JP7017235B2 - Manufacturing method of light emitting device and light emitting member - Google Patents

Description

The present invention relates to a light emitting device and a method for manufacturing a light emitting member that display a pattern, characters, or the like by using a light emitting element as a light source.

Conventionally, a high-luminance LED has been used as a light-emitting element as a high-luminance light source with low power consumption, and a light-emitting device or a lighting device using the high-luminance LED has been proposed. Light emitting devices using high-brightness LEDs include lighting devices used for lighting inspection devices and lighting devices used for ceilings and walls of buildings, as well as light emitting devices used as decorations as part of car interiors. It has been proposed.
As a light emitting device, a half mirror has been conventionally proposed, and a light emitting device has been proposed in which a drawn pattern, characters, etc. are multiplely projected and used as a decoration.

For example, in Patent Document 1, a light source member, a mirror surface member arranged on the back surface side, and a part of the traveling light transmitted on the front side and emitted from the upper surface side, and other light is emitted. A half mirror that reflects in the rear direction, a tubular outer frame that supports the mirror surface member on the back side and the half mirror on the front side, and forms a space between the mirror surface member and the half mirror. It has a recess formed between the mirror surface member and the half mirror along the inner circumference of the outer peripheral frame and formed at least a part on the outer peripheral surface side, and a first reflection member arranged in the recess. Examples thereof include an invention including a light guide member.

Japanese Unexamined Patent Publication No. 2015-18014

However, the conventional light emitting device is provided with a light emitting portion on the side surface, the inner side surface thereof is illuminated by a light emitting element, and the light emitting side surface is reflected multiple times to be illuminated as a pattern. In addition, a space is provided between the surface on which the half mirror is mounted and the mirror to display information above the mirror. Therefore, there is a concern that the space will be thicker and the device will be larger.
For example, as shown in FIG. 10, a light emitting device using a mirror 324 and a half mirror 321 sandwiches a light guide plate 322 in between, and when transfer or engraving 326 is performed in advance on the mirror 324 side, it is processed into a full mirror in advance. There was a problem that it was necessary, the processing man-hours were large, and the cost was high. Further, as shown in FIG. 10, by scraping the vapor-filmed layer 324 (FIG. 10 (position of 323)) to form the pattern 328, there is a problem that light escapes from the scraped portion 323 and the loss of light increases. At the same time, even when the light emitting element is not lit, there is a problem that the light from the outside light is reflected, the pattern 328 is reflected thinly, and the impression at the time of lighting is blurred.

The present invention is to provide a method for manufacturing a light emitting device and a light emitting member, which can give an impression when the light emitting element emits light by reducing the thickness of the light emitting device and reducing the number of man-hours as much as possible.

The substrate portion that emits light from the light emitting element mounted by the supplied power, the first reflective layer that transmits display information from the outside and can reflect the light reflected by the display information, and the light from the light emitting element. A second reflective layer that is provided with the display information to be received and displayed and that is in close contact with a shielding layer that blocks the transmission of light and can reflect light, and guides the light of the light emitting element to the first reflective layer and the said. It is characterized by being provided with a light guide member that is in close contact with the second reflective layer.

Based on the above features, in the present invention, the shielding layer prevents the light from being transmitted through the second reflective layer, so that the light and darkness of the light emitting element at the time of light emission can be clearly highlighted, and the impression at the time of light emission is strong. Has the effect of

It is a perspective view which attached the light emitting device of embodiment to an automobile. It is a perspective view of the whole of the light emitting device of an embodiment. It is a perspective view which showed by disassembling the light emitting device of embodiment. It is a top view which showed the light emitting part of the light emitting device of embodiment. It is a perspective view which showed the component which disassembled the light emitting part of the light emitting device of embodiment. FIG. 5 is an enlarged cross-sectional view showing a cross-sectional view taken along the line AA of FIG. 4 showing a light emitting portion of the embodiment. It is explanatory drawing which shows the state that the light emitting device of an embodiment emits light. It is a schematic diagram which shows the state of manufacturing the light emitting part of an embodiment. It is a schematic diagram which shows the other embodiment by a sectional view. It is explanatory drawing which shows by the sectional view of the conventional light emitting part.

