a durable and economical sheet member with an optical lens can be produced. Among polyethylene terephthalate resins, a material called a so-called white film is particularly excellent in heat resistance and durability, and is suitable for the sheet portion 20 because it serves as a light reflecting layer.

  The glass nonwoven fabric is lightweight and excellent in heat resistance and dimensional stability because glass fibers are entangled and fixed in a sheet shape. Further, by using a glass nonwoven fabric having a high impregnation property, the optical lens portion 10 can be formed by impregnating a lens material such as a silicone resin at a predetermined position without providing a hole in the sheet portion 20. In addition, it is more preferable from the viewpoint of optical characteristics if the difference between the refractive index of the glass nonwoven fabric and the refractive index of the silicone lens is within a range of 0.03. Examples of the glass nonwoven fabric include Cumulus (registered trademark) “EPM-4025”, “EPM-4100B”, “GPM-8325”, “SGM-3025” (manufactured by Nippon Vilene Co., Ltd.), and glass par “GHN = 00- 025 (G) "(manufactured by Oji Specialty Paper Co., Ltd.) and the like.

  As will be described later, the sheet unit 20 uses a sheet having functions such as a light guide sheet, a light scattering sheet, a reflection sheet, a transparent sheet, a flame retardant sheet, and an aluminum vapor deposition sheet depending on the use of the sheet member with an optical lens. can do.

  In order to place the sheet member with an optical lens of the present invention on a substrate and install the optical lens portion at a position corresponding to each LED on the substrate by a single operation, as described above, the sheet member with an optical lens. It is preferable that the installation workability is good, and it is preferable that the seat portion has a certain degree of stiffness. For example, when a PET film is used for the sheet portion, the thickness is preferably 25 to 1000 μm, and more preferably 50 to 300 μm.

  When the thickness of the sheet portion is less than the above range, wrinkles are formed in the sheet portion, and therefore, it is difficult to make all the LEDs and the optical lens portion face each other in a single installation operation. On the other hand, if the thickness of the sheet part exceeds the above range, the sheet part becomes plate-like, so the sheet member with an optical lens and the substrate can be mechanically mounted by a robot with a sucker, etc., and there is no problem in installation workability. However, due to the reduced flexibility, for large signboards and liquid crystal display devices, the accumulated dimensional deviation at both ends of the sheet member with an optical lens increases due to the thermal expansion of the sheet part after mounting, and the appropriate optical path Tends to be difficult to obtain. Giving the sheet portion flexibility may be effective in that the deviation can be eliminated.

1.2 Second Embodiment A sheet member with an optical lens according to a second embodiment of the present invention is a sheet member for mounting on a substrate having a solar cell element portion, and the sheet member is a sheet. And an optical lens portion, and the optical lens portion is provided only in a portion facing the solar cell element portion when mounted on the substrate.

  The sheet member with an optical lens according to the second embodiment has the same configuration as the sheet member with an optical lens according to the first embodiment shown in FIG. 1, but differs in the following points.

  (1) The optical lens portion is intended to concentrate on the solar cell element portion. Therefore, the shape of the optical lens portion is preferably a convex lens or its Fresnel lens. Since the Fresnel lens has a shape obtained by dividing and joining the curved surfaces of the convex lens, the shape can be made smaller than that of the convex lens and is economical.

  (2) The above-described silicone resin is preferably used as the material of the optical lens portion, but other transparent materials having heat resistance against sunlight can also be used.

  (3) It is preferable that the material of a sheet | seat part is a glass plate, a transparent resin board, a glass cloth part, and a glass nonwoven fabric from a viewpoint which has translucency. When the sheet portion is a glass plate or a transparent resin plate, it can serve as a light guide plate for condensing sunlight irradiated to the elements other than the solar cell element portion.

1.3 Manufacturing method of sheet member with optical lens The manufacturing method of the sheet member with optical lens according to the present embodiment is an optical in which an optical lens portion is provided in the sheet portion so as to face a position of a light emitting diode arranged on a substrate. A method for producing a lens-attached sheet member, comprising: preparing a mold provided with a lens mold in accordance with the position of the light emitting diode; injecting a lens material into the lens mold of the mold; A step of setting the sheet portion on the mold so as to contact the lens material; and a step of curing the lens material to integrate the optical lens portion and the sheet portion. Hereinafter, each step will be described in detail.

