Light Source Module

Abstract

To provide a light source module with good light guide efficiency of the package layer [Solution] The light source module (10) includes a circuit board (100), a light emitting element (120), a package layer (140), and a plurality of microcavities. The light emitting element is mounted on a substrate surface similar to the circuit board and electrically connected to the circuit board. The package layer directly covers the substrate surface and the light emitting element and has a first surface connected to the substrate surface. A plurality of microcavities (CV1, CV2, CV3) are embedded in the package layer. At least some of the microcavities are adjacent to the first surface (140s1) and do not overlap with the light emitting surface (120es) of the light emitting element along the normal direction of the substrate surface.

Description

[Technical Field]

[0001] The present invention relates to an optical module, and more particularly to a light source module. [Background technology]

[0002] As the use of non-self-emissive displays such as LCDs expands, the design of backlight modules must also be tailored to suit various applications. To meet the display requirements of panel products with high dynamic range (HDR) and high contrast, backlight modules must have local dimming. Therefore, direct-type backlight modules have gradually become the mainstream in the market as the main light source mechanism.

[0003] Because such backlight modules are expected to be thinner (e.g., optical path length less than 10 mm), the light emitting elements are usually covered with a package layer having a reflective member or structure to achieve a more uniform light emitting effect on the light emitting surface of the backlight module. However, during lateral transmission in the package layer, part of the light emitted from the light emitting elements is prevented from continuing to transmit within the package body due to reflection by the solder mask ink on the circuit board, resulting in a decrease in the light guiding efficiency of the package layer. Summary of the Invention [Problem to be solved by the invention]

[0004] The present invention provides a light source module with a package layer having good light guide efficiency. [Means for solving the problem]

[0005] The light source module of the present invention includes a circuit board, a light-emitting element, a package layer, and a plurality of microcavities. The light-emitting element is mounted on a substrate surface similar to the circuit board and electrically connected to the circuit board. The package layer directly covers the substrate surface and the light-emitting element and has a first surface connected to the substrate surface. The plurality of microcavities are embedded in the package layer. At least some of the plurality of microcavities are disposed adjacent to the first surface and do not overlap with the light-emitting surface of the light-emitting element along the normal direction of the substrate surface.

[0006] In one embodiment of the present invention, at least some of the microcavities of the light source module include a plurality of first microcavities that are adjacent to the first surface and arranged at intervals in a direction parallel to the first surface to form reflective units, the reflective units being arranged at intervals along the direction, and the interval between any two adjacent reflective units of the plurality of reflective units along the direction being greater than the interval between any two adjacent first microcavities along the direction.

[0007] In one embodiment of the present invention, the interval between any two adjacent first microcavities of the light source module gradually decreases or increases with increasing distance from the light emitting element.

[0008] In one embodiment of the present invention, any two adjacent first microcavities of the plurality of first microcavities of the light source module are offset from each other along the direction.

[0009] In one embodiment of the present invention, the plurality of microcavities of the light source module further includes a plurality of second microcavities arranged at a distance from each other along the direction opposite to the first surface of the plurality of first microcavities to form a refractive unit, wherein the distance between the refractive unit and the first surface or the second surface in the normal direction to the substrate surface is equal to or greater than the thickness of the refractive unit.

[0010] In one embodiment of the present invention, the interval between any two adjacent second microcavities of the plurality of second microcavities of the light source module gradually decreases or increases with increasing distance from the light emitting element.

[0011] In one embodiment of the present invention, any two adjacent second microcavities of the plurality of second microcavities of the light source module are offset from each other along the direction.

[0012] In one embodiment of the present invention, a portion of the refractive unit overlaps the reflecting unit in the normal direction of the substrate surface of the light source module, and the refractive unit and the reflecting unit are offset from each other.

[0013] In one embodiment of the present invention, the plurality of microcavities of the light source module further includes a plurality of second microcavities disposed on one side of the light-emitting surface of the light-emitting element, and the dimming unit formed by the plurality of second microcavities overlaps the light-emitting surface in the normal direction of the substrate surface.

