Light source device

Abstract

Provided is a light source device that can make the luminance uniform in the plane even when the plane shape is irregular. The light source device includes: a plurality of light sources; a substrate on which the plurality of light sources are arranged in a matrix; a reflection member including a first wall portion that surrounds each light source, and a second wall portion that is located outside the first wall portion and has an opening portion on the outside; a region surrounded by the second wall portion includes a second region having an area that is more than half the area of a first region surrounded by the first wall portion, and a third region having an area that is less than half the area of the first region, the light source is arranged in the second region, and no light source is arranged in the third region.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a light source device. BACKGROUND

[0002] As a direct type backlight used for liquid crystal televisions, on-vehicle instruments, and the like, a light source device of a surface light emission type is known. For example, as one example of the light source device of the surface light emission type, a light source device described in Patent Literature 1 is known. This light source device has a frame body having a reflective peripheral wall around a plurality of light sources and is configured in a matrix shape. Thus, a light emission region is divided to prevent light leakage to the outside of the region.

[0003] PRIOR ART DOCUMENTS

[0004] PATENT LITERATURE

[0005] Patent Literature 1: Japanese Patent Application Publication No. 2013-25945 SUMMARY

[0006] PROBLEMS TO BE SOLVED BY THE INVENTION

[0007] However, particularly in on-vehicle instruments and the like, since the planar shape thereof is irregular, it is not always possible to regularly arrange the light sources at the outer peripheral end portion thereof, and it is often difficult to make the luminance uniform in the plane.

[0008] The present invention has been made in view of the above problems, and an object thereof is to provide a light source device that can make the luminance uniform in the plane even in a case where the planar shape is irregular.

[0009] TECHNICAL SOLUTION FOR SOLVING THE PROBLEMS

[0010] The present application includes the following inventions.

[0011] A light source device includes:

[0012] a plurality of light sources;

[0013] a substrate on which the plurality of light sources are arranged in a matrix shape;

[0014] a reflection member including a first wall portion surrounding each of the light sources and a second wall portion located outside the first wall portion and having an opening portion on the outside;

[0015] a region surrounded by the second wall portion has a second region having an area of more than half of an area of a first region surrounded by the first wall portion and a third region having an area smaller than half of the area of the first region,

[0016] the light sources are arranged in the second region, and no light source is arranged in the third region.

[0017] Inventive Effects

[0018] The light source device according to one embodiment of the present application can make the luminance uniform in the plane even if the plane shape is irregular. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1A is a schematic plan view of a light source device according to one embodiment of the present application.

[0020] Figure 1B is a sectional view taken along line A-A' of Figure 1A

[0021] Figure 1C is a sectional view taken along line B-B' of Figure 1A

[0022] Figure 1D is a partially enlarged schematic sectional view of a first wall portion periphery of Figure 1A

[0023] Figure 1E is a schematic exploded perspective view of a light source device according to one embodiment of the present application.

[0024] Figure 1F is a schematic sectional view of a main portion of a light source device including a portion of the components shown in Figure 1E

[0025] Figure 2A is a partially enlarged schematic sectional view of a light emitting element periphery of the light source device of Figure 1A

[0026] Figure 2B is a graph showing a batwing light distribution characteristic of the light emitting element of the light source device of Figure 1A

[0027] is a schematic plan view of a light source device according to another embodiment of the present application. Figure 3A

[0028] is a schematic plan view of a light source device according to still another embodiment of the present application. Figure 3B

[0029] is a schematic plan view of a light source device according to yet another embodiment of the present application. Figure 3C

[0030] LIST OF REFERENCES

[0031] 2 Cover member

[0032] 3 Bonding member

[0033] 4A, 4B Wiring layer

[0034] 5 Sealing member​​​​​​

[0035] 5a underfill

[0036] 6 light-reflecting film

[0037] 7 light-emitting element

[0038] 8 substrate

[0039] 9 light source

[0040] 10, 20, 30, 40 reflecting member

[0041] 10c bottom surface

[0042] 11 first wall portion

[0043] 11R first region

[0044] 12 second wall portion

[0045] 12R second region

[0046] 13R third region

[0047] 14 diffusion plate

[0048] 22 diffusion sheet

[0049] 23 wavelength conversion sheet

[0050] 24 prismatic sheet

[0051] 25 polarizing sheet

[0052] 26 cover substrate

[0053] 27 outer substrate

[0054] 28, 29, 31 adhesive layer and / or reflecting layer

[0055] 32 through hole DETAILED DESCRIPTION

[0056] Hereinafter, embodiments of the present disclosure will be described with appropriate reference to the accompanying drawings. However, the following described embodiments are all embodiments in which the technical idea of the present disclosure is embodied, and the present disclosure is not limited to the following embodiments unless otherwise specified. In addition, the content described in one embodiment, example can also be applied to other embodiments and examples. The size and positional relationship of the components shown in each drawing are exaggerated for the purpose of clear description.

