TW201533211A - 密封膠帶、螢光體片、照明裝置、液晶顯示裝置、螢光體片的製造方法以及密封方法 - Google Patents

密封膠帶、螢光體片、照明裝置、液晶顯示裝置、螢光體片的製造方法以及密封方法 Download PDF

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TW201533211A
TW201533211A TW104105295A TW104105295A TW201533211A TW 201533211 A TW201533211 A TW 201533211A TW 104105295 A TW104105295 A TW 104105295A TW 104105295 A TW104105295 A TW 104105295A TW 201533211 A TW201533211 A TW 201533211A
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Taiwan
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layer
phosphor
sealing tape
adhesive layer
phosphor sheet
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TW104105295A
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TWI661024B (zh
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伊藤靖
堀智充
樋山晃男
山崎章浩
上野祥史
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迪睿合股份有限公司
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Abstract

本發明提供一種密封膠帶、使用所述密封膠帶的螢光體片、照明裝置、液晶顯示裝置、螢光體片的製造方法以及密封方法，所述密封膠帶即使當彎折而貼附時，亦可防止膠帶寬度的偏差、氣泡的混入、及褶皺的產生。密封膠帶10是將黏著層11、氣體阻隔層12、接著層13以及支撐膜層14依序積層，且在寬度方向的大致中心部，沿長度方向在支撐膜層14的厚度方向上形成切口15而成。藉此，即使當彎折而貼附時，亦可防止膠帶寬度的偏差、氣泡的混入、及褶皺的產生。

Description

密封膠帶、螢光體片、照明裝置、液晶顯示裝置、 螢光體片的製造方法以及密封方法
本發明是有關於一種阻隔水蒸氣的密封膠帶(tape)、使用該密封膠帶的螢光體片(sheet)、照明裝置、液晶顯示裝置、螢光體片的製造方法以及密封方法。
在液晶顯示器(liquid crystal display)中，使用自背後向前表面對液晶面板(panel)進行照射的背光(backlight)光源。近年來，隨著液晶顯示器的大型化、薄型化、輕量化、長壽命化等，且就利用亮滅控制的動態圖像特性改善的觀點而言，在基板上配設多個發光二極體(LED：Light Emitting Diode)而進行面發光的發光裝置受到注目。在此種發光裝置中，為了提取白色光，主要採用如下兩種方法。
第一種方法是配設分別發出R、G、B(紅、綠、藍)三種顏色的光的LED，並將該些LED同時點燈，藉此使三種顏色的光合成而獲得白色光。而且，第二種方法是利用含螢光體的樹脂包 圍例如藍色LED，將藍色光顏色轉換為白色光。所述利用含螢光體的樹脂包圍藍色LED的構造體被稱為「白色LED」。
然而，第一種方法需要R、G、B三種顏色的LED，因此成本高。另外，在所述第二種方法中，由於對LED的微小面積灌注(potting)含螢光體的樹脂，故而難以使含螢光體的樹脂無偏差地均勻形成。
因此，近年來作為代替第二種方法的第三種方法，如下方法備受注目：使用以片狀基材夾持含螢光體的樹脂而成者、或使用將含螢光體的樹脂加工成片形狀的含螢光體的片，來對藍色LED進行顏色轉換(例如，參照專利文獻1、專利文獻2)。