The light emitting device and the manufacturing method thereof according to the present invention will be described in detail with reference to the drawings. It should be noted that the embodiments and drawings described below exemplify a part of the embodiments of the present invention, are not used for the purpose of limiting to these configurations, and do not deviate from the gist of the present invention. Can be changed as appropriate in.

(Example 1)
A state when the light emitting device 10 is attached to the automobile C will be described with reference to FIG. 1. FIG. 1 is a perspective view in which the light emitting device 10 of the embodiment is mounted on the automobile C. As shown in FIG. 1, a light emitting device 10 used in the interior of an automobile C is shown. In particular, this embodiment shows that the light emitting device 10 is arranged on the door side surface 3 which is the side surface of the door 2 of the automobile C, and the light emitting device 10 emits light. The light emitting device 10 can emit light of different patterns M1, M2, and M3 by causing the light emitting element 31 (FIG. 3) provided inside thereof to emit light.
The patterns M1, M2, and M3 are not limited to figures, but may be logo marks, characters, symbols, or the like, and may be displayed in combination. Further, the light emitting device 10 can be used as a light emitting display for decoration near the emblem of the automobile C or the step.

Next, the structure of the light emitting device 10 will be described with reference to FIGS. 2 and 3. FIG. 2 is an overall perspective view of the light emitting device 10 of the embodiment. FIG. 3 is a perspective view showing the light emitting device 10 of the embodiment in an exploded manner.
As shown in FIGS. 2 and 3, in the light emitting device 10, the light emitting portion 20 is fixed by the upper housing 11 and the lower housing 13. The light emitting device 10 has a substrate unit 30 having a substrate 32 on which a light emitting element 31 that incidents light from the side surface of the light emitting unit 20 is mounted on one side thereof. Although the light emitting element 31 uses an LED element, it may be an organic EL, a cold cathode tube, or the like capable of incident light from the side surface of the light emitting unit 20. Further, the light emitting element 31 may be a light emitting element capable of producing not only a single color but also a full color or the like. Although the substrate portion 30 is mounted on only one side, it may be provided on the other side surface as appropriate according to the length of the light emitting portion 20 and the amount of light of the light emitting element 31.

Further, the upper housing 11 that covers the light emitting portion 20 is provided with a notch portion 12 cut out in a square shape so that the patterns M1, M2, and M3 of the light emitting portion 20 can be visually recognized. Further, the lower housing 13 has a plate shape larger than the light emitting unit 20 so as to support the light emitting unit 20. The upper housing 11 and the lower housing 13 may be formed of a material such as resin or metal and may have rigidity capable of supporting the light emitting portion 20 and the substrate portion 30.
As shown in FIG. 2, the patterns M1, M2, and M3 printed on the light emitting unit 20 described later are reflected multiple times by the half mirror layer 21 (FIG. 5) and the half mirror layer 23 (FIG. 5), and the patterns M1, M2 are reflected. , M1a, M1b, M1c, M1d, M1e, M2a, M2b, M2c, M2d, M2e, M3a, M3b, M3c, M3d and M3e are projected as the respective virtual images of M3.

Next, the light emitting unit 20 will be described in detail with reference to FIGS. 4 to 6. FIG. 4 is a plan view showing the light emitting unit 20 of the light emitting device 10 of the embodiment. FIG. 5 is a perspective view showing each component obtained by disassembling the light emitting unit 20 of the light emitting device 10 of the embodiment. FIG. 6 is an enlarged cross-sectional view showing a cross-sectional view taken along the line AA of FIG. 4 showing the light emitting unit 20 of the embodiment.
The light emitting unit 20 is integrally formed by a manufacturing method described later, but FIG. 5 shows each component in an exploded manner. The light emitting unit 20 includes half mirror layers 21 and 23 formed in a half mirror shape and a film shape by depositing a reflective member forming a mirror surface on the uppermost portion and the intermediate portion.

Further, patterns M1, M2, and M3 produced by inkjet printing or silk printing are printed on the lower half mirror layer 23. The patterns M1, M2, and M3 can be printed in white or according to each color preference, and if they are printed with an ink containing a fluorescent paint, a reflective material, or the like, the light emitting element 31 emits light to further improve the color development, which is even better. Further, the shielding layer 24 facing the half mirror layer 23 is a layer in close contact with the half mirror layer 23 by a black film or black printing. The shielding layer 24 has a function of preventing light transmitted through the half mirror layer 23 from escaping, and when microraise is included in the integrally molded resin, even if it is reflected whitish, the patterns MH1, M2, and M3 are more than black. It has a function that allows shadows to be clearly projected.
As described above, the cost of the half mirror layers 21 and 23 can be reduced by using the same product.
The half mirror layer 23 may be formed into a film-like or plate-like layer on which a reflective member such as silver or tin forming a mirror surface is vapor-deposited to form a full mirror.