  First, a sheet part is prepared. As the sheet portion, a sheet that has been cut to a size to be used in advance may be used, or a continuous sheet that can be wound into a roll may be used.

  Next, in the prepared sheet portion, a hole having a predetermined shape is formed at a predetermined position in order to mold the lens portion at a position facing the LEDs arranged on the substrate. In order to form a predetermined hole in the sheet portion, a known method such as punching can be applied. When a continuous sheet that can be wound into a roll is used, holes can be continuously formed by using a rotary punching machine, so that the production efficiency is improved. Further, the lens mold may be embossed at a position where the lens of the sheet portion is provided, instead of forming a hole having a predetermined shape at the position where the lens portion is molded.

  Next, a lens mold having a lens pattern in which the shape of the lens portion is engraved in accordance with the position of the LED is prepared. The lens mold is a mold made of metal such as aluminum, brass or alloy; a mold made of synthetic resin such as silicone resin, polyurethane resin, epoxy resin, ABS resin, fluororesin or polymethylpentene resin; An electroforming mold or the like can be used. Such a lens mold is preferably plated with copper, nickel or the like on its surface in order to prevent corrosion. Furthermore, a plating pattern such as copper or nickel can be formed thick to form a lens pattern on the plated layer portion.

  Next, the sheet part is set in the lens mold so that the lens pattern of the lens mold and the hole of the sheet part coincide. Thereafter, a lens material such as silicone resin is injected into the lens mold and cured under predetermined conditions. At this time, the lens portion can be molded with high accuracy and continuously by providing a feed hole in the sheet portion and setting the feed hole in the mold while aiming at the feed hole. Moreover, the same high precision can be obtained by providing the contact part of a sheet | seat sheet in a metal mold | die. Through the above process, the sheet part and the optical lens part can be integrally formed. In order to increase the adhesive strength between the sheet part and the optical lens part, the sheet part is preliminarily treated with primer, corona treatment, plasma treatment, and frame treatment. Moreover, well-known adhesion techniques, such as an intro process and UV process, can also be used. Moreover, the adhesiveness with a sheet | seat part can also be improved by adding an adhesive component to an optical lens part. When the lens mold is embossed on the sheet portion, the lens material may be injected into the recess and cured.

  Further, in the process of handling the sheet member with an optical lens, the sheet part and the optical lens part may be peeled off due to tension or refraction, or the lens part may fall off from the sheet part. Therefore, in order to firmly fix the optical lens portion and the sheet portion, the following means can be adopted. FIG. 2 is a perspective view of a sheet member with an optical lens incorporating means for firmly fixing the optical lens portion and the sheet portion. FIG. 3 is a view showing a cross section taken along the line AA of FIG. As shown in FIG. 2, not only the hole in which the lens is molded in the sheet portion 21 but also a small hole 21 a (diameter 2 mm or less, preferably 1 mm or less) into which the same resin as the lens enters as an anchor at the periphery of the hole. ) Should be provided. As shown in FIG. 3, the optical lens unit 11 includes a lens fixing unit 11 a formed in a U shape so as to sandwich the sheet unit 21, and a fitting unit 11 b for fitting the LED. . The lens fixing portion 11a extends to a length that can cover at least the hole 21a. With this configuration, the same resin as the lens enters the hole 21a and is integrally molded, so that the optical lens portion 11 and the sheet portion 21 can be firmly fixed.

  Through the above steps, a sheet member with an optical lens in which an optical lens portion is disposed only at a portion facing the LED when mounted on a substrate including the LED can be manufactured.

  In addition, as described above, when a highly impregnated glass nonwoven fabric is used as the sheet portion, a sheet member with an optical lens is formed by molding while impregnating a lens material in a predetermined portion without providing a hole. can do.

2. 2. Light Emitting Device 2.1 Third Embodiment A light emitting device according to the present invention is characterized in that the sheet member with an optical lens is mounted on a substrate provided with a light emitting diode. FIG. 4 is a cross-sectional view schematically showing the light emitting device according to the third embodiment.