[0014] In one embodiment of the present invention, the plurality of second microcavities of the light source module are respectively arranged along a plurality of imaginary planes parallel to the light-emitting surface, the imaginary planes are spaced apart along the normal direction of the light-emitting surface, and the number of the plurality of second microcavities arranged in each imaginary plane gradually increases or decreases with increasing distance from the light-emitting surface.

[0015] In one embodiment of the present invention, two portions of each of the second microcavities of the light source module, which are arranged along any two adjacent imaginary planes, are offset from each other in the normal direction of the light-emitting surface.

[0016] In one embodiment of the present invention, the plurality of second microcavities of the light source module are respectively arranged along a plurality of imaginary planes parallel to the light-emitting surface, the imaginary planes are spaced apart along the normal direction of the light-emitting surface, and the number of the imaginary planes of the plurality of second microcavities is the same.

[0017] In one embodiment of the present invention, the plurality of second microcavities of the light source module include a first second microcavity, a second second microcavity, and a third second microcavity arranged along each imaginary plane, the first second microcavity and the second second microcavity being arranged adjacent to each other at a first interval along a direction, and the second second microcavity and the third second microcavity being arranged adjacent to each other at a second interval along the direction, the first interval being different from the second interval.

[0018] In one embodiment of the present invention, the plurality of second microcavities of the light source module are respectively arranged along a plurality of imaginary planes parallel to the light-emitting surface, the plurality of imaginary planes being spaced apart along a normal direction of the light-emitting surface, the plurality of second microcavities including a first second microcavity disposed on one imaginary plane of the plurality of imaginary planes and a second second microcavity disposed on another imaginary plane of the plurality of imaginary planes, and the structural shape of the first second microcavity is different from the structural shape of the second second microcavity.

[0019] In one embodiment of the present invention, the one of the plurality of imaginary planes of the light source module is located between another imaginary surface of the plurality of imaginary planes and the light-emitting element. The structural shape of a first of the plurality of second microcavities includes a spherical shape, a conical shape, an elliptical shape, or a rectangular shape, and the structural shape of a second of the plurality of second microcavities includes an asymmetric conical shape or an irregular shape.

[0020] In one embodiment of the present invention, the plurality of second microcavities of the light source module are respectively arranged along a plurality of imaginary planes parallel to the light-emitting surface. The plurality of imaginary planes are arranged at intervals along a normal direction of the light-emitting surface. The plurality of second microcavities includes a first second microcavity provided in one imaginary plane of the plurality of imaginary planes and a second second microcavity provided in another imaginary plane of the plurality of imaginary planes. The package layer has a first cavity surface defining the first second microcavity and a second cavity surface defining the second second microcavity, and the surface roughness of the first cavity surface is different from the surface roughness of the second cavity surface.

[0021] In one embodiment of the present invention, the plurality of second microcavities of the light source module are respectively arranged along a plurality of imaginary planes parallel to the light-emitting surface. The plurality of imaginary planes are arranged at intervals along a normal direction of the light-emitting surface. The plurality of second microcavities includes a first second microcavity and a second second microcavity provided in each imaginary plane. The package layer has a first cavity surface defining the first second microcavity and a second cavity surface defining the second second microcavity, and the surface roughness of the first cavity surface is different from the surface roughness of the second cavity surface.

[0022] In one embodiment of the present invention, the packaging layer of the light source module further has a second surface opposite to the first surface, and the plurality of microcavities further include a plurality of second microcavities adjacent to the second surface and arranged at intervals along a direction parallel to the second surface to form a refractive unit.

[0023] In one embodiment of the present invention, a surface microstructure is provided on a second surface of the packaging layer of the light source module, and a plurality of second microcavities are embedded in the surface microstructure and are conformally arranged along a portion of the second surface that defines the surface microstructure.