螢光體亦有對氧或水蒸氣脆弱者。例如，SrGa2S4：Eu、CaS：Eu、SrS：Eu等硫化物螢光體由於具有陡峭的發光光譜(spectrum)，故而為可實現廣色域的色彩再現的優異的螢光體材料，且(Ba,Sr)3SiO5：Eu為高亮度的橙色發光螢光體材料，但在高溫高濕環境下易因水蒸氣而劣化。
當使用該些螢光體時，需要用於阻隔水蒸氣的某些手段。在白色LED中，難以採用該些螢光體，但在第三種方法的情況下，可藉由以水蒸氣阻隔膜(barrier film)覆蓋螢光體層等而予以應對。作為示例，提出有以下方法：在含螢光體的樹脂上設置矽化合物等保護層的方法(參照專利文獻3)、或在含螢光體的樹脂的表面形成水蒸氣阻隔層的方法(參照專利文獻4、專利文獻5)。
另外，作為防止水分自端部侵入的對策，可列舉如圖14 所示的袋裝(pouch)構造。袋裝構造是以第一膜101與第二膜102夾著螢光體層123，進而第一膜101與第二膜102的外側分別以第一水蒸氣阻隔膜121與第二水蒸氣阻隔膜122夾著，且利用密封樹脂103進行密封，所述構造的層數多而不易製作。
另外，可列舉如圖15所示的膠帶密封構造。膠帶密封構造是以第一水蒸氣阻隔膜121與第二水蒸氣阻隔膜122夾著螢光體層123，且利用密封膠帶130將第一水蒸氣阻隔膜121與第二阻隔膜122的端部密封，所述構造的層數少而易於製作。作為膠帶，鋁箔有優勢，此外可列舉蒸鍍有二氧化矽的聚對苯二甲酸乙二酯(Polyethylene terephthalate，PET)等水蒸氣透過率為1g/m2/day(40℃/90%RH)以下者等。
[現有技術文獻] [專利文獻]
[專利文獻1]日本專利特開2005-108635號公報
[專利文獻2]日本專利特開2009-283438號公報
[專利文獻3]日本專利特公平6-58440號公報
[專利文獻4]日本專利特開2009-283441號公報
[專利文獻5]日本專利特開2011-13567號公報
然而，現有的密封膠帶當彎折而貼附時，有如下情況：膠帶寬度產生偏差，混入氣泡，產生褶皺等，而有損端部的密封 性。
本發明是鑒於此種實際情況而完成，提供一種密封膠帶、使用該密封膠帶的螢光體片、照明裝置、液晶顯示裝置、螢光體片的製造方法以及密封方法，所述密封膠帶即使當彎折而貼附時，亦可防止膠帶寬度的偏差、氣泡的混入及褶皺的產生。
為了解決所述問題，本發明的密封膠帶的特徵在於：將黏著層、氣體阻隔層、接著層以及支撐膜層依序積層，且在寬度方向的大致中心部，沿長度方向在所述支撐膜層的厚度方向上形成切口而成。
另外，本發明的螢光體片的特徵在於包括：第一水蒸氣阻隔膜；第二水蒸氣阻隔膜；螢光體層，被所述第一水蒸氣阻隔膜與所述第二水蒸氣阻隔膜夾著；以及密封膠帶，將所述第一水蒸氣阻隔膜與所述第二阻隔膜的端部密封；所述密封膠帶是將黏著層、氣體阻隔層、接著層以及支撐膜層依序積層，且在寬度方向的大致中心部，沿長度方向在所述支撐膜層的厚度方向上形成切口而成。
另外，本發明的照明裝置的特徵在於：包括所述螢光體片。
另外，本發明的液晶顯示裝置的特徵在於：包括所述螢光體片。
另外，本發明的螢光體片的製造方法是以第一水蒸氣阻 隔膜與第二水蒸氣阻隔膜夾著螢光體層，並利用密封膠帶貼附所述第一水蒸氣阻隔膜與所述第二阻隔膜的端部，所述螢光體片的製造方法的特徵在於：所述密封膠帶是將黏著層、氣體阻隔層、接著層以及支撐膜層依序積層，且在寬度方向的大致中心部，沿長度方向在所述支撐膜層的厚度方向上形成切口而成。
另外，本發明的密封方法是利用密封膠帶貼附第一膜與所述第二膜的端部，其特徵在於：所述密封膠帶是將黏著層、氣體阻隔層、接著層以及支撐膜層依序積層，且在寬度方向的大致中心部，沿長度方向在所述支撐膜層的厚度方向上形成切口而成。
根據本發明，在寬度方向的大致中心部，沿長度方向在支撐膜層的厚度方向上形成有切口，因此即使當彎折而貼附時，亦可防止膠帶寬度的偏差、氣泡的混入及褶皺的產生。
10、60、70、80、130‧‧‧密封膠帶
11、61、71、81‧‧‧黏著層
12、62、72、82‧‧‧氣體阻隔層
13、73、83、622、624、722、724、822、824‧‧‧接著層