  As shown in FIG. 4, the light emitting device 200 includes a substrate 40 on which the LEDs 30 are provided, and a sheet member 110 with an optical lens having the optical lens portion 12 and the sheet portion 22. The light emitting device 200 is formed by combining the substrate 40 and the sheet member 110 with an optical lens, and the optical lens unit 12 and the LED 30 are fitted. Thereby, the sheet member 110 with an optical lens can be accurately positioned and mounted on the substrate 40. In addition, you may fix the sheet | seat member 110 with an optical lens, and the board | substrate 40 by attaching an adhesive agent to at least one of the optical lens part 12 and LED30, and making it adhere | attach.

  As the sheet member 110 with an optical lens, the sheet member with an optical lens according to the first embodiment described above can be used. A reflective layer (not shown) may be further formed on the surface of the sheet portion 22 that contacts the substrate 40. By forming the reflective layer, the light emitted from the LED 30 is refracted by the optical lens portion 12 and partially diffused into the sheet portion 22 and further reflected by the reflective layer, and thus the light emitting device 200 having higher luminance. Can be manufactured.

  The substrate 40 is mainly an electronic circuit printed circuit board, and a rigid plate-shaped rigid substrate, a flexible substrate that can be bent, or the like can be used depending on the application. As the substrate 40, a substrate using various materials for a base material or a resin, a multilayer substrate for increasing the mounting density, or the like can be used. The LED 30 is fixed to the substrate 40 and can be fixed to the electronic circuit using a known bonding method such as a reflow soldering method using lead-free solder.

  The LED 30 may be any known LED, for example, Ga: ZnO red LED, GaP: N green LED, GaAsP red LED, GaAsP orange / yellow LED, GaAlAs LED, InGaAlP orange / yellow LED, Examples include GaN-based blue LEDs, SiC blue LEDs, II-VI group blue LEDs, and white LEDs in which a phosphor layer is provided on a blue LED chip. The LED may be in any form, and for example, an LED lamp, a chip type LED, a segment type LED, or the like can be used.

  The light emitting device 200 according to the third embodiment can be used for applications such as a backlight of a liquid crystal display device or a signboard, for example.

2.2 Fourth Embodiment FIG. 5 is a cross-sectional view schematically showing a light emitting device according to a fourth embodiment.

  As shown in FIG. 5, the light emitting device 300 includes an optical lens in which the sheet portion 24 is formed on the substrate 42 on which the LEDs 32 are provided and the reflective layer 50, and the optical lens portion 14 is formed at a position facing the LEDs 32. The attached sheet member 120 and the diffusion plate 60 are stacked in this order. The light emitting device 300 is formed by combining the substrate 42 and the sheet member 120 with an optical lens as in the third embodiment, and the optical lens unit 14 and the LED 32 are fitted. Thereby, the sheet member 120 with an optical lens can be accurately positioned and mounted on the substrate 42. Although not shown, a phosphor layer may be provided between the LED 32 and the optical lens unit 14. After the sheet member 120 with the optical lens is mounted on the substrate, an optical lens is attached by adhering at least one of the optical lens unit 14 and the LED 32 so that the positions of the optical lens unit 14 and the LED 32 do not deviate. The attached sheet member 120 and the substrate 42 may be fixed. Further, the sheet portion 24 between the optical lens portions 14 and the vacant surface of the substrate 42 may be fixed with an adhesive, scissors or the like. Furthermore, as shown in FIG. 6, the sheet portion 24 is provided with a substrate fixing portion 24a such as a convex portion, a concave portion or a hole by pressing, punching, etc., and the substrate 42 has a hole, a concave portion, It can also be fixed by providing convex portions and fitting them.

  The same substrate 42 as in the third embodiment can be used.

  The shape of the optical lens unit 14 is preferably a light diffusion type lens, and is not particularly limited as long as it can guide light to the diffusion plate. When the optical lens unit 14 is a light diffusion type lens, the light emitted from the LED 32 is diffused in the direction of the diffusion plate 60, and a part thereof is diffused toward the sheet unit.