[0057] In this embodiment, the side from which the light source of the light source is extracted is referred to as the upper surface or above. Additionally, unless otherwise stated, when viewed from above, the center side of the light source device, substrate, and / or reflective component is referred to as the inner side, and the side opposite to the center is referred to as the outer side.

[0058] like Figures 1A-1F As shown, a light source device according to one embodiment of the present invention includes: a plurality of light sources 9, a substrate 8 on which the plurality of light sources 9 are disposed, and a reflective member 10. This light source device functions as a surface-emitting type light source device. The reflective member 10 includes: a first wall portion 11 surrounding each light source 9, and a second wall portion 12 located outside the first wall portion 11 and having an opening on the outside. The reflective member 10 has a first region 11R, a second region 12R, and a third region 13R. The region surrounded by the first wall portion 11 is called the first region 11R, the region within the region surrounded by the second wall portion 12 that has an area more than half the area of ​​the first region 11R is called the second region 12R, and the region that has an area smaller than half the area of ​​the first region 11R is called the third region 13R. The light source 9 is disposed in the second region 12R, and no light source 9 is disposed in the third region 13R.

[0059] By having this structure, even in light source devices with irregular planar shapes, it is possible to achieve uniform brightness within the surface.

[0060] (Light source 9)

[0061] The light source 9 is a light-emitting component, and may include, for example, a self-emissive light-emitting element itself, a light source made by sealing the light-emitting element with a transparent resin, or a surface-encapsulated light-emitting device (also known as an LED) encapsulating a light-emitting element. Multiple light sources 9 are preferably arranged regularly on the substrate 8 in a horizontal, vertical, row, column, or matrix pattern. This ensures uniform brightness within the surface. That is, as... Figure 1A As shown, the multiple light sources 9 are preferably arranged regularly in rows and columns, or as shown in... Figure 3C As shown, they are arranged regularly in the row direction and in the column direction, the light sources 9 are shifted by half the amount (length) in the row direction in such a way that they are positioned between adjacent rows.

[0062] For example, as light source 9, such as Figure 2A As shown, a light source consisting of a sealing component 5 enclosing a light-emitting element 7 can be exemplified. The light source 9 can also be a light source using a single light-emitting element 7, or a light source using multiple light-emitting elements 7 as a single light source.

[0063] The light source 9 can also be a light source with certain light distribution characteristics, but in order to emit light in a manner that reduces brightness unevenness in each region surrounded by the wall of the reflective member 10 (described later), a wide light distribution is preferred. In particular, each light source 9 preferably has...Figure 2B The batwing light distribution characteristic is shown. Thus, by suppressing the amount of light emitted directly above the light source 9 and widening the light distribution of each light source, and by causing the widened light to be emitted to the reflection member 10, it is possible to suppress unevenness in brightness in each region surrounded by the wall portion.

[0064] Here, the batwing light distribution characteristic refers to a light distribution characteristic defined such that, with the optical axis L taken as 0°, the light intensity distribution has a light intensity stronger than 0° in an angle in which the absolute value of the light distribution angle is greater than 0°. Note that the optical axis L is defined, as shown in FIG. 1, by a line passing through the center of the light source 9 and perpendicularly intersecting a line on the plane of the substrate 8 described later. Figure 2A

[0065] In particular, as the light source 9 having the batwing light distribution characteristic, for example, a light source using a light emitting element 7 having a reflective film 6 on the upper surface can be cited, as shown in FIG. 2. Figure 2A Thus, light toward the upper side of the light emitting element 7 is reflected by the reflective film 6, the amount of light directly above the light emitting element 7 is suppressed, and a batwing light distribution characteristic can be obtained. Since the reflective film 6 can be formed directly on the light emitting element 7, there is no need to additionally combine a special lens for setting the batwing light distribution, and the thickness of the light source 9 can be reduced.

[0066] The reflective film 6 formed on the upper surface of the light emitting element 7 can be any one of a metal film such as silver or copper, a dielectric multilayer film (DBR film), a combination thereof, or the like. In the case of the reflective film 6, it is preferable to have an angle dependence of reflectance with respect to the incident angle with respect to the light emitting wavelength of the light emitting element 7. Specifically, the reflectance of the reflective film 6 is preferably set to be lower for oblique incidence than for perpendicular incidence. Thus, the change in brightness directly above the light emitting element becomes gentle, and it is possible to suppress the case where the directly above the light emitting element becomes a dark spot or the like becomes extremely dark.

[0067] As the light source 9, for example, a light source in which the height of the light emitting element 7 directly packaged on the substrate is 100 μm to 500 μm can be cited. The thickness of the reflective film 6 can be cited as 0.1 μm to 3.0 μm. Even if the sealing member 5 described later is included, the thickness of the light source 9 can be set to about 0.5 mm to 2.0 mm.

[0068] The plurality of light sources 9 can be independently driven from each other, and are preferably mounted on the substrate 8 described later in a manner that enables dimming control (for example, local dimming or HDR) of each light source.