14、74、84‧‧‧支撐膜層
15、85‧‧‧切口
21、121‧‧‧第一水蒸氣阻隔膜
22、122‧‧‧第二水蒸氣阻隔膜
23、123‧‧‧螢光體層
23a‧‧‧螢光體
31‧‧‧紅色螢光體
32‧‧‧綠色螢光體
33‧‧‧棒塗機
34‧‧‧烘箱
35‧‧‧熱貼合機
36‧‧‧壓製機
41、51‧‧‧藍色LED
42‧‧‧導光板
43‧‧‧螢光體片
44‧‧‧光學膜群
52‧‧‧基板
53‧‧‧擴散板
60a‧‧‧氣泡
101‧‧‧第一膜
102‧‧‧第二膜
103‧‧‧密封樹脂
621、625、721、725、821、825‧‧‧鋁層
623‧‧‧PET膜
723、823‧‧‧PET膜
W1、W2‧‧‧膠帶寬度
a、b‧‧‧光譜
圖1是表示本實施方式的密封膠帶的構成的剖面圖。
圖2是表示螢光體片端部的構成例的剖面圖。
圖3(A)~圖3(D)是用以對螢光體片的製造方法的一例進行說明的示意圖。
圖4是表示邊緣光(edge light)型的照明裝置的概略剖面圖。
圖5是表示直下型的照明裝置的概略剖面圖。
圖6是使用硫化物系螢光體的背光及使用現有的黃色螢光體 的背光的光譜。
圖7是表示使用硫化物系螢光體的背光及使用現有的黃色螢光體的背光的液晶顯示裝置的色空間的國際照明委員會(Commission International de l'Eclairage，CIE)1931色度圖。
圖8是表示比較例1的膠帶構造的概略剖面圖。
圖9是示意性表示膠帶寬度的偏差的概略剖面圖。
圖10是示意性表示氣泡的混入的概略剖面圖。
圖11是表示比較例2的膠帶構造的概略剖面圖。
圖12是示意性表示無法彎折的狀態的概略剖面圖。
圖13是表示實施例1的膠帶構造的概略剖面圖。
圖14是表示現有的螢光體片的袋裝構造的剖面圖。
圖15是表示現有的螢光體片的膠帶密封構造的剖面圖。
以下，一面參照圖式，一面按下述順序對本發明的實施方式進行詳細說明。
1.密封膠帶
2.螢光體片
3.照明裝置
4.實施例
<1.密封膠帶>
圖1是表示本實施方式的密封膠帶的構成的剖面圖。所述密封膠帶10是將黏著層11、氣體阻隔層12、接著層13以及支撐膜 層14依序積層，且在寬度方向的大致中心部，沿長度方向在支撐膜層14的厚度方向上形成切口15。藉此可將支撐膜層14在固定位置彎折，且即使當彎折而貼附時，亦可防止上下的寬度偏差、氣泡的混入及褶皺的產生。
另外，既可在寬度方向的大致中心部，沿長度方向在支撐膜層14的厚度方向整體形成切口15，亦可在寬度方向的大致中心部，沿長度方向將切口15形成至接著層13的厚度方向的中途。藉此，可將支撐膜層14在固定位置容易地彎折，而可使密封作業性提昇。
黏著層11為貼附於被黏著體的層。作為形成黏著層11的黏著劑或接著劑，可根據被黏著體的材質而適當選擇。例如，可使用含有丙烯酸樹脂、丙烯酸改質矽樹脂化合物、矽改質丙烯酸樹脂化合物等作為主要成分的接著劑而形成。
氣體阻隔層12是作為至少具有對水蒸氣及氧的高氣體阻隔性的層而構成，例如為具有1g/m2/day(40℃/90%RH)以下的水蒸氣透過率的基材。氣體阻隔層12雖亦可為例如鋁單層，但較佳為將鋁層、接著層、基材、接著層以及鋁層依序積層而成。當鋁層與支撐膜的伸縮率大時，會發生捲曲(curl)，但藉由將鋁層對稱地積層，可抑制捲曲，而可使密封作業性提昇。
另外，氣體阻隔層12亦可代替鋁而使用例如二氧化矽、氧化鋁(alumina)等金屬氧化物，將金屬氧化物層、接著層、基材、接著層以及金屬氧化物層依序積層而成。
接著層13包含例如紫外線硬化樹脂或熱塑性樹脂，具有良好的透明性，並且具有對氣體阻隔層12及支撐膜層14的充分的接著性。紫外線硬化樹脂或熱塑性樹脂可使用公知材料，並無特別限定。作為紫外線硬化樹脂，例如可列舉利用光硬化劑而聚合的丙烯酸樹脂、環氧樹脂等。作為熱塑性樹脂，可列舉丙烯酸樹脂、聚苯乙烯樹脂(polystyrene resin，PS樹脂)、苯乙烯-丙烯腈共聚合樹脂(styrene-acrylonitrile copolymer resin，AS樹脂)、苯乙烯-甲基丙烯酸甲酯共聚合樹脂(styrene-methyl methacrylate copolymer resin，MS樹脂)、苯乙烯-丁二烯嵌段共聚合樹脂(styrene-butadiene block copolymer resin，SBC樹脂)等。其中，可較佳地使用透明性優異的熱塑性丙烯酸樹脂。