  Since the sheet member 120 with an optical lens is provided with the reflection layer 50, the diffused light can be reflected in the direction of the diffusion plate 60. The sheet | seat part 24 is comprised from the material which has translucency and heat resistance, For example, the polyethylene terephthalate resin mentioned above, a glass nonwoven fabric, etc. can be used. The thickness of the laminate of the sheet portion 24 and the reflective layer 50 and the height of the optical lens portion 14 are the same, and can be about 2 mm. Although not shown, an insulating layer can be formed below the reflective layer 50 as necessary.

  The diffuser plate 60 is made of a glass-like diffusive diffuser plate, which has been smoothed by corroding the surface with hydrogen fluoride after one side of the glass has been ground, a frost-type diffuser plate in which one side of the glass has been processed into a frosted glass, A known diffusion plate such as an opal type diffusion plate to which a film is added, a polycarbonate sheet filled with a light scattering agent, or white PET can be used. By imparting roughness to one side of the glass, the diffusivity can be further increased.

  The light-emitting device 300 having the above configuration is a light-emitting device having high brightness in which the entire surface of the diffusion plate 60 is uniformly surface-emitting. The light emitting device 300 according to the fourth embodiment can be used for applications such as a backlight for a liquid crystal display panel and a backlight for a signboard.

3. Backlight and Signboard FIG. 7 is a cross-sectional view schematically showing a signboard according to the fifth embodiment. As shown in FIG. 7, the signboard 400 incorporates a light emitting device 200 including a substrate 40 provided with LEDs 30 and an optical lens-attached sheet member 110 having the optical lens portion 12 and the sheet portion 22. Although not shown, a phosphor layer or a color filter layer may be provided between the LED 30 and the optical lens unit 12. Further, a diffusion plate 62 is formed above the light emitting device 200. The diffusion plate 62 is a member for further diffusing the light emitted from the LED 30 through the optical lens unit 12 as described above. Further, an information board 70 on which information such as characters, designs, and photographs is printed is formed on the diffusion plate 62. The information board 70 is preferably made of an acrylic board, a backlight film, printed paper, or the like, from the viewpoint of light transmittance.

  A reflective layer (not shown) may be further formed on the surface of the sheet portion 22 that contacts the substrate 40. By forming the reflective layer, the light emitted from the LED 30 is refracted by the optical lens unit 12 and further reflected by the reflective layer, so that the sign 400 having higher brightness can be manufactured. In such a case, the sheet portion 22 may have a light guide function.

4). Solar cells There are two types of solar cells: a flat plate type that is used as it is when sunlight falls on it, and a concentrating type that makes sunlight enter a solar cell element after increasing the density by using an optical system or the like. . The solar cell according to the present invention includes the above-described sheet member with an optical lens, and corresponds to a concentrating solar cell. FIG. 8 is a cross-sectional view schematically showing an example of the solar cell according to the sixth embodiment.

  As shown in FIG. 8, the solar cell 500 includes an optical lens unit 16 at a position facing the substrate 44 on which the solar cell element unit 34 is provided and the solar cell element unit 34 of the light guide plate 80 that is a sheet unit. A lens-attached sheet member 130.

  As the sheet member 130 with an optical lens, the sheet member with an optical lens according to the second embodiment described above can be used. The optical lens portion 16 is disposed at a position facing the solar cell element portion 34, and the light collected by the optical lens portion 16 is efficiently absorbed by the facing solar cell element portion 34. Thereby, electric power can be generated efficiently even in a situation where the amount of sunlight is small. When the sheet member 130 with an optical lens has a large area, the sheet member 130 with an optical lens can be supported by providing the support net 90. It is preferable to provide a roughening treatment of 1 μm or less or an antireflection layer on the surface of the light guide plate 80 that is also the sheet portion on the side irradiated with sunlight.

  The solar cell element 34 has a pn junction structure in which a p-type semiconductor plate and an n-type semiconductor plate (not shown) are combined. Electrodes (not shown) are provided on both surfaces of the pn junction structure.