[0069] (Light Emitting Element 7)

[0070] ​As the light-emitting element 7, known light-emitting elements can be used. For example, a light-emitting diode (LED) is preferably used. Regarding the light-emitting element, any wavelength can be selected. For example, as a blue or green light-emitting element, a light-emitting element using a nitride-based semiconductor can be used. Furthermore, as a red light-emitting element, GaAlAs, AlInGaP, etc., can be used. Moreover, semiconductor light-emitting elements made of other materials can also be used. The composition, color, size, and number of light-emitting elements used can be appropriately selected according to the purpose.

[0071] As a light-emitting element 7, such as Figure 2A As shown, an example of a light-emitting element 7 can be flip-chip packaged via a bonding member 3, spanning a pair of positive and negative wiring layers 4A and 4B disposed on the upper surface of the substrate 8. However, the light-emitting element 7 can be flip-chip packaged or conventionally packaged. The bonding member 3 is a component used to fix the light-emitting element 7 to the substrate or conductor wiring, and examples include insulating resin or conductive components. Figure 2A In the case of the flip-chip package shown, conductive components can be used. Specifically, examples include: alloys containing Au, Ag, Pd, In, Pb-Pd, Au-Ga, Au-Sn, Sn, Sn-Cu, Sn-Cu-Ag, Au-Ge, Au-Si, Al, Cu-In, and mixtures of metals and fluxes.

[0072] (Sealing component 5)

[0073] The sealing component 5 covers the light-emitting element for the purpose of protecting it from external environmental influences and optically controlling the light emitted from the light-emitting element. The sealing component 5 is formed of a light-transmitting material. Suitable materials include epoxy resin, silicone resin, or a mixture of both, as well as glass. Silicone resin is preferred considering its lightfastness and ease of molding. The sealing component 5 may also contain: a wavelength-converting material such as a phosphor that absorbs light from the light-emitting element and emits light of a different wavelength than the output light from the light-emitting element; a diffusing agent for diffusing light from the light-emitting element; and a colorant corresponding to the emission color of the light-emitting element.

[0074] Fluorescent agents, dispersants, and colorants can utilize materials known in this field.

[0075] The sealing component 5 can also directly contact the substrate 8.

[0076] The sealing component 5 is adjusted to a viscosity suitable for printing, dispensing, etc., and can be cured by heat treatment or light irradiation. The shape of the sealing component 5 can be, for example, a generally hemispherical shape, a convex shape with a longitudinal length (a shape where the length in the Z direction is longer than the length in the X direction) in cross-section, a flattened convex shape (a shape where the length in the X direction is longer than the length in the Z direction) in cross-section, a circular shape in plan view, or an elliptical shape.

[0077] The sealing component 5 can also be configured as a bottom filler 5a between the lower surface of the light-emitting element 7 and the upper surface of the substrate 8.

[0078] (Substrate 8)

[0079] The substrate 8 is a component used to configure multiple light sources 9, such as... Figure 2A As shown, the upper surface of the substrate 8 has wiring layers 4A and 4B for supplying power to the light source 9 such as the light-emitting element 7. Preferably, the areas of the wiring layers 4A and 4B that are not electrically connected are covered by the covering member 2.

[0080] The material used for substrate 8 can be any material capable of insulatingly separating at least one pair of wiring layers 4A and 4B. Examples include ceramics, resins, and composite materials. Examples of ceramics include alumina, mullite, forsterite, glass ceramics, nitride-based (e.g., AlN), carbide-based (e.g., SiC), and LTCC. Examples of resins include phenolic resins, epoxy resins, polyimide resins, BT resins, polyphthalamide (PPA), and polyethylene terephthalate (PET). Examples of composite materials include composite materials formed by mixing glass fibers, inorganic fillers such as SiO2, TiO2, and Al2O3 into the above-mentioned resins, glass fiber reinforced resins (glass epoxy resins), and metal substrates with insulating layers formed on metal parts.

[0081] The thickness of substrate 8 can be appropriately selected, and it can be either a flexible substrate or a rigid substrate that can be manufactured by roll-to-roll. The rigid substrate can also be a thin, flexible rigid substrate.

[0082] If wiring layers 4A and 4B are conductive components, they can be made of any material, and components used as wiring layers in circuit boards, etc., are generally acceptable. Electroplating films, reflective films, etc., can also be formed on the surface of the conductor wiring.

[0083] The cover member 2 is preferably formed of an insulating material. As the material, the same materials as exemplified as the material of the substrate can be given. The cover member can prevent leakage or absorption of light by using a material containing a white filler or the like in the above-described resin, thereby improving the light extraction efficiency of the light source device.

[0084] (reflection member 10)

[0085] The reflection member 10 has a first wall portion 11 and a second wall portion 12 that surround each light source 9.