[0024] In one embodiment of the present invention, the light source module further includes a plurality of microparticles filled in the plurality of microcavities, the refractive index of the plurality of microparticles being different from the refractive index of the packaging layer. [Effects of the Invention]

[0025] In view of the above, in a light source module according to one embodiment of the present invention, a package layer has a first surface directly covering a substrate surface of a circuit board, and a plurality of microcavities are provided in a portion of the package layer adjacent to the first surface, thereby effectively avoiding unexpected light emission caused by poor reflection of part of the light at the first surface of the package layer. [Brief explanation of the drawings]

[0026] [Figure 1] 1 is a schematic cross-sectional view of a light source module according to a first embodiment of the present invention. [Figure 2] 2 is an enlarged schematic view of a partial area of ​​the light source module of FIG. 1. [Figure 3A] 3 is a schematic cross-sectional view showing another modified example of the reflection unit of FIG. 2. FIG. [Figure 3B] 3 is a schematic cross-sectional view showing another modified example of the reflection unit of FIG. 2. FIG. [Figure 3C] 3 is a schematic cross-sectional view showing another modified example of the reflection unit of FIG. 2. FIG. [Figure 3D] 3 is a schematic cross-sectional view showing another modified example of the reflection unit of FIG. 2. FIG. [Figure 3E] 3 is a schematic cross-sectional view showing another modified example of the reflection unit of FIG. 2. FIG. [Figure 3F] 3 is a schematic cross-sectional view showing another modified example of the reflection unit of FIG. 2. FIG. [Figure 3G] 3 is a schematic cross-sectional view showing another modified example of the reflection unit of FIG. 2. FIG. [Figure 3H] 3 is a schematic cross-sectional view showing another modified example of the reflection unit of FIG. 2. FIG. [Figure 4] 2 is an enlarged schematic view of a partial area of ​​the light source module of FIG. 1. [Figure 5A]5 is a schematic cross-sectional view of another modified example of the refraction unit of FIG. 4. FIG. [Figure 5B] 5 is a schematic cross-sectional view of another modified example of the refraction unit of FIG. 4. FIG. [Figure 5C] 5 is a schematic cross-sectional view of another modified example of the refraction unit of FIG. 4. FIG. [Figure 6A] FIG. 5C is a cross-sectional schematic view of another modification of the refractive unit of FIG. 5B. [Figure 6B] FIG. 5C is a cross-sectional schematic view of another modification of the refractive unit of FIG. 5B. [Figure 6C] FIG. 5C is a cross-sectional schematic view of another modification of the refractive unit of FIG. 5B. [Figure 6D] FIG. 5C is a cross-sectional schematic view of another modification of the refractive unit of FIG. 5B. [Figure 7] 2 is an enlarged schematic view of a partial area of ​​the light source module of FIG. 1. [Figure 8A] FIG. 8 is a schematic cross-sectional view of another modified example of the refraction unit of FIG. 7. [Figure 8B] FIG. 8 is a schematic cross-sectional view of another modified example of the refraction unit of FIG. 7. [Figure 9] FIG. 6 is a schematic cross-sectional view of a light source module according to a second embodiment of the present invention. [Figure 10] FIG. 10 is a schematic cross-sectional view of a light source module according to a third embodiment of the present invention. [Figure 11] 11 is an enlarged schematic view of a partial area of ​​the light source module of FIG. 10. [Figure 12A] 12 is a schematic cross-sectional view of another modified example of the light source module of FIG. [Figure 12B] 12 is a schematic cross-sectional view of another modified example of the light source module of FIG. [Figure 12C] 12 is a schematic cross-sectional view of another modified example of the light source module of FIG. [Figure 13] FIG. 10 is a schematic cross-sectional view of a light source module according to a fourth embodiment of the present invention. [Figure 14] FIG. 10 is a schematic cross-sectional view of a light source module according to a fifth embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0027] The above and other technical contents, features, and advantages of the present invention will be made clear in the following detailed description of preferred embodiments with reference to the accompanying drawings. Terms such as up, down, left, right, front, and rear used in the following embodiments only indicate directions in the accompanying drawings. Therefore, the directional terms used are intended to explain the present invention, but are not intended to limit the present invention.