For the solar cell element portion 34, for example, a semiconductor such as a group IV semiconductor, a compound semiconductor, or an organic semiconductor can be used. Examples of the group IV semiconductor include crystalline semiconductors such as single crystal silicon, single crystal germanium, polycrystalline silicon, and microcrystalline silicon; and amorphous semiconductors such as amorphous silicon. Examples of the compound semiconductor include III-V group GaAs, InP, AlGaAs; II-VI group CdS, CdTe, Cu ₂ S; I-III-VI group CuInSe ₂ , CuInS _{2, and the} like. Examples of the organic semiconductor include phthalocyanine and polyacetylene.

4). Examples Hereinafter, the present invention will be specifically described by way of examples. However, the present invention is not limited to the following examples.

4.1 Example 1
As the sheet member, “Lumirror (registered trademark) E60V” (manufactured by Toray Industries, Inc.), which is a discoloration-resistant, high-light reflection white PET sheet having a thickness of 194 μm, was used. As the optical lens member, “SR7010A / B” (manufactured by Toray Dow Corning Silicone Co., Ltd.), which is a silicone resin, was used.

  The PET sheet was subjected to corona discharge treatment, and holes with a diameter of 8 mm were formed in accordance with the arrangement pitch of 25 mm of the LEDs arranged on the liquid crystal backlight substrate. At the same time, six holes with a diameter of 1 mm were made in the periphery. Next, this PET sheet was set in a mold for molding the optical lens portion. At this time, the sheet portion was set so that the hole portion of the sheet portion coincided with the lens portion of the mold. Next, a silicone resin was injected into the mold and cured under the conditions of 120 ° C. for 20 minutes, thereby producing a PET sheet in which the silicone resin optical lens portion was firmly fixed.

  Since the sheet member with an optical lens according to Example 1 uses a high light reflection white PET sheet as the sheet member, the sheet member with an optical lens was excellent in the light reflection function. In addition, since the sheet member has a sufficient thickness, it is excellent in installation workability. By providing a 1 mm hole for receiving silicone resin as an anchor, the optical lens part and the sheet part are firmly fixed. I was able to.

4.2 Example 2
As a sheet member, “Lumirror (registered trademark) U426” (manufactured by Toray Industries, Inc.), which is a highly transparent PET sheet having a thickness of 100 μm, was used. As the optical lens member, “SR7010A / B” (manufactured by Toray Dow Corning Silicone Co., Ltd.), which is a silicone resin, was used.

  The PET sheet used was subjected to a coupling treatment. Next, a silicone resin was injected into a mold for molding the optical lens portion, and this PET sheet was set in accordance with the arrangement pitch of the LEDs arranged on the liquid crystal backlight substrate. Next, a PET sheet having an optical lens portion made of silicone resin was produced by curing under conditions of 120 ° C. and 20 minutes.

  Since the sheet member with an optical lens according to Example 2 uses a highly transparent PET sheet as the sheet member, the sheet member was excellent in light transmittance.

4.3 Example 3
As a sheet member, “Lumirror (registered trademark) ZV10” (manufactured by Toray Industries, Inc., thermal expansion coefficient: 2 × 10 ⁻⁵ / K), which is a flame-retardant PET sheet, was used. Two types of PET sheets having a thickness of 40 μm and 90 μm were prepared, and a sheet member with an optical lens was prepared from each PET sheet. As the optical lens member, “SR7010A / B” (manufactured by Toray Dow Corning Silicone Co., Ltd.), which is a silicone resin, was used.

  The PET sheet was subjected to corona discharge treatment, and holes with a diameter of 8 mm were formed in accordance with the arrangement pitch of 25 mm of the LEDs arranged on the liquid crystal backlight substrate. Next, this PET sheet was set in a mold for molding the optical lens portion. At this time, the sheet portion was set so that the hole portion of the sheet portion coincided with the lens portion of the mold. Next, a PET sheet having an optical lens portion made of silicone resin was prepared by injecting a silicone resin into a mold and curing the resin under conditions of 120 ° C. for 20 minutes.