另外，接著層13較佳為含有螢光體。螢光體並無特別限定，但較佳為使用耐水分的釔鋁石榴石(Yttrium Aluminum Garnet，YAG)系螢光體或氮化物系螢光體。尤其當使用藍色LED而獲得白色光時，較佳為使用(Y,Gd)3(Al,Ga)5O12：Ce(YAG：Ce)等黃色的YAG系螢光體。藉此，當將密封膠帶用於螢光體片端部時，可消除螢光體片端部附近的藍度。
為了防止切入至氣體阻隔層12，接著層13的厚度較佳為10μm以上、50μm以下。
支撐膜層14包含具有韌性的透明的塑膠膜。作為具體例，可列舉聚酯(聚對苯二甲酸乙二酯、聚萘二甲酸乙二酯、聚對苯二甲酸丁二酯等)、聚烯烴(聚乙烯、聚丙烯)、聚芳酯、聚 碳酸酯、聚丙烯酸酯、聚醚碸等或該些共聚物的未延伸膜及延伸膜，且均可根據用途而適當選擇。
支撐膜層14的厚度若過薄，則無法獲得適度的韌性，若過厚，會導致膠帶厚度增加，因此較佳為10μm以上、50μm以下。
根據包含此種構成的密封膠帶10，可使彎折位置固定化，因此，可消除彎折而貼附時的被黏著體端部的膠帶寬度的偏差。另外，利用最表面的支撐膜層14的硬度，可防止氣泡的混入，並且可抑制被黏著體的撓曲所引起的褶皺的產生。而且，由於最表面為支撐膜層14，故而可保護氣體阻隔層12免受機械損傷。
<2.螢光體片>
圖2是表示螢光體片端部的構成例的剖面圖。所述螢光體片包括：第一水蒸氣阻隔膜21；第二水蒸氣阻隔膜22；螢光體層23，被第一水蒸氣阻隔膜21與第二水蒸氣阻隔膜22夾著；以及密封膠帶10，將第一水蒸氣阻隔膜21與第二阻隔膜22的端部密封。
就水蒸氣阻隔性及強度的觀點而言，貼附於第一水蒸氣阻隔膜21上或第二水蒸氣阻隔膜22上的密封膠帶10的寬度較佳為1mm~10mm，更佳為4mm~8mm。
根據包含此種構成的螢光體片，可防止水蒸氣自水蒸氣阻隔膜的端部向螢光體層23侵入，而可防止螢光體層23中的螢光體23a的劣化。
第一水蒸氣阻隔膜21及第二水蒸氣阻隔膜22例如為具 有1g/m2/day以下的水蒸氣透過率的基材，且為在PET(Polyethylene terephthalate)等塑膠基板或膜的表面形成氧化鋁、氧化鎂、氧化矽等金屬氧化物薄膜而成的氣體阻隔性膜。另外，亦可使用PET/SiOx/PET等多層構造者。
螢光體層23是將含有粉末狀的螢光體23a的樹脂組成物成膜而成。螢光體並無特別限定，可自硫化物系螢光體、氧化物系螢光體、氮化物系螢光體、氟化物系螢光體等中，根據螢光體的種類、吸收帶、發光帶等，組合1種或2種以上而使用。
作為硫化物系螢光體的具體例，例如可列舉CaS：Eu、SrS：Eu、SrGa2S4：Eu、CaGa2S4：Eu、(Sr,Ca,Ba,Mg)Ga2S4：Eu、(Sr,Ca,Ba)S：Eu、Y2O2S：Eu、La2O2S：Eu、Gd2O2S：Eu等。另外，作為氧化物系螢光體的具體例，可列舉(Ba,Sr)3SiO5：Eu、(Ba,Sr)2SiO4：Eu、Tb3Al5O12：Ce、Ca3Sc2Si3O12：Ce等。另外，作為氮化物系螢光體的具體例，例如可列舉Ca2Si5N8：Eu、Sr2Si5N8：Eu、Ba2Si5N8：Eu、(Ca,Sr,Ba)2Si5N8：Eu、Cax(Al,Si)12(O,N)16：Eu(0<x≦1.5)、CaSi2O2N2：Eu、SrSi2O2N2：Eu、BaSi2O2N2：Eu、(Ca,Sr,Ba)Si2O2N2：Eu、CaAl2Si4N8：Eu、CaSiN2：Eu、CaAlSiN3：Eu等。另外，作為氟化物系螢光體的具體例，可列舉K2TiF6：Mn4+、Ba2TiF6：Mn4+、Na2TiF6：Mn4+、K3ZrF7：Mn4+、K2SiF6：Mn4+等。另外，作為其他螢光體，可列舉(Y,Gd)3(Al,Ga)5O12：Ce(YAG：Ce)等YAG系螢光體、Lu(Si,Al)12(O,N)16：Eu等賽隆(sialon)系螢光體。另外，在螢光 體材料的記載中，「：」之前表示母體，「：」之後表示活化劑。