[0028] FIG. 1 is a cross-sectional schematic view of a light source module according to a first embodiment of the present invention. FIG. 2 is an enlarged schematic view of a partial region of the light source module of FIG. 1. FIGS. 3A to 3H are cross-sectional schematic views showing other modified examples of the reflection unit of FIG. 2. FIG. 4 is an enlarged schematic view of a partial region of the light source module of FIG. 1. FIGS. 5A to 5C are cross-sectional schematic views of other modified examples of the refraction unit of FIG. 4. FIGS. 6A to 6D and 5B are cross-sectional schematic views of other modified examples of the refraction unit of FIG. 5B. FIG. 7 is an enlarged schematic view of a partial region of the light source module of FIG. 1. FIGS. 8A and 8B are cross-sectional schematic views of other modified examples of the refraction unit of FIG. 7. FIG. 2 corresponds to region A1 of FIG. 1. FIG. 4 corresponds to region A2 of FIG. 1. FIG. 7 corresponds to region A3 of FIG. 1.

[0029] 1 and 2, the light source module 10 includes a circuit board 100, a light emitting element 120, and a package layer 140. The light emitting element 120 is provided on a board surface 100s of the circuit board 100 and is electrically connected to the circuit board 100. In this embodiment, the light emitting element 120 may be a light emitting diode (LED) such as a submillimeter light emitting diode (mini LED) or a micro light emitting diode (micro LED).

[0030] The package layer 140 directly covers the light emitting element 120 and the substrate surface 100s of the circuit board 100, and has a first surface 140s1 and a second surface 140s2 facing each other. More specifically, the first surface 140s1 of the package layer 140 is connected to the substrate surface 100s of the circuit board 100. Examples of materials for the package layer 140 include plastic, a resin material (such as acrylic), or other suitable transparent package materials.

[0031] For example, in this embodiment, a solder mask ink layer 110 having moisture-proof, insulating, solder-resistant, and high-temperature-resistant properties may be provided on the substrate surface 100s of the circuit board 100 to prevent the circuit from being oxidized by moisture due to exposure to air or from being short-circuited by welding. To prevent unexpected light emission due to reflection of the solder mask ink layer 110 from a portion of the light emitted from the light-emitting element 120 during lateral transmission through the package layer 140, the light source module 10 has a plurality of microcavities CV1 embedded in a portion of the package layer 140 adjacent to the first surface 140s1. Note that the plurality of microcavities CV1 do not overlap the light-emitting surface 120es of the non-light-emitting element 120 along the normal direction (e.g., the Z direction) of the substrate surface 100s.

[0032] From another perspective, the plurality of microcavities CV1 are provided on opposite sides along an arbitrary direction (e.g., the X direction) parallel to the substrate surface 100s of the light-emitting element 120. For example, the plurality of microcavities CV1 can be arranged at intervals along an arbitrary direction (e.g., the X direction) parallel to the first surface 140s1 to form a plurality of reflective units U1, and the interval Su between any two adjacent microcavities CV1 of any reflective unit U1 along this arbitrary direction is larger than the interval Sc1 between any two adjacent microcavities CV1 of any reflective unit U1 along this arbitrary direction.

[0033] However, the present invention is not limited to this. In another embodiment, the spacing Su between any two adjacent reflective units U1 may be equal to or close to the spacing Sc1 between any two adjacent microcavities CV1 in each reflective unit U1. That is, the number and arrangement of the reflective units U1 near the first surface 140s1 can be adjusted according to the actual requirements of the light emission pattern, and the present invention is not limited to the content disclosed in the drawings.

[0034] For example, a portion of light L emitted from the light emitting element 120 is totally reflected by the second surface 140s2 of the package layer 140 and then transmitted toward the circuit board 100. By providing the microcavity CV1 of the reflecting unit U1, the light L can be totally reflected again by the cavity surface that defines the microcavity CV1 of the package layer 140 and guided again to the second surface 140s2 of the package layer 140. This reduces the possibility of unexpected light emission due to the light L emitted from the light emitting element 120 being reflected or scattered by the board surface 100s of the circuit board 100, and further improves the light guiding efficiency of the package layer 140.