  Since the sheet member with an optical lens according to Example 3 uses a flame-retardant PET sheet as the sheet member, safety against high heat could be secured. On the other hand, the PET sheet having a thickness of 40 μm is slightly lacking in stiffness, and the installation workability is slightly impaired as compared with the PET sheet having a thickness of 90 μm. Moreover, since the sheet member with an optical lens according to Example 3 is not provided with an anchor as in Example 1, the fixing stability between the sheet part and the optical lens part is higher than that of the sheet member with optical lens according to Example 1. Slightly inferior.

4.4 Example 4
As the sheet member, “Torerina (registered trademark)” (manufactured by Toray Industries, Inc.), which is a flame-retardant PPS sheet, was used. As the optical lens member, “SR7010A / B” (manufactured by Toray Dow Corning Silicone Co., Ltd.), which is a silicone resin, was used.

  The PPS sheet was subjected to a coupling process, and holes with a diameter of 8 mm were formed in accordance with the arrangement pitch of 25 mm of the LEDs arranged on the liquid crystal backlight substrate. Next, this PPS sheet was set in a mold for molding the optical lens portion. At this time, the sheet portion was set so that the hole portion of the sheet portion coincided with the lens portion of the mold. Next, a PPS sheet having an optical lens portion made of a silicone resin was produced by injecting a silicone resin into the mold and curing it under the conditions of 120 ° C. and 20 minutes.

4.5 Example 5
As the sheet member, “Cumulus (registered trademark) EPM-4025” (manufactured by Japan Vilene Co., Ltd.), which is a glass nonwoven fabric, was used. As the optical lens member, “SR7010A / B” (manufactured by Toray Dow Corning Silicone Co., Ltd.), which is a silicone resin, was used.

  The glass nonwoven fabric was directly impregnated with a silicone resin in accordance with the position facing the LEDs arranged on the liquid crystal backlight substrate. Next, this glass nonwoven fabric was allowed to stand at 120 ° C. for 20 minutes to cure the silicone resin, thereby producing a glass nonwoven fabric having a lens portion made of silicone resin.

4.6 Example 6
FIG. 9 is a cross-sectional view schematically illustrating the sheet member 140 with an optical lens according to the sixth embodiment. As the sheet part 142, “Lumirror (registered trademark) U426” (manufactured by Toray Industries, Inc.), which is a highly transparent PET sheet, was used. First, a lens-shaped concave portion was formed in a portion to be a lens portion by vacuum forming on a highly transparent PET sheet. Next, a silicone gel “SE1891H” (manufactured by Toray Dow Corning Silicone Co., Ltd.) is quantitatively potted in the recesses and cured at room temperature, so that the outer side as shown in FIG. 9 is filled with the PET layer and the inner side with the silicone gel. The optical lens-equipped sheet member 140 having the optical lens portion 144 was continuously molded. Even without a primer or surface treatment, it was possible to adhere well to the highly transparent PET sheet due to the adhesiveness of the silicone gel.

  FIG. 10 is a cross-sectional view schematically showing a light emitting device 150 in which a sheet member 140 with an optical lens is mounted on a circuit board provided with LEDs 146. As shown in FIG. 10, since the optical lens portion 144 filled with the silicone gel is in close contact with the LED 146, the light reflection loss due to the air interface can be reduced.

4.7 Example 7
As the sheet member, “Glasspar (registered trademark) GHN = 00-025 (G)” (manufactured by Oji Specialty Paper Co., Ltd.), which is glass paper, was used. First, a hole having a diameter of 5 mm was punched in a portion where a lens portion corresponding to the position of an LED installed on a circuit board of glass paper was formed. Subsequently, the glass paper was set to the metal mold | die which shape | molds an optical lens part so that a sheet | seat hole part and an optical lens part may correspond. An optical lens in which “LPS-5510” (manufactured by Shin-Etsu Chemical Co., Ltd.) is filled in a mold as an optical lens member, heated and cured at 170 ° C. for 20 minutes, a sheet portion is glass paper, and an optical lens portion is a silicone resin. An attached sheet member was produced.

  At this time, the silicone resin penetrated into the gaps in the glass paper, so that anchoring was possible and the adhesive was firmly fixed. Integral molding was possible without primer or plasma treatment.