作為為了使用藍色LED或近紫外LED獲得白色光而組合的螢光體，可使用黃色螢光體、黃色螢光體與紅色螢光體、綠色螢光體與紅色螢光體等。在本實施方式中，可較佳地使用易因水蒸氣而劣化的硫化物系螢光體、氧化物系螢光體或它們的混合系螢光體，從而可實現廣色域。
作為為了使用藍色LED獲得白色光而組合的硫化物系螢光體，可列舉：利用藍色激發光的照射而具有波長為620nm~660nm的紅色螢光波峰(peak)的硫化物系螢光體，較佳為CaS：Eu、SrS：Eu；或利用藍色激發光的照射而具有波長為530nm~550nm的綠色螢光波峰的硫化物系螢光體，較佳為SrGa2S4：Eu。
另外，作為為了使用藍色LED獲得白色光而組合的氧化物系螢光體，可列舉：利用藍色激發光的照射而發出波長為590nm~620nm的紅色螢光的氧化物系螢光體，較佳為(Ba,Sr)3SiO5：Eu、(Ba,Sr)2SiO4：Eu等。
另外，亦可使用為了使用藍色LED獲得白色光而組合的硫化物系螢光體或氧化物螢光體以外的螢光體，例如亦可使用(Y,Gd)3(Al,Ga)5O12：Ce、賽隆螢光體等。
另外，硫化物系螢光體或氧化物螢光體較佳為其表面經過被覆。作為用於被覆表面的化合物，可列舉氧化矽、氧化釔、氧化鋁、或氧化鑭等氧化物。該些氧化物亦可組合1種或2種以上而使用。
當在圖2所示的單層型的發光體片中，使用所述螢光體的混合物作為螢光體時，為了使螢光體片發出白色光，較佳為使用混合螢光體，即，利用藍色激發光的照射而發出波長為620nm~660nm的紅色螢光的硫化物系螢光體或利用藍色激發光的照射而發出波長為590nm~620nm的紅色螢光的氧化物系螢光體、與利用藍色激發光的照射而發出波長為530nm~550nm的綠色螢光的硫化物系螢光體的混合螢光體。尤佳的組合為發出紅色螢光的CaS：Eu或(BaSr)3SiO5：Eu、與發出綠色螢光的SrGa2S4：Eu的混合螢光體。
在形成螢光體層的樹脂組成物中，較佳為含有聚烯烴共聚物成分或光硬化性(甲基)丙烯酸樹脂成分的任一樹脂成分。
作為聚烯烴共聚物，可列舉苯乙烯系共聚物或其氫化物。作為此種苯乙烯系共聚物或其氫化物，可較佳地列舉苯乙烯-乙烯-丁烯-苯乙烯嵌段共聚物或其氫化物、苯乙烯-乙烯-丙烯嵌段共聚物或其氫化物。其中，就透明性或氣體阻隔性的方面而言，可尤佳地使用苯乙烯-乙烯-丁烯-苯乙烯嵌段共聚物的氫化物。藉由含有此種聚烯烴共聚物成分，可獲得優異的耐光性與低吸水性。
作為光硬化型丙烯酸酯樹脂成分，可列舉(甲基)丙烯酸胺基甲酸酯、聚酯(甲基)丙烯酸酯、環氧(甲基)丙烯酸酯等，其中，就光硬化後的耐熱性的觀點而言，可較佳地使用(甲基)丙烯酸胺基甲酸酯。藉由含有此種光硬化型(甲基)丙烯酸酯樹脂成分，可獲得優異的耐光性與低吸水性。
另外，在樹脂組成物中，亦可視需要在無損本發明的效果的範圍內，調配其他透光性樹脂、著色顏料、溶劑等。
[螢光體片的製造方法]
本實施方式的螢光體片的製造方法是以第一水蒸氣阻隔膜與第二水蒸氣阻隔膜夾著螢光體層，並利用密封膠帶將第一水蒸氣阻隔膜與第二阻隔膜的端部密封。
圖3(A)~圖3(D)是用以對螢光體片的製造方法的一例進行說明的示意圖。作為具體例所示的螢光體片的製造方法如圖3(A)~圖3(D)所示般包括攪拌步驟(A)、層壓(laminate)步驟(B)、沖裁加工步驟(C)以及密封步驟(D)。
在攪拌步驟(A)中，例如在利用溶劑溶解的樹脂膏(paste)中，以預先決定的調配比混合紅色螢光體31與綠色螢光體32，而獲得含螢光體的樹脂膏。在層壓步驟(B)中，在第一水蒸氣阻隔膜21上塗佈螢光體樹脂膏，使用棒塗機(bar coater)33而使螢光體樹脂膏的膜厚均勻，並利用烘箱(oven)34使螢光體樹脂膏乾燥，而形成螢光體層23。然後，使用熱貼合機(laminator)35而在螢光體層23上貼合第二水蒸氣阻隔膜22，從而獲得螢光體層23被第一水蒸氣阻隔膜21與第二水蒸氣阻隔膜22夾著的螢光體片的原片。在沖裁加工步驟(C)中，利用壓製機(pressing machine)36對螢光體片的原片進行沖裁加工，而獲得螢光體層露出於端部側面的規定尺寸的螢光體片。在密封步驟(D)中，使用密封膠帶10貼附第一水蒸氣阻隔膜21的端部與 第二水蒸氣阻隔膜22的端部，而將螢光體層23密封。