[0035] In this embodiment, the spacing Sc1 along the arrangement direction (e.g., the X direction) of any two adjacent microcavities CV1 in each reflecting unit U1 may be the same, but the present invention is not limited to this. In a variant not shown, the microcavities CV1 in the same reflecting unit U1 may be arranged at the same spacing Sc1, but the microcavities CV1 in different reflecting units U1 may be arranged at different spacings Sc1. In other words, the arrangement spacing of the microcavities CV1 in each reflecting unit U1 can be individually designed depending on the position of the reflecting unit U1.

[0036] In the modified example shown in FIG. 3A, the spacing Sc1 between any two adjacent microcavities CV1 in the reflecting unit U1-A can gradually increase with increasing distance from the light-emitting element 120. If the cavity surface of the microcavity CV1 is smoother, the arrangement shown in FIG. 3A can guide the light L to an area further away from the light-emitting element 120. However, the present invention is not limited to this. In the modified example shown in FIG. 3B, the spacing Sc1 between any two adjacent microcavities CV1 in the reflecting unit U1-B can gradually decrease with increasing distance from the light-emitting element 120. This can improve the uniformity of the light L emitted in different areas of the package layer 140. In the modified example shown in FIG. 3C, any two adjacent microcavities CV1 in the reflecting unit U1-C can be offset from each other along the arrangement direction (e.g., the X direction). The offset design shown in FIG. 3C can also be applied to the reflecting units of FIG. 3A or 3B.

[0037] Meanwhile, in this embodiment, the structural shape of the microcavity CV1 of the reflective unit U1 is, for example, spherical (as shown in FIG. 2), but the present invention is not limited thereto. In a modified example shown in FIG. 3D, the structural shape of the microcavity CV1-D of the reflective unit U1-D may be elliptical. In a modified example shown in FIG. 3E, the structural shape of the microcavity CV1-E of the reflective unit U1-E may be conical. In a modified example shown in FIG. 3F, the structural shape of the microcavity CV1-F of the reflective unit U1-F may be irregular. In a modified example shown in FIG. 3G, the structural shape of the microcavity CV1-G of the reflective unit U1-G may be rectangular. In a modified example shown in FIG. 3H, the structural shape of the microcavity CV1-H of the reflective unit U1-H may be asymmetric conical.

[0038] 1 and 4, to ensure that the light L has a uniform light-emitting effect on the second surface 140s2 of the package layer 140, the light source module 10 may further include a plurality of microcavities CV2 embedded in the package 140. The plurality of microcavities CV2 are disposed on one side of the light-emitting surface 120es of the light-emitting element 120 and overlap the light-emitting surface 120es along the normal direction (e.g., the Z direction) of the substrate surface 100s. In this embodiment, the structural shape of the microcavities CV2 may be spherical, but the present invention is not limited thereto. In other embodiments, the structural shape of the microcavities CV2 may include any structural shape shown in the microcavities of FIGS. 3C to 3H, such as an ellipse (see FIG. 3D), a cone (see FIG. 3E), an irregular shape (see FIG. 3F), a square (see FIG. 3G), or an asymmetric cone (see FIG. 3H).

[0039] Each of the multiple microcavities CV2 also includes multiple imaginary planes VP1-VP4 arranged parallel to the light-emitting surface 120es, constituting a single dimming unit U2. In this embodiment, the multiple imaginary planes VP1-VP4 are arranged at equal intervals along the normal direction (e.g., the Z direction) of the light-emitting surface 120es, but the present invention is not limited to this. For example, the number of microcavities CV2 provided in each imaginary plane may increase with increasing distance from the light-emitting surface 120es. In other words, the multiple imaginary planes VP1-VP4 are named in ascending order according to the number of microcavities CV2 provided, namely, imaginary plane VP1, imaginary plane VP2, imaginary plane VP3, and imaginary plane VP4, respectively.