4.8 Example 8
FIG. 11 is a cross-sectional view schematically illustrating the sheet member 160 with an optical lens according to the eighth embodiment. As the sheet part 162, “Teonex (registered trademark)” (manufactured by Teijin DuPont Films Ltd.), which is a PEN film, was used. First, after corona treatment was performed on the PEN film, a hole having a diameter of 5 mm was formed by punching in a portion where the lens portion was molded. Next, using a silicone adhesive “SE9185” (manufactured by Toray Dow Corning Silicone), a silicone lens 164 including a phosphor layer 166 formed by color matching in advance is bonded to the opposite side of the surface facing the LED. Thus, a sheet member 160 with an optical lens having a wavelength conversion function was produced. The adhesive was applied to the flange portion 164a on the outer periphery of the lens and adhered to the PEN film. The phosphor layer 166 is provided with a fitting portion 168 that matches the outer shape of the LED so as to cover the entire light emitting surface of the LED, and the fitting portion 168 and the LED are fitted.

4.9 Example 9
FIG. 12 is a cross-sectional view schematically illustrating the sheet member 170 with an optical lens according to the ninth embodiment. As the sheet member 172, a polyetherimide (PEI) film was used. First, after corona treatment was performed on the PEI film, a hole having a diameter of 5 mm was formed by punching in a portion where the optical lens portion was molded. Next, using a silicone adhesive “SE9185” (manufactured by Toray Dow Corning Silicone Co., Ltd.), a silicone lens 174 including a light diffusion layer 176 made of calcium carbonate that has been molded in accordance with the degree of diffusion in advance is adhered. A sheet member 170 with an optical lens capable of mixing light in the case of an LED having three colors of green and blue was produced. The adhesive was applied to the flange portion 174a on the outer periphery of the lens and adhered to the PEI film. The light diffusion layer 176 is provided with a fitting portion 178 that matches the outer shape of the LED so as to cover the entire light emitting surface of the LED, and the fitting portion 178 and the LED are fitted.

4.10 Example 10
The LED mounted on a flexible circuit board (FPC) made of a polyamide film “Kapton (registered trademark)” (manufactured by Toray DuPont Co., Ltd.) was provided with a side-emitting lens that was optically designed in accordance with a pre-formed application. A flexible light-emitting device was obtained by incorporating the sheet member with an optical lens according to Example 8.

4.11 Comparative Example 1
Using “SR7010A / B” (made by Toray Dow Corning Silicone), which is a silicone resin, a sheet member with an optical lens in which a sheet portion and an optical lens portion are integrally formed was produced.

  Since the sheet member with an optical lens according to Comparative Example 1 is integrally formed, it is likely to be distorted by heat generated from the LED, and particularly when used for a large-screen liquid crystal display panel, the optical axis is shifted due to thermal expansion. There has occurred.

4.12 Comparative Example 2
A side-emitting lens that has been optically designed for an LED mounted on a flexible circuit board (FPC) made of polyamide film “Kapton” (manufactured by Toray DuPont Co., Ltd.) is used as a silicone adhesive “SE9185”. (Toray Dow Corning Silicone Co., Ltd.).

  In Comparative Example 2, the side-emitting lenses must be bonded to the LEDs of the flexible circuit board one by one, and the work is not efficient.

4.13 Stability at the time of use The sheet member with an optical lens according to Examples 1 to 10 and Comparative Example 1 was mounted on a substrate equipped with LEDs and used continuously for 200 days. About each sheet member with an optical lens, the presence or absence of the position shift by the thermal deformation after continuous use for 200 days was evaluated. The evaluation results are summarized in Table 1. In Table 1, the evaluation criteria were as follows.
(Double-circle): Even if it used continuously for 200 days, the position shift by a thermal deformation was not recognized at all.
○: A slight misalignment due to thermal deformation is observed after 200 days of continuous use, but it is within the range where there is no problem on the product.
X: When used continuously for 200 days, a position shift due to thermal deformation is recognized, and there is a problem in product.