Further, the light guide member 22 is made of a transparent resin through which the light of the light emitting element 31 can pass through, and is, for example, a methacrylic resin such as methyl methacrylate or ethyl methacrylate, or an acrylic such as methyl acrylate or ethyl acrylate. Various materials such as resin, polycarbonate, polyethylene, and glass can be used. The light guide member 22 is not particularly limited as long as it is a material having high transparency.

Next, the formation of the patterns M1, M2, and M3 will be described with reference to FIGS. 2 and 7. FIG. 7 is an explanatory diagram showing how the light emitting device 10 of the embodiment emits light. The light H1 emitted by the light emitting element 31 on the substrate 32 to which the electric power is supplied guides the inside of the light guide member 22 and is reflected by the printed pattern M1. The reflected light H2 is multiplely reflected in the half mirror layers 21 and 23, and projects virtual images of M1a, M1b, M1c, M1d, and M1e. Therefore, the light emitting unit 20 is formed with multiple patterns M1a, M1b, M1c, M1d, and M1e having depth. Further, the shielding layer 24 has the effect of strengthening the impression at the time of light emission by preventing the transmission of light by the half mirror layer 23 so that the light and darkness at the time of light emission of the light emitting element 31 can be clearly highlighted.
Further, the distance between the virtual images M1a, M1b, M1c, M1d, and M1e (FIG. 2) changes depending on the distance of H2 (distance between the arrows) shown in FIG. 7, that is, the thickness of the light guide portion. From the above, it is also possible to adjust the intervals of the projected virtual images M1a, M1b, M1c, M1d, and M1e (FIG. 2) by changing the thickness.

(Manufacturing method of light emitting part)
Next, with reference to FIG. 8 regarding the manufacturing method of the light emitting unit 20, an example of manufacturing by so-called double-in-mold molding will be described. FIG. 8A is a schematic diagram showing a state when the resin forming the light emitting portion 20 is filled, and FIG. 8B is a schematic diagram showing a state when the light emitting portion 20 is released from the mold. ..
As shown in FIG. 8A, the first transfer film 27 first forms a film-like half mirror layer 21 on which silver or tin for transfer is vapor-deposited. Similarly, the second transfer film 28 is laminated on the half mirror layer 23 and the half mirror layer 23 on which the film-like patterns M1, M2, and M3 on which silver or tin for transfer is vapor-deposited are printed, and is blackened. A printed or colored shielding layer 24 is formed.
The first transfer film 27 and the second transfer film 28 are wound around the first roller 54 and the second roller 55 so that they can be mass-produced at the time of production, and the first transfer film 27 and the first transfer film 28 at the time of molding. The transfer film 28 of 2 moves.

The first transfer film 27 and the second transfer film 28 are arranged so as to be aligned with the positions to be transferred in the fixed mold 51 and the moving mold 52 and to face each other. The fixed mold 51 and the moving mold 52 are mold-tightened in preparation for filling the resin with the first transfer film 27 and the second transfer film 28 sandwiched therein. The space between the first transfer film 27 and the second transfer film 28 in the molded fixed mold 51 and the moving mold 52 is filled with a light-transmitting resin from the port 53.
The thickness of the light guide member 22 is determined by the thickness of the filled space, and is formed to a thickness of 3 mm in this embodiment. The thickness can be changed as appropriate, and a thickness of 0.5 mm to 10 mm is most suitable for the decorative member to be repeatedly reflected.

When the filling of the resin into the fixed mold 51 and the moving mold 52 is completed, the moving mold 52 moves as shown in FIG. 8B, and the first transfer film 27 and the second transfer film 28 are moved. The half mirror layer 21 and the patterns M1, M2, and M3 are printed on the light emitting portion 20, the shielding layer 24 printed in black on the back surface, and the half mirror layer 23 are integrally molded on the light guide member 22.
In this way, since the light emitting portion 20 decorated at one time is formed in a large amount, the number of processes can be reduced and the manufacturing can be performed, so that the manufacturing cost can be suppressed. Further, it is possible to manufacture a device in which the thickness of the entire light emitting device 10 is thin.