利用以上的步驟(A)~步驟(D)，可獲得利用密封膠帶10貼附第一水蒸氣阻隔膜21與第二水蒸氣阻隔膜22的端部而成的螢光體片。
另外，所述密封膠帶並不限於螢光體片的製造方法，亦可用於貼附第一膜與第二膜的端部的密封方法。
<3.照明裝置>
圖4是表示邊緣光型的照明裝置的概略剖面圖。如圖4所示，照明裝置構成所謂的「邊緣光型背光」，包括：藍色LED 41；導光板42，使自側面入射的藍色LED 41的藍色光擴散，而在表面出射均勻的光；螢光體片43，自藍色光獲得白色光；以及光學膜群44。
藍色LED 41構成所謂的「LED封裝(package)」，例如具有InGaN系的LED晶片(chip)作為藍色發光元件。導光板42使自壓克力板(acrylic plate)等透明基板的端面入射的光均勻地進行面發光。螢光體片43含有自藍色發光元件的藍色光獲得白色光的粉末狀的螢光體。螢光體的粉末使用平均粒徑為數μm~數十μm的粉末。藉此，可使螢光體片43的光散射效果提高。光學膜群44例如包含用以使液晶顯示裝置的視覺辨認性提高的反射型偏光膜、擴散膜等。
另外，圖5是表示直下型的照明裝置的概略剖面圖。如圖5所示，照明裝置構成所謂的「直下型背光」，包括：基板52， 二維配置有藍色LED 51；擴散板53，使藍色LED 51的藍色光擴散；螢光體片43，與基板52隔開配置，自藍色光獲得白色光；以及光學膜群44。
藍色LED 51構成所謂的「LED封裝」，例如具有InGaN系的LED晶片作為藍色發光元件。基板52包含利用有酚、環氧、聚醯亞胺等樹脂的玻璃布基材，在基板52上，與螢光體片43的整個面對應地，以規定間距(pitch)等間隔地二維配置有藍色LED 51。另外，亦可視需要對基板52上的藍色LED 51的搭載面實施反射處理。基板52與螢光體片43隔開約10mm~50mm左右而配置，照明裝置構成所謂的「遠程螢光體(remote phosphor)構造」。基板52與螢光體片43的間隙利用多個支撐柱或反射板而保持，且設置成支撐柱或反射板將基板52與螢光體片43所形成的空間的四方包圍。擴散板53使來自藍色LED 51的放射光廣範圍擴散成看不見光源形狀的程度，例如具有20%以上、80%以下的全光線透過率。
在此種構成的照明裝置中，螢光體片43的端部被覆蓋(cover)構件密封，因此，可較佳地使用易因水蒸氣而劣化的硫化物系螢光體、氧化物系螢光體或它們的混合系螢光體。
圖6是使用硫化物系螢光體的背光及使用現有的黃色螢光體的背光的光譜。在圖6中，a為使用硫化物系螢光體的背光的光譜，b為使用現有的黃色螢光體的背光的光譜。
另外，圖7是表示使用硫化物系螢光體的背光及使用現 有的黃色螢光體的背光的液晶顯示裝置的色空間的CIE1931色度圖。在圖7中，a為利用使用硫化物系螢光體的背光的液晶顯示裝置的色空間，b為利用使用現有的黃色螢光體的背光的液晶顯示裝置的色空間，c為美國國家電視標準委員會(National Television Standards Committee，NTSC)方式的色空間，d為標準紅綠藍(standard Red Green Blue，sRGB)方式的色空間。
使用硫化物系螢光體的背光使用如下螢光體片：使用綠色硫化物系螢光體(SrGa2S4：Eu)與紅色硫化物系螢光體(CaS：Eu)作為硫化物系螢光體，且分散於苯乙烯-乙烯-丁烯-苯乙烯嵌段(styrene-ethylene-butylene-styrene，SEBS)樹脂中。
在使用硫化物系螢光體的螢光體片中，含有紅色硫化物系螢光體，因此，如圖6所示，使用硫化物系螢光體的背光的光譜a的650nm附近的強度較使用黃色螢光體的背光的光譜b大。而且，如圖7所示，利用使用硫化物系螢光體的背光的液晶顯示裝置的色空間為NTSC方式的色空間的85%~90%左右的面積比率，相對於此，利用使用黃色螢光體的背光的液晶顯示裝置的色空間為NTSC方式的色空間的72%左右的面積比率。所述面積比率是由背光光譜與液晶顯示裝置內的彩色濾光片(color filter)的分光透過率的乘積而決定。已指出根據後者的彩色濾光片的分光透過率，所述面積比率的數值稍微變動。