[0086] The first wall portion 11 is preferably configured so that each light source 9 disposed on the substrate is located near the center (or the center of gravity), and more preferably configured so that each light source 9 disposed on the substrate is located at the center (or the center of gravity). As the first wall portion 11, for example, a frame-shaped wall portion having a polygonal shape such as a quadrangle, a hexagon, or the like, a circular shape, an elliptical shape, or the like can be given. Among them, a lattice shape of a quadrangle as shown in Figure 1A a frame shape of a hexagon as shown in Figure 3C a lattice shape of a quadrangle, particularly a square, is preferable. Thus, the first wall portion 11 defines a plurality of regions of a predetermined shape, i.e., first regions 11R, by the above-described frame-shaped wall portion. As the shape of the region of the reflection member 10 that surrounds the light source 9, i.e., the shape of the first regions 11R defined by the first wall portion 11, a circular shape, an elliptical shape, or the like, a polygonal shape such as a quadrangle, a hexagon, or the like, or the like can be given in plan view. Among them, a polygonal shape, particularly a quadrangle, is preferable. Thereby, it is easy to define the light emitting regions in an arbitrary number from the first wall portion 11 according to the area of the light emitting surface of the surface light source device, and it is possible to arrange the light emitting regions at a high density. The first regions 11R defined by the first wall portion 11 are preferably regions that are regularly defined. The number of the first regions 11R defined by the first wall portion 11 can be arbitrarily set, and can be appropriately adjusted according to the desired size of the light source device. Note that the first regions 11R can be partially different in size and / or shape, but it is preferable that a plurality of regions are all the same in size and the same in shape.

[0087] In other words, in the reflection member 10, the first wall portion 11 is preferably arranged so as to be regularly arranged in a longitudinal and lateral, row and column, matrix, or the like, in a frame shape by linking the first regions 11R that surround each light source 9.

[0088] The second wall portion 12 defines one or more, preferably a plurality of regions of a predetermined shape, i.e., second regions 12R and third regions 13R. In the reflection member 10, the second wall portion 12 is disposed outside the first wall portion 11, and has an opening portion outside the reflection member 10, i.e., outside the light source device. The opening portion here can be open in part in the height direction of the second wall portion 12, but it is preferable that the second wall portion 12 is open in the entire height direction. In addition, the outside of the first wall portion means, for example,Figure 1A As shown, the outer side of the first side wall is close to the outer periphery of the reflection member 10 in plan view. Also, as shown, in the case where the reflection member 10 has a through-hole 32 inside the outermost periphery in plan view, the outer side of the first wall portion also refers to the through-hole 32 side of the first wall portion close to the through-hole 32. Figure 3B As shown, the outer side of the first side wall is close to the outer periphery of the reflection member 10 in plan view. Also, as shown, in the case where the reflection member 10 has a through-hole 32 inside the outermost periphery in plan view, the outer side of the first wall portion also refers to the through-hole 32 side of the first wall portion close to the through-hole 32.

[0089] In other words, in the reflection member 10, the second wall portion 12 is arranged in connection with the first wall portion 11 in a manner of constituting a part of a frame outside the first wall portion 11.

[0090] The region surrounded by a part of the second wall portion 12, that is, the region defined by a part of the second wall portion 12 is referred to as a second region 12R or a third region 13R. The second region 12R and the third region 13R are different in shape from the first region 11R, and have a shape in which a part of the shape of the first region 11R is cut off in plan view. In particular, the second region 12R has an area of more than half the area of the first region 11R surrounded by the first wall portion 11. The third region 13R has an area smaller than half the area of the first region 11R. In addition, it can also be said that the second region 12R is a region in which a region corresponding to the center or the center of gravity of the first region 11R exists and has an area of more than half the area of the first region 11R, and the third region 13R is a region in which a region corresponding to the center or the center of gravity of the first region 11R does not exist and has an area smaller than half the area of the first region 11R. Furthermore, it can also be said that the second region 12R is a region in which a region corresponding to the center or the center of gravity of the first region 11R exists, and the third region 13R is a region in which a region corresponding to the center or the center of gravity of the first region 11R does not exist.

[0091] The planar shape of the second region 12R and the third region 13R can be appropriately set according to, for example, the planar shape of the first region 11R, the planar shape of the reflection member 10, the instrument or the like to which the light source device is applied, and the like. In the case where there are a plurality of second regions 12R and a plurality of third regions 13R, respectively, all of them can be the same, but all or a part of them can be different. Thus, it is possible to provide a light source device having an irregular shape along the shape of the instrument, and it is possible to downsize the light source device itself. For example, it is possible to cite: a region formed by cutting one first region 11R defined by the first wall portion 11 at an arbitrary position parallel to one side (in Figure 1A and Figures 3A-3C , refer to the N portion), a region formed by cutting one first region 11R defined by the first wall portion 11 at a position inclined at an arbitrary angle with respect to one side (in Figures 3A-3C and Figures 3A-3C , refer to the J, W, L portions), a region formed by cutting one first region 11R defined by the first wall portion 11 with an arbitrary curved line and a straight line (inFigures 3A-3C and Figures 3A-3C Various shapes, such as the region formed by cutting a first region 11R defined by the first wall portion 11 along an arbitrary curve (referring to part K).