The light guide portion is first manufactured by double in-mold molding in which resin is poured between the half mirror layer 21 and the half mirror layer 23 or the full mirror, and then the half mirror layer 23 or the full mirror is engraved with a laser or an engraving machine. After forming M1, M2, and M3, the shielding layer 24 may be manufactured by printing or painting in black.

(Example 2)
Next, the light emitting unit 120 of another embodiment will be described with reference to FIG. The light emitting unit 120 is a light emitting unit 120 capable of clearly showing a pattern visually recognized from both sides by sandwiching the shielding layer 224 in the intermediate portion.
The light emitting unit 120 has a half mirror layer 121 above and a light guide member 122 below it. The light emitting unit 120 has a half mirror layer 123 on which the patterns M2 and M3 are printed below the light guide member 122, and a black shielding layer 224 is printed on the light emitting unit 120.
Further, the light emitting unit 120 has a half mirror layer 223 on which patterns M1 and M2 are printed below the shielding layer 224, and a light guide member 222 below the half mirror layer 223. Further, the light emitting unit 120 has a half mirror layer 221 below the light guide member 222.

The light emitting portion 120 can be integrally formed by filling the resin by performing the above-mentioned in-mold molding twice. Therefore, since the light emitting unit 120 decorated at one time is formed in a large amount, the number of processes can be reduced and the production can be performed, so that the production cost can be suppressed. Further, it is possible to manufacture a device in which the thickness of the entire light emitting device 10 is thin.
Further, the shielding layer 224 makes it possible to clearly highlight the light and darkness of a light emitting element (not shown) at the time of light emission by preventing the transmission of light reflected by the patterns M1, M2, and M3, and enhances the impression at the time of light emission. effective.

(Technical features)
An example of the technical feature points of the present embodiment is shown in parentheses below, but the present invention is not particularly limited and is exemplified, and the effects considered from these features are also described.

<First feature point>
A substrate portion (for example, mainly the substrate portion 30) that emits light of a light emitting element (for example, mainly a light emitting element 31) mounted by the supplied power, and display information (for example, mainly patterns M1, M2, M3) from the outside. ), And the first reflective layer (for example, mainly the half mirror layers 21, 121, 221) capable of reflecting the light reflected on the display information, and the display that receives and displays the light from the light emitting element. A second reflective layer (eg, mainly half mirror layers 23, 123, 223) that provides information and is in close contact with a shielding layer that blocks light transmission (eg, mainly shielding layers 24, 224) and can reflect light (eg, mainly half mirror layers 23, 123, 223). And a light guide member (for example, mainly light guide members 22, 122, 222) that guides the light of the light emitting element and is in close contact with the first reflective layer and the second reflective layer. It is a feature.

Based on the above features, in the present invention, the shielding layer prevents the light from being transmitted through the second reflective layer, so that the light and darkness of the light emitting element at the time of light emission can be clearly highlighted, and the impression at the time of light emission is strong. Has the effect of

<Second feature point>
The first reflective layer and the second reflective layer are characterized by being formed of a film-shaped half mirror.
Due to the above characteristics, the present invention can reduce the cost by using the same material for the first reflective layer and the second reflective layer. Further, by forming the film, a thinner light emitting device can be formed.

<Third feature point>
The first reflective layer is formed of a film-shaped half mirror, and the second reflective layer is formed of a film-shaped full mirror.
Due to the above features, in the present invention, since the light transmittance of the full mirror is lower than that of the half mirror, the loss of the light emitted from the light emitting element is reduced, and the virtual image of the information display can be clearly confirmed. be.

<Fourth feature>
The display information and the shielding layer are formed by printing.
With the above features, the present invention can simplify the manufacturing process and form a thin light emitting device.

<Fifth feature point>
The shielding layer is characterized in that it is colored with black color.
With the above features, the present invention can fulfill the shielding function and make the shadow of the displayed information clear.

<Sixth feature point>
A light emitting unit (for example, mainly light emitting units 20 and 120) in which the first reflective layer and the second reflective layer containing the display information are integrally formed by the light guide member obtained by curing a resin. It is characterized by being prepared.
With the above features, in the present invention, it is possible to form a thin light emitting portion, and at the same time, it is possible to form the manufacturing process by a simplified manufacturing process, so that the number of working steps can be reduced.