[0040] In this embodiment, any two adjacent microcavities CV2 in the same virtual plane along any direction parallel to the virtual plane (e.g., the X direction) have the same spacing Sc2, and two portions arranged along any two adjacent microcavities CV2 in each of the multiple virtual planes VP1 to VP4 of the multiple microcavities CV2 are offset from each other in the normal direction of the light-emitting surface 120es.

[0041] However, the present invention is not limited to this. In the modified example shown in Fig. 5A, the number of microcavities CV2 in each imaginary plane of the dimming unit U2-A may gradually decrease with increasing distance from the light-emitting surface 120es. That is, the multiple imaginary planes VP1 to VP4 are, in ascending order according to the number of microcavities CV2, imaginary plane VP4, imaginary plane VP3, imaginary plane VP2, and imaginary plane VP1. In the modified example shown in Fig. 5B, the number of microcavities CV2 in each imaginary plane of the dimming unit U2-B is the same.

[0042] In the modified example shown in FIG. 5C , the arrangement intervals of the multiple microcavities CV2 of the dimming unit U2-C in the same imaginary plane may be different. For example, the multiple microcavities CV2 include a first second microcavity (e.g., microcavity CV2-1), a second second microcavity (e.g., microcavity CV2-2), and a third second microcavity (e.g., microcavity CV2-3) arranged along an imaginary plane VP4. The first second microcavity and the second second microcavity are arranged adjacent to each other along the arrangement direction (e.g., the X direction) at an interval Sc2a, and the second second microcavity and the third second microcavity are arranged adjacent to each other along the arrangement direction at an interval Sc2b, where the interval Sc2a is different from the interval Sc2b. The arrangement of the microcavities CV2 in the imaginary planes VP1, VP2, and VP3 is similar to the arrangement in the imaginary plane VP4, and will not be described in detail here.

[0043] 6A to 6D show several modified examples in which the arrangement distribution of the multiple microcavities is similar to that of FIG. 5B. The difference is that in the dimming units of FIGS. 6A to 6D, the cavity surfaces of the multiple microcavities may have different surface roughnesses. In the dimming units of FIGS. 6A to 6C, the surface roughness of the cavity surfaces CV2s defining the microcavities of the package layer 140 varies depending on the distance between the virtual plane on which the microcavities are located and the light-emitting surface 120es.

[0044] For example, in the dimming unit U2-D of FIG. 6A, the surface roughness of the cavity surface CV2s of the microcavity gradually increases as the virtual plane on which it is located increases away from the light-emitting surface 120es. Specifically, the microcavities constituting the dimming unit U2-D include a first second microcavity (i.e., microcavity CV2a) arranged on the virtual plane VP1, a second second microcavity (i.e., microcavity CV2b) arranged on the virtual plane VP2, a third second microcavity (i.e., microcavity CV2c) arranged on the virtual plane VP3, and a fourth second microcavity (i.e., microcavity CV2d) arranged on the virtual plane VP4. The microcavities CV2a to CV2d are arranged in ascending order of the roughness of the cavity surface CV2s as follows: microcavity CV2a, microcavity CV2b, microcavity CV2c, and microcavity CV2d.

[0045] 6B, the surface roughness of the cavity surface CV2s of the microcavity gradually decreases as the virtual plane on which it is located moves away from the light-emitting surface 120es. That is, the multiple microcavities CV2a to CV2d are, in ascending order according to the roughness of the cavity surface CV2s, microcavity CV2d, microcavity CV2c, microcavity CV2b, and microcavity CV2a.

[0046] 6C, the surface roughness of the cavity surface CV2s of the microcavity first gradually increases and then gradually decreases as the virtual plane on which it is located moves away from the light-emitting surface 120es. For example, the multiple microcavities CV2a to CV2d are named, in ascending order according to the roughness of the cavity surface CV2s, as microcavity CV2a, microcavity CV2b, microcavity CV2d, and microcavity CV2c.