[0092] A light source 9 is disposed in the second region 12R, but no light source is disposed in the third region 13R. As described above, if there is a region in the second region 12R that corresponds to the center or centroid of the first region 11R, the light source 9 is disposed in or near that region. It should be noted that if there is no region in the second region 12R that corresponds to the center or centroid of the first region 11R, but there is a region in the second region 12R with an area more than half the area of ​​the first region 11R, then the light source 9 may not be disposed.

[0093] The third region 13R, which is partly surrounded by the second wall 12 and is not equipped with a light source 9, is not vertically, horizontally, or obliquely continuous (in...). Figures 3A-3C and Figures 3A-3C (Refer to parts J, W, K, N, and L, etc.). Therefore, when using irregular reflective components, darker areas will not exist at their ends, effectively preventing uneven brightness within the surface.

[0094] When viewed from above, the reflective component 10 has parallel upper and lower edges or parallel left and right edges formed by the first wall portion 11 (in... Figures 3A-3C and Figures 3A-3C In the middle, referring to Q), the second wall portion 12, the second region 12R, or the third region 13R form an edge that is inclined or curved relative to the upper and lower edges or the left and right edges of the first wall portion 11 or the first region 11R (in Figures 3A-3C and Figures 3A-3C (Refer to J, W, K, N, L, etc.). The tilt and curvature here can be appropriately set according to the size, configuration, and purpose of the light source 9. That is, regarding the outer periphery of the reflecting member 10, in the case where there are mutually parallel edges vertically and / or horizontally (in... Figure 1D and Figure 1A In the middle (referring to part Q), a first wall portion 11 is provided to form the edge, but the second wall portion 12 does not form the edge of the outer periphery of the reflective member. Instead, the second region 12R or the third region 13R together with the first wall portion 11 forms the outer periphery of the reflective member 10 (in Figure 1D and Figure 1D (Refer to parts J, W, K, N, and L, etc.)

[0095] The first wall portion 11 and the second wall portion 12 preferably form the boundary of adjacent regions in cross-section and have an inclination extending upwards towards the light source 9. The angle of the wall portions (in...) Figure 3C In the case of γ), for example, 45° to 75° can be cited.

[0096] The upper end of the first wall portion 11 and the second wall portion 12 can also be flat, but is preferably in the shape of a corner formed by at least two wall portions surrounding an adjacent region. In other words, as shown in FIG. 1, the longitudinal cross section of at least two wall portions constituting the top portion preferably forms an acute triangle, more preferably an acute isosceles triangle. The acute angle of the acute triangle or the acute isosceles triangle, i.e., the angle of the top portion (in the case of FIG. 1, α) is preferably set to 30° to 90°, for example. By setting to such a range, the space and the region occupied by the reflection member 10 can be reduced, the height of the reflection member 10 can be reduced, and miniaturization and thinning of the light source device can be achieved. Figure 1A Figure 1B The acute angle of the acute triangle or the acute isosceles triangle, i.e., the angle of the top portion (in the case of FIG. 1, α) is preferably set to 30° to 90°, for example. By setting to such a range, the space and the region occupied by the reflection member 10 can be reduced, the height of the reflection member 10 can be reduced, and miniaturization and thinning of the light source device can be achieved.

[0097] The width (in the case of FIG. 1, M) of the first wall portion 11 and / or the second wall portion 12 can be arbitrarily set by the angles α, γ of the first wall portion 11 and the second wall portion 12, the height OD of the reflection member to be described later, and the like, and miniaturization of the light source device can be achieved. Figure 1A

[0098] The first wall portion 11 and the second wall portion 12 can be set to various shapes such as a shape in which three first regions 11R and / or second regions 12R and / or third regions 13R are adjacent and the end portions of three top portions are concentrated at one point (refer to FIG. 1), a shape in which four first regions 11R and / or second regions 12R and / or third regions 13R are adjacent and four top portions are concentrated at one point as shown in FIG. 2, a shape in which six first regions 11R and / or second regions 12R and / or third regions 13R are adjacent and six top portions are concentrated at one point, and the like, depending on the number and the position of the light source 9 disposed on the substrate 8. Figure 1D Figure 1E The pitch (in the case of FIG. 1, P) of the first wall portion 11 and / or the second wall portion 12 can be appropriately adjusted depending on the size of the light source to be used, the size and the performance of the light source device desired, and the like. For example, 1 mm to 50 mm can be cited, preferably 5 mm to 20 mm, and more preferably 6 mm to 15 mm.