如上所述，使用硫化物系螢光體的螢光體片可表現廣色域，因此，如本實施方式般螢光體片的端部被覆蓋構件密封而防 止水蒸氣的侵入的技術對使用硫化物系螢光體的螢光體片而言非常有用。而且，藉由將具備使用硫化物系螢光體的螢光體片的照明裝置配置於例如成為液晶顯示裝置的顯示畫面的液晶面板，不僅可實現廣色域，且可使液晶顯示裝置長壽命化。
另外，本發明並不僅限定於所述實施方式，當然在不脫離本發明的主旨的範圍內可加以各種更新。例如，在所述實施方式中，表示將照明裝置應用於顯示裝置用的背光光源的例，但亦可應用於照明用光源。當應用於照明用光源時，多數情況下不需要光學膜34。而且，含螢光體的樹脂不僅可為平面的片形狀，亦可具有杯(cup)型形狀等立體的形狀。
[實施例]
<4.實施例>
以下，舉出實施例對本發明進行具體說明。在本實施例中，製作構成不同的密封膠帶。而且，對將密封膠帶貼附於螢光體片的邊緣(edge)部並彎折而密封時的膠帶寬度偏差、氣泡混入及褶皺產生進行評價。另外，本發明並不限定於該些實施例。
螢光體片使用如下者：使用厚度為約40μm的水蒸氣阻隔膜夾著螢光體層且尺寸為65英吋(1450mm×820mm)。螢光體片的厚度為約130μm。
另外，膠帶寬度偏差、氣泡混入及褶皺產生的評價以如下方式進行。
[膠帶寬度偏差的評價]
使用寬度約6mm的密封膠帶，將螢光體片的端部密封。然後，測定螢光體片的邊緣部的膠帶寬度，而對表面及背面的膠帶寬度偏差進行評價。將膠帶寬度為3mm±0.5mm以內的情況評價為「○」，將膠帶寬度超過3mm±0.5mm的情況評價為「×」。
[氣泡混入的評價]
使用寬度約6mm的密封膠帶，將螢光體片的端部密封。然後，觀察密封膠帶，將混入的氣泡小於1mm2的情況評價為「○」，將混入的氣泡為1mm2以上的情況評價為「×」。
[褶皺產生的評價]
使用寬度約6mm的密封膠帶，將螢光體片的端部密封。然後，將螢光體片彎折之後，觀察密封膠帶，將未產生褶皺的情況評價為「○」，將產生褶皺的情況評價為「×」。
<比較例1>
圖8是表示比較例1的膠帶構造的概略剖面圖。比較例1的密封膠帶60包含黏著層61以及氣體阻隔層62。黏著層61為約25μm厚的丙烯酸系黏著層。氣體阻隔層61是將約7μm厚的鋁層621、約3μm厚的接著層622、約12μm厚的PET膜623、約3μm厚的接著層624、以及約7μm厚的鋁層625依序積層而成。
將比較例1的膠帶構造體切開成約6mm寬度的尺寸，而製成比較例1的密封膠帶。使用比較例1的密封膠帶，將螢光體片的端部密封。
如表1所示，比較例1的膠帶寬度偏差的評價為×，氣 泡混入的評價為×，及褶皺產生的評價為×。比較例1的密封膠帶難以明確地決定彎折位置，而如圖9所示，表面及背面的膠帶寬度W1、膠帶寬度W2產生大偏差。而且，比較例1的密封膠帶由於柔軟，故而如圖10所示，產生氣泡60a的混入。此外，當將螢光體片彎折時，因螢光體片的撓曲，而在膠帶部產生褶皺。
[比較例2]
圖11是表示比較例2的膠帶構造的概略剖面圖。比較例2的密封膠帶70包含黏著層71、氣體阻隔層72、接著層73以及支撐膜層74。黏著層71為約25μm厚的丙烯酸系黏著層。氣體阻隔層72是將約7μm厚的鋁層721、約3μm厚的接著層722、約12μm厚的PET膜723、約3μm厚的接著層724、以及約7μm厚的鋁層725依序積層而成。接著層73包含約25μm厚的熱塑性樹脂層。支撐膜層74包含約25μm厚的PET膜。
將比較例2的膠帶構造體切開成約6mm寬度的尺寸，而製成比較例2的密封膠帶。使用比較例2的密封膠帶，將螢光體片的端部密封。
如表1所示，比較例2無法進行膠帶寬度偏差、氣泡混入、及褶皺產生的評價。比較例2的密封膠帶由於支撐膜層74的PET膜硬，故而如圖12所示，無法進行彎折，但已貼附密封膠帶的部分既無氣泡混入亦未產生褶皺。
[實施例1]
圖13是表示實施例1的膠帶構造的概略剖面圖。實施例1的 密封膠帶80包含黏著層81、氣體阻隔層82、接著層83、以及支撐膜層84。黏著層81為約25μm厚的丙烯酸系黏著層。氣體阻隔層81是將約7μm厚的鋁層821、約3μm厚的接著層822、約12μm厚的PET膜823、約3μm厚的接著層824、以及約7μm厚的鋁層825依序積層而成。接著層83包含約25μm厚的熱塑性樹脂層。支撐膜層84包含約25μm厚的PET膜。