[0047] Unlike the dimming units of Figures 6A to 6C, in the dimming unit U2-G of Figure 6D, the multiple microcavities arranged in the same imaginary plane can have cavity surfaces with different surface roughnesses. For example, the multiple microcavities include a first second microcavity (e.g., microcavity CV2a) and a second second microcavity (e.g., microcavity CV2b) arranged in each imaginary plane, and the surface roughness of the cavity surface CV2s defining the first second microcavity of the package layer 140 can be different (e.g., larger) from the surface roughness of the cavity surface CV2s defining the second second microcavity. In another variation, the surface roughness of the cavity surface CV2s of each of the multiple microcavities arranged in the same imaginary plane can be divided into three or more levels according to the requirements of different light types.

[0048] The various micro-cavity arrangements mentioned above provide greater flexibility and variety in adjusting the light deflection, reflection and scattering capabilities of the dimming unit, thereby helping to meet different light emission requirements of the light source module.

[0049] 1 and 7, the light source module 10 further includes a plurality of microcavities CV3 embedded in a portion of the package layer 140 adjacent to the second surface 140s2. The microcavities CV3 are arranged at intervals along any direction parallel to the second surface 140s2 (e.g., the X direction) to form a plurality of refractive units U3. The refractive units U3 are adapted to emit light L at specific angles to meet different light emission requirements. In this embodiment, the microcavities CV3 constituting the refractive unit U3 may be arranged along the arrangement direction (e.g., the X direction) at the same intervals Sc3, but the present invention is not limited thereto. In the variation of FIG. 8A, the intervals Sc3 between any two adjacent microcavities CV3 constituting the refractive unit U3-A may gradually increase with increasing distance from the light emitting element 120. In the modification of FIG. 8B, the spacing Sc3 between any two adjacent microcavities CV3 constituting the refractive unit U3-B may gradually decrease with increasing distance from the light emitting element 120.

[0050] In this embodiment, the structural shape of the microcavity CV3 may be spherical, but the present invention is not limited thereto. In other embodiments, the structural shape of the microcavity CV3 may include any structural shape shown in the microcavities of Figures 3C to 3H, such as an ellipse (see Figure 3D), a cone (see Figure 3E), an irregular shape (see Figure 3F), a square (see Figure 3G), or an asymmetric cone (see Figure 3H).

[0051] The microcavities constituting the reflecting unit U1, the dimming unit U2, or the refractive unit U3 can be manufactured using a laser sintering process technology of a packaging material such as silicone, but the present invention is not limited thereto. Preferably, the size of the microcavities in any direction may be 10 micrometers or more and 100 micrometers or less.

[0052] Below, other embodiments will be presented to explain the present invention in detail, but the same components will be given the same symbols, and explanations of the same technical content will be omitted. For the omitted parts, please refer to the above-mentioned embodiments and will not be repeated below.

[0053] Fig. 9 is a schematic cross-sectional view of a light source module according to a second embodiment of the present invention. Referring to Fig. 9, the light source module 20 of this embodiment differs from the light source modules 10 of Figs. 1 and 4 in the compositional arrangement of the dimming units. Specifically, in the light source module 20 of this embodiment, the structural shapes of the microcavities provided on each imaginary plane of the dimming unit U2-H are different from each other.

[0054] For example, the imaginary planes VP1, VP2, VP3, VP4, and VP5 of the dimming unit U2-H are provided with microcavities CV2-E, CV2-D, CV2, CV2-G, and CV2-F, respectively. Note that the structural shape of the microcavity CV2-E is conical, the structural shape of the microcavity CV2-D is elliptical, the structural shape of the microcavity CV2 is spherical, the structural shape of the microcavity CV2-G is rectangular, and the structural shape of the microcavity CV2-F is irregular, but the present invention is not limited thereto.

[0055] In addition, the multiple microcavities CV2-F arranged on the virtual plane VP5 farthest from the light-emitting element 120 are suitable for scattering light to achieve the effect of atomizing light, and the microcavities CV2-E, CV2-D, CV2 and CV2-G arranged between the virtual plane VP5 and the light-emitting element 120 are suitable for refracting or reflecting light to achieve a functional and accurate deflection effect.