[0099] The pitch (in the case of FIG. 1, P) of the first wall portion 11 and / or the second wall portion 12 can be appropriately adjusted depending on the size of the light source to be used, the size and the performance of the light source device desired, and the like. For example, 1 mm to 50 mm can be cited, preferably 5 mm to 20 mm, and more preferably 6 mm to 15 mm. Figure 1B

[0100] Further, the reflection member 10 preferably has a bottom surface 10c in each region. The bottom surface 10c has a through hole disposed in the first region 11R at substantially the center. As shown in FIG. 1, a light source 9 is preferably disposed in the through hole. The shape and the size of the through hole can be any shape and size in which the light source 9 is exposed, and the outer edge of the through hole is preferably set to be located only in the vicinity of the light source 9. By this, light from the light source can also be reflected by the bottom surface 10c, and the light extraction efficiency can be improved. Figure 2A

[0101] ​​​​​The height of the reflection member 10 itself, that is, the height from the lower surface of the bottom surface 10c of the reflection member 10 to the upper end of the first wall portion 11 and the second wall portion 12 (OD) is preferably about 1 mm to 4 mm in the case of a thinner light source device in which the thickness is set to 8 mm or less. By this, a very thin backlight unit including an optical member such as a diffusion plate described later can be produced. Figure 1E In the case of a thinner light source device in which the thickness is set to 8 mm or less, the OD is preferably about 1 mm to 4 mm. By this, a very thin backlight unit including an optical member such as a diffusion plate described later can be produced.

[0102] The thickness of the reflection member 10 is, for example, 100 μm to 300 μm.

[0103] The reflection member 10 is preferably arranged on the substrate 8, and the lower surface of the bottom surface 10c of the reflection member 10 and the upper surface of the substrate 8 are preferably fixed. It is particularly preferable to fix the periphery of the through hole using a light-reflecting adhesive member so that the emission light from the light source 9 does not enter between the substrate 8 and the reflection member 10. For example, it is more preferable to arrange the light-reflecting adhesive member annularly along the outer edge of the through hole. The adhesive member can be a double-sided tape, a hot-melt type adhesive sheet, or a resin-based adhesive such as a thermosetting resin and a thermoplastic resin. These adhesive members preferably have high flame retardancy. However, the fixing of the reflection member 10 to the substrate 8 can also be performed using a screw or the like.

[0104] The reflection member 10 is a member having light-reflecting properties. By this, the light emitted from the light source 9 can be efficiently reflected by the first wall portion 11 and the second wall portion 12 and the bottom surface 10c. In particular, in the case where the first wall portion 11 and the second wall portion 12 have the above-described inclination, the light emitted from the light source 9 can be made to irradiate the first wall portion 11 and the second wall portion 12, and the light can be reflected upward. In addition, even in the case where the adjacent first region 11R and / or the second region 12R is not lit, the contrast ratio can be improved, and the reflection of the light reflected upward can be performed more efficiently.

[0105] The reflection member 10 can also be molded using a resin containing a reflection material composed of metal oxide particles such as titanium oxide, aluminum oxide, and silicon oxide, or a reflection material or a reflection film can be provided on the surface after molding using a resin not containing a reflection material. The reflectance with respect to the emission light from the light source 9 is preferably set to 70% or more.

[0106] The reflection member 10 itself can be a rigid member, a flexible member, or a member partially having both. In addition, it can be a flat member constituting a flat surface, a member constituting a curved surface or the like, or a member having both.

[0107] The reflective component 10 can be formed by molding using a mold, a light-based molding method, or the like. As a molding method using a mold, injection molding, extrusion molding, compression molding, vacuum molding, compressed air molding, stamping, and other molding methods can be applied. For example, by vacuum molding using a reflective sheet made of PET or the like, a reflective component 10 integrally formed from a bottom surface 10c, a first wall portion 11, and a second wall portion 12 can be formed.

[0108] (Other components)

[0109] like ​ and 1F As shown, the light source device of this embodiment preferably further includes: a diffuser plate 14 and / or a diffuser sheet 22, a wavelength conversion sheet 23, a prism sheet 24, a polarizer 25, an outer substrate 27 having a reflective wall surrounding the outer periphery of the substrate, and a covering substrate 26 having a reflective wall surrounding the outer periphery of the reflective member, etc. Furthermore, these components can be arbitrarily stacked via adhesive layers and / or reflective layers 28, 29, 31, etc. In this light source device, a liquid crystal panel or the like can also be disposed on the light source device, making it a surface-emitting light source device used as a direct-lit backlight. The stacking order of these optical components can be arbitrarily set.

[0110] (Diffuser plate 14 and / or diffuser sheet 22)

[0111] The diffuser plate 14 and / or diffuser sheet 22 (hereinafter simply referred to as diffuser plate 14) are components that diffuse and transmit incident light. Preferably, a diffuser plate 14 is disposed above the plurality of light sources 9. The diffuser plate 14 is preferably configured to substantially contact the upper ends of the first wall portion 11 and the second wall portion 12. The diffuser plate 14 is preferably a flat plate-shaped component, but it may also have irregularities on its surface. The diffuser plate 14 is preferably configured to be substantially parallel to the substrate 8. The diffuser plate 14 can be made of, for example, a material that absorbs less visible light, such as polycarbonate resin, polystyrene resin, acrylic resin, or polyethylene resin. In order to diffuse the incident light, irregularities may be provided on the surface of the diffuser plate 14, and materials with different refractive indices may be dispersed in the diffuser plate 14.