將實施例1的膠帶構造體切開成約6mm寬度尺寸之後，在密封膠帶的中心部形成半切口(half cut)。具體而言，在最表面的25μm的PET膜與至接著層的中途為止形成切口。將該密封膠帶設為實施例的密封膠帶，使用該密封膠帶，將螢光體片的端部密封。
如表1所示，實施例1的膠帶寬度偏差的評價為○，氣泡混入的評價為○，及褶皺產生的評價為○。實施例1的密封膠帶利用形成於支撐膜層84的PET膜的切口，而可明確地決定彎折位置，因此，在被黏著體的表面及背面，膠帶寬度未產生大偏差。而且，實施例1的密封膠帶由於支撐膜層84的PET膜硬，故而未產生氣泡的混入。此外，由於支撐膜層的PET膜硬，故而即使當將螢光體片彎折時，膠帶部亦未產生褶皺。
10‧‧‧密封膠帶
11‧‧‧黏著層
12‧‧‧氣體阻隔層
13‧‧‧接著層
14‧‧‧支撐膜層
15‧‧‧切口

Claims (18)

  1. 一種密封膠帶，是將黏著層、氣體阻隔層、接著層以及支撐膜層依序積層，且在寬度方向的大致中心部，沿長度方向在所述支撐膜層的厚度方向上形成切口而成。
  2. 如申請專利範圍第1項所述的密封膠帶，是在寬度方向的大致中心部，沿長度方向在所述支撐膜層的厚度方向整體形成切口而成。
  3. 如申請專利範圍第2項所述的密封膠帶，是在寬度方向的大致中心部，沿長度方向將切口形成至所述接著層的厚度方向的中途而成。
  4. 如申請專利範圍第1項至第3項中任一項所述的密封膠帶，其中所述氣體阻隔層是將鋁層、接著層、基材、接著層以及鋁層依序積層而成。
  5. 如申請專利範圍第1項至第3項中任一項所述的密封膠帶，其中所述氣體阻隔層是將金屬氧化物層、接著層、基材、接著層以及金屬氧化物層依序積層而成。
  6. 如申請專利範圍第1項至第3項中任一項所述的密封膠帶，其中所述接著層含有螢光體。
  7. 如申請專利範圍第1項至第3項中任一項所述的密封膠帶，其中所述支撐膜層包含聚酯、聚烯烴、聚芳酯、聚碳酸酯、聚丙烯酸酯、聚醚碸中的至少一種以上。
  8. 如申請專利範圍第1項至第3項中任一項所述的密封膠帶，其中所述支撐膜層的厚度為10μm以上、50μm以下。
  9. 如申請專利範圍第1項至第3項中任一項所述的密封膠帶，其中所述接著層的厚度為10μm以上、50μm以下。
  10. 一種螢光體片，包括：一第一水蒸氣阻隔膜；一第二水蒸氣阻隔膜；一螢光體層，被所述第一水蒸氣阻隔膜與所述第二水蒸氣阻隔膜夾著；以及一密封膠帶，將所述第一水蒸氣阻隔膜與所述第二阻隔膜的端部密封；所述密封膠帶是將黏著層、氣體阻隔層、接著層以及支撐膜層依序積層，且在寬度方向的大致中心部，沿長度方向在所述支撐膜層的厚度方向上形成切口而成。
  11. 如申請專利範圍第10項所述的螢光體片，其中所述密封膠帶的接著層含有螢光體。
  12. 如申請專利範圍第11項所述的螢光體片，其中所述螢光體層含有自藍色光獲得白色光的螢光體，且所述螢光體含有黃色螢光體。
  13. 如申請專利範圍第10項至第12項中任一項所述的螢光體片，其中所述螢光體層含有硫化物系螢光體。
  14. 如申請專利範圍第13項所述的螢光體片，其中所述螢光 體層含有紅色螢光體與綠色螢光體。
  15. 一種照明裝置，包括如申請專利範圍第10項至第12項中任一項所述的螢光體片。
  16. 一種液晶顯示裝置，包括如申請專利範圍第10項至第12項中任一項所述的螢光體片。
  17. 一種螢光體片的製造方法，以第一水蒸氣阻隔膜與第二水蒸氣阻隔膜夾著螢光體層，並利用密封膠帶貼附所述第一水蒸氣阻隔膜與所述第二阻隔膜的端部，所述密封膠帶是將黏著層、氣體阻隔層、接著層以及支撐膜層依序積層，且在寬度方洵的大致中心部，沿長度方向在所述支撐膜層的厚度方向上形成切口而成。
  18. 一種密封方法，利用密封膠帶貼附第一膜與所述第二膜的端部，所述密封膠帶是將黏著層、氣體阻隔層、接著層以及支撐膜層依序積層，且在寬度方向的大致中心部，沿長度方向在所述支撐膜層的厚度方向上形成切口而成。
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