<Seventh feature point>
The first reflective member (for example, mainly the half mirror layer 21) that can be released from the mold, is transmissible, and can reflect the light reflected on the display information (for example, mainly the patterns M1, M2, and M3) is the first. A first sheet forming step of forming on one sheet (for example, mainly the first transfer film 27) and a second reflective member (for example, mainly a half mirror layer) that can be released and can reflect light. A second sheet forming step of forming 23) on a second sheet (for example, mainly a second transfer film 28) and a light emitting element filled with a softened resin between the first sheet and the second sheet. A light guide member forming step of forming a light guide member (for example, mainly a light guide member 22) that guides light from (for example, mainly a light emitting element 31), and the first sheet and the said after the resin is cured. It is characterized by comprising a light emitting portion forming step of removing the mold from the second sheet and taking out the light emitting portion (for example, mainly the light emitting portion 20).
Based on the above features, in the present invention, the light emitting portion can be formed by integral molding, and a thin light emitting portion can be formed, and at the same time, the light emitting portion can be formed in a state where the manufacturing process is simplified.

<Eighth feature point>
It is characterized by including a winding step of winding and moving the first sheet and the second sheet by first and second rollers (for example, mainly the first roller 54 and the second roller 55).
Due to the above characteristics, the present invention can be mass-produced, and the light emitting portion can be manufactured at a high speed.

<Ninth feature point>
The second sheet forming step is characterized by including a display information printing step of printing the display information on the surface of the second sheet.
Based on the above features, the present invention can produce display information in large quantities at low cost by printing on the second sheet. Further, the present invention facilitates the manufacture of a thin light emitting portion by printing.

<10th feature point>
The second sheet forming step is characterized by including a shielding layer printing step of printing a shielding layer (for example, mainly a shielding layer 24) on the back surface of the second sheet.
With the above features, the present invention can fulfill the shielding function by the shielding layer and make the shadow of the displayed information clear. Further, according to the present invention, it is possible to produce display information in a large amount at low cost by printing on the second sheet. Further, the present invention facilitates the manufacture of a thin light emitting portion by printing.

It can be used not only as a light emitting device for automobile decoration, but also as a light emitting device for decoration of outdoor and indoor commercial facilities, a light emitting device for freezers and decorative showcases, and a light emitting device for decoration such as libraries and museums. Is.

2 ... door, 3 ... door side, 10 ... light emitting device, 11 ... upper housing, 13 ... lower housing,
20.120 ... light emitting part, 21.23.121.123.221.223 ... half mirror layer,
22.122.222 ... light guide member, 24.224 ... shielding layer, 27 ... first transfer film, 28 ... second transfer film, 30 ... substrate portion, 31 ... light emitting element, 32 ... substrate,
51 ... fixed mold, 52 ... moving mold, 53 ... port, 54 ... first roller, 55 ... second roller,
C ... Car, M1, M2, M3 ... Pattern,
M1 (a, b, c, d, e), M2 (a, b, c, d, e), M3 (a, b, c, d, e) ... Virtual image.

Claims (4)

A first sheet forming step of forming a first reflective member on the first sheet, which can be released from the mold, can be transmitted, and can reflect the light reflected on the display information.
A second sheet forming step of forming a second reflective member that can be released from the mold and can reflect light on the second sheet,
A light guide member forming step of filling a softened resin between the first sheet and the second sheet to form a light guide member that guides light from a light emitting element.
A method for manufacturing a light emitting member, comprising a step of forming a light emitting portion, which comprises a step of forming a light emitting portion by releasing the mold from the first sheet and the second sheet after the resin is cured and taking out the light emitting portion.
A method for manufacturing a light emitting member, which comprises a winding step of winding and moving the first sheet and the second sheet by first and second rollers. The method for manufacturing a light emitting member according to claim 1, wherein the second sheet forming step includes a display information printing step of printing the display information on the surface of the second sheet. The production of the light emitting member according to any one of claims 1 and 2, wherein the second sheet forming step includes a shielding layer printing step of printing a shielding layer on the back surface of the second sheet. Method. A light emitting device comprising a light emitting member manufactured by the manufacturing method according to any one of claims 1 to 3, wherein the light emitting member emits light by a light emitting element that emits light using the supplied electric power.

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