[0112] The size of the bump or recess can be set to, for example, 0.01mm to 0.1mm.

[0113] As materials with different refractive indices, they can be selected from polycarbonate resins, acrylic resins, etc.

[0114] The thickness and degree of light diffusion of the diffuser plate 14 can be appropriately set, and it can be used as a component sold as a light diffuser sheet, diffuser film, etc. For example, the thickness of the diffuser plate 14 can be set to 1 mm to 2 mm.

[0115] In a case where the distance between the first wall portion 11 and / or the second wall portion 12 of the reflection member 10 is P, the diffusion plate 14 is preferably arranged in a manner such that the distance between the diffusion plate 14 and the light source, i.e., the height OD, is, for example, 0.3P or less, and more preferably 0.25P or less. Here, as shown in FIG. 9, the height OD refers to the distance from the uppermost surface of the substrate 8, i.e., the distance from the uppermost surface of the substrate 8 to the lower surface of the diffusion plate 14 in a case where the substrate 8 has the cover member 2, the wiring layers 4A and 4B, and the like on the surface thereof. From another viewpoint, as shown in FIG. 10, the distance from the diffusion plate 14 to the upper surface of the bottom surface 10c of the reflection member 10 is preferably 1.5 mm to 5 mm, and more preferably 2 mm to 3 mm. ​ ​

[0116] A reflection portion can also be arranged on the upper surface and / or the lower surface of the diffusion plate 14, above the light source, preferably directly above the light source. In the region above the light source, particularly the region directly above the light source, the distance between the diffusion plate 14 and the light source 9 is the shortest. Thus, the luminance of this region is increased. The shorter the distance between the diffusion plate 14 and the light source 9, the more significant the luminance unevenness between the region directly above the region where the light source 9 is not arranged. Therefore, by providing the reflection portion on the surface of the diffusion plate 14, it is possible to alleviate the luminance unevenness by reflecting and returning a portion of the light having a high directivity of the light source 9 to the direction of the light source 9.

[0117] Furthermore, a reflection portion can also be arranged on the upper surface and / or the lower surface of the diffusion plate 14, above the upper end of the first wall portion 11 and / or the second wall portion 12, preferably directly above the upper end.

[0118] In a case where the light source 9 is locally dimmed, because the upper end of the first wall portion 11 and / or the second wall portion 12 is a region that becomes the boundary between the unlit region and the lit region, by arranging a reflection portion at this portion, it is possible to prevent the light of the lit region from leaking to the unlit region, and to reflect the light toward the unlit region to the upper side of the light source 9.

[0119] The reflection portion can be formed of a material containing a light-reflecting material. For example, a resin and / or an organic solvent, and the like containing a light-reflecting material can be given. As the light-reflecting material, for example, metal oxide particles such as titanium oxide, aluminum oxide, and silicon oxide can be given. The resin and the organic solvent can be appropriately selected in consideration of the metal oxide particles to be used, the characteristics required of the manufactured light source device, and the like. Among them, as the resin, a light-transmissive and light-hardening resin in which an acrylate resin, an epoxy resin, and the like are used as the main component is preferably used.

[0120] The reflection portion can be provided in various shapes or patterns such as a stripe shape, an island shape, and the like. The method of forming the reflection portion can be, for example, any of the methods known in the field such as a printing method, an inkjet printing method, a spray coating method, and the like.

[0121] ​​The thickness of the reflective part can be, for example, 10 μm to 100 μm.

[0122] (Wavelength conversion plate 23)

[0123] The wavelength conversion plate 23 can also be disposed on either the upper or lower surface of the diffuser plate 14, but as... ​ and 1F As shown, the wavelength conversion sheet 23 is preferably disposed on the upper surface of the diffuser plate 14 and / or the diffuser sheet 22. The wavelength conversion sheet 23 absorbs a portion of the light emitted from the light source 9 and emits light with a wavelength different from the emitted light from the light source 9. For example, the wavelength conversion sheet 23 can be configured to absorb a portion of the blue light from the light source 9 and emit yellow, green, and / or red light, and emit white light in a light source device. Because the wavelength conversion sheet 23 is located away from the light-emitting element of the light source 9, phosphors or similar materials that are difficult to use near the light-emitting element and have poor resistance to heat or light intensity can be used. This improves the performance of the light source device as a backlight. The wavelength conversion sheet 23 has a sheet shape or a layer shape and contains the aforementioned phosphors or similar materials.