It is a top view showing typically an example of a sheet member with an optical lens concerning a 1st embodiment. It is a perspective view of a sheet member with an optical lens incorporating means for firmly fixing the optical lens part and the sheet part. It is a figure which shows the AA cross section of FIG. It is sectional drawing which shows typically the light-emitting device which concerns on 3rd Embodiment. It is sectional drawing which shows typically the light-emitting device which concerns on 4th Embodiment. It is a figure for demonstrating the board | substrate fixing means of the light-emitting device which concerns on 4th Embodiment. It is sectional drawing which shows typically an example of the signboard which concerns on 5th Embodiment. It is sectional drawing which shows typically an example of the solar cell which concerns on 6th Embodiment. 10 is a cross-sectional view schematically showing a sheet member with optical lens 140 according to Example 6. FIG. It is sectional drawing which shows typically the light-emitting device 150 which attached the sheet | seat member 140 with an optical lens to the circuit board provided with LED. 10 is a cross-sectional view schematically showing a sheet member 160 with an optical lens according to Example 8. FIG. 10 is a cross-sectional view schematically showing a sheet member with an optical lens 170 according to Example 9. FIG.

Explanation of symbols

10, 11, 12, 14, 16 ... optical lens part, 11a ... lens fixing part, 11b ... fitting part, 20, 21, 22, 24, 142, 162, 172 ... sheet part, 21a ... hole, 24a ... substrate Fixed part, 30, 32, 146 ... Light emitting diode (LED), 34 ... Solar cell element part, 40, 42, 44 ... Substrate, 50 ... Reflective layer, 60, 62 ... Diffuser plate, 70 ... Information plate, 80 ... Lead Optical plate, 90 ... support net, 100, 102, 110, 120, 130, 140, 160, 170, 180 ... sheet member with optical lens, 144 ... silicone gel, 164, 174 ... silicone lens, 164a, 174a ... flange part, 166 ... phosphor layer, 168,178 ... LED fitting portion, 176 ... light diffusion layer, 150,200,300 ... light emitting device, 400 ... signboard, 500 ... solar cell

Claims (10)

A sheet member with an optical lens for mounting on a substrate having a light emitting diode or a solar cell element part,
The sheet member with an optical lens,
A plurality of optical lens portions made of silicone resin;
And having a stiffness and flexibility made of a resin or glass having a smaller coefficient of thermal expansion than the silicone resin, and
When mounted on the substrate, the optical lens portion is disposed only in a portion facing the light emitting diode or the solar cell element portion,
The optical lens part and the light emitting diode or the solar cell element part are fitted, or by attaching an adhesive to at least one of the optical lens part and the light emitting diode or the solar cell element part, A sheet member with an optical lens, which is fixed to a substrate. In claim 1,
The sheet member with an optical lens, wherein the sheet portion is a resin film made of polyethylene terephthalate resin, polyphenylene sulfide resin, polycarbonate resin, polyethylene naphthalate resin, polyetherimide resin, polyamide resin, or liquid crystal polymer. In claim 1,
The said sheet | seat part is a sheet | seat member with an optical lens which is a glass sheet, glass paper, or a glass nonwoven fabric with a smaller thermal expansion coefficient than the said silicone resin. Oite to claim 2,
A sheet member with an optical lens, wherein the sheet portion is a polyethylene terephthalate resin having a thickness of 25 to 1000 µm. A light emitting device in which the sheet member with an optical lens according to any one of claims 1 to 4 is mounted on a substrate having a light emitting diode,
The optical lens portion of the sheet member with the optical lens and the light emitting diode of the substrate are fitted, or an adhesive is attached to at least one of the optical lens portion of the sheet member with the optical lens and the light emitting diode of the substrate. A light emitting device, wherein the light emitting device is fixed to the substrate by bonding. In claim 5,
The light emitting device, wherein the substrate is an electronic circuit printed circuit board. In claim 5 or claim 6,
Furthermore, the said sheet member with an optical lens is a light-emitting device containing a reflection layer in the side by which the board | substrate provided with the said light emitting diode was mounted | worn. In any one of Claims 5 thru | or 7,
Furthermore, the light-emitting device by which the diffusion plate was formed in the opposite side to the side with which the board | substrate provided with the said light emitting diode of the said sheet member with an optical lens was mounted | worn.   A liquid crystal display device comprising the light emitting device according to any one of claims 5 to 8.   A signboard comprising the light emitting device according to any one of claims 5 to 8.

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