[0124] (Prism Slide 24)

[0125] The prism sheet 24 has a shape in which multiple prisms extending in a predetermined direction are arranged on its surface. For example, when observing the plane of the sheet from a two-dimensional plane in the x-direction and the y-direction perpendicular to the x-direction, the prism sheet 24 can be used by stacking sheets with multiple prisms extending in the y-direction and sheets with multiple prisms extending in the x-direction. The prism sheet can refract light incident from various directions toward the display panel opposite the light source device. Therefore, light emitted from the light-emitting surface of the light source device can be mainly emitted in a direction perpendicular to the upper surface, improving the brightness when observing the light source device from the front.

[0126] (Polarizer 25)

[0127] The polarizer 25 selectively transmits light with a polarization direction consistent with that of a polarizer disposed on the backlight side of a display panel, such as a liquid crystal display panel, and reflects polarized light perpendicular to that polarization direction toward the prism sheet 24. A portion of the polarized light returning from the polarizer 25 is reflected again by the prism sheet 24, the wavelength conversion plate 23, and the diffuser plate 14. At this time, the polarization direction changes, for example, becoming polarized light with the polarization direction of the polarizer in the liquid crystal display panel, and then incident on the polarizer 25 again and exits toward the display panel. Thus, the polarization direction of the light emitted from the light source device can be aligned, and light with a polarization direction effective in improving the brightness of the display panel can be emitted efficiently. The polarizer 25, prism sheet 24, and other components can be polarizers and prism sheets sold as optical components for backlighting.

[0128] (coating substrate 26 and / or outer substrate 27, adhesive layer, and / or reflection layers 28, 29, 31)

[0129] The coating substrate 26 is a member having a reflection wall that surrounds the outer periphery of the reflection member 10, and is coated in a manner that presses the outer edge of the reflection member 10 and the optical member such as the diffusion plate 14 described above from above.

[0130] In addition, the outer substrate 27 is a member having a reflection wall that surrounds the outer periphery of the substrate 8, and is coated from the back surface side of the substrate 8.

[0131] They are members that prevent the light emitted from the light emitting device from leaking to the outside of their reflection walls, i.e., the outside of the light source device, by abutting or engaging the reflection walls with each other, thereby achieving an increase in the luminance of the light emitting surface.

[0132] These members, if they are members that reflect the light emitted from the light emitting device, can each be formed of various materials such as a resin containing a reflection material, a metal, a ceramic, or the like.

[0133] In addition, the adhesive layer and the reflection layer are materials that adhere the members thereon and above, and are capable of reflecting the direct light and the indirect light emitted from the light emitting device. For example, various materials such as a double-sided tape, an adhesive sheet of a hot melt type, a thermosetting resin, a thermoplastic resin, and an adhesive of a resin type such as a hot melt type can be used.

[0134] Industrial applicability

[0135] The light source device of the present application can be used for various light source devices such as a light source for a backlight of a display device, a lighting device, a light source for an instrument for a vehicle, and the like.

Claims

1. A light source device comprising: a plurality of light sources; a substrate on which the plurality of light sources are arranged in a matrix; a reflection member including a first wall portion surrounding each of the light sources, and a second wall portion located outside the first wall portion and having an opening portion on the outside, the first wall portion defining a first region, the second wall portion defining a second region and a third region, the light sources being arranged in the first region and the second region, and the light sources not being arranged in the third region, in the reflection member, in a plan view, upper and lower sides parallel to each other or left and right sides parallel to each other are formed by the first wall portion, and sides inclined or curved with respect to the upper and lower sides or the left and right sides are formed by the second wall portion, the second region, or the third region.

2. The light source device according to claim 1, wherein the third region is not continuous in an up-down direction, a left-right direction, or an inclined direction.

3. The light source device according to claim 1 or 2, wherein an area of the second region is larger than an area of the third region.

4. The light source device according to claim 1 or 2, wherein the second region has an area of more than half of an area of the first region surrounded by the first wall portion, and the third region has an area smaller than half of the area of the first region.

5. The light source device according to claim 1 or 2, wherein the reflection member in the first region and the second region has a through hole in a bottom surface.

6. The light source device according to claim 1 or 2, wherein the reflection member in the third region does not have a through hole in a bottom surface.

7. The light source device according to claim 1 or 2, wherein the first wall portion of the reflection member is arranged on the substrate in a lattice shape of quadrilaterals.

8. The light source device according to claim 1 or 2, further comprising at least one selected from the group consisting of a diffusion plate, a diffusion sheet, a wavelength conversion sheet that converts light from the light source into light of a different wavelength, a prism sheet, and a polarizing sheet.

9. The light source device according to claim 1 or 2, further comprising an outer substrate having a reflection wall surrounding an outer periphery of the substrate.

10. The light source device according to claim 1 or 2, further comprising a cladding substrate having a reflection wall surrounding an outer periphery of the reflection member.

11. The light source device according to claim 1 or 2, wherein the light source is a light source having a batwing light distribution. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​

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