[0056] Fig. 10 is a schematic cross-sectional view of a light source module according to a third embodiment of the present invention. Fig. 11 is an enlarged schematic view of a partial region of the light source module of Fig. 10. Figs. 12A to 12C are schematic cross-sectional views of another modified example of the light source module of Fig. 11. Referring to Figs. 10 and 11, the light source module 30 of this embodiment differs from the light source module 10 of Fig. 1 in that the light source module 30 further includes a plurality of microcavities CV4 that are provided on one side facing the first surfaces 140s1 of the plurality of microcavities CV1 and are arranged at intervals along a direction parallel to the first surfaces 140s1 (e.g., the X direction) to form a refraction unit U4.

[0057] In addition, in the normal direction of the substrate surface 100s, a portion of the refractive unit U4 overlaps the reflective unit U1, and the refractive unit U4 and the reflective unit U1 are offset from each other. The distance d1 between the refractive unit U4 and the first surface 140s1 and the distance d2 between the refractive unit U4 and the second surface 140s2 are equal to or greater than the thickness t of one refractive unit U4. Preferably, the package layer 140 has a thickness 140t along the normal direction of the substrate surface 100s, and the ratios of the distances d1 and d2 to the thickness 140t are in the range of 0.5 to 0.95. That is, the refractive unit U4 is embedded in a portion of the package layer 140 that is farther away from the first surface 140s1 and the second surface 140s2. The provision of the refractive unit U4 can improve the concealer effect of the package layer 140.

[0058] In this embodiment, the spacing Sc4 between any two adjacent microcavities CV4 in each refraction unit U4 arranged along a direction parallel to the first surface 140s1 (e.g., the X direction) may be the same, but the present invention is not limited to this. In a modified example not shown, the microcavities CV4 in the same refraction unit U4 may be arranged at the same spacing Sc4, but the microcavities CV4 in different refraction units U4 may be arranged at different spacings Sc4. In other words, the spacing between the microcavities CV4 in each refraction unit U4 can be individually designed depending on the position of the refraction unit U4.

[0059] In the modified example shown in FIG. 12A, the spacing Sc4 between any two adjacent microcavities CV4 in the refractive unit U4-A may gradually increase as the distance from the light-emitting element 120 increases. However, the present invention is not limited to this. In the modified example shown in FIG. 12B, the spacing Sc4 between any two adjacent microcavities CV4 in the refractive unit U4-B may gradually decrease as the distance from the light-emitting element 120 increases. In the modified example shown in FIG. 12C, any two adjacent microcavities CV4 in the refractive unit U4-C may be offset from each other along the arrangement direction (e.g., the X direction). Note that the offset design shown in FIG. 12C can also be applied to the refractive units of FIG. 12A or 12B.

[0060] FIG. 13 is a cross-sectional schematic diagram of a light source module according to a fourth embodiment of the present invention. Referring to FIG. 13, the main difference between the light source module 40 of this embodiment and the light source module 10 of FIG. 1 is the structural shape of the second surface of the package layer. Specifically, in the light source module 40 of this embodiment, a plurality of surface microstructures SMS may be provided on the second surface 140s2 of the package layer 140A. The surface microstructures SMS may be, for example, convex structures protruding from the second surface 140s2, but the present invention is not limited thereto. In other embodiments, the surface microstructures SMS may be concave structures recessed from the second surface 140s2 toward the inside of the package layer 140A. Meanwhile, in this embodiment, the board surface 100s of the circuit board 100 is not covered with the solder mask ink layer 110 shown in FIG. 1, and the package layer 140A directly covers the circuit layer (not shown) of the circuit board 100.

[0061] In this embodiment, the surface microstructures SMS are, for example, microlens structures, but the present invention is not limited thereto. In other embodiments, the structural shape of the surface microstructures SMS can include boss structures, groove structures, or other suitable convex or concave structures, or a combination thereof.

[0062] In this embodiment, the microcavities CV3 adjacent to the second surface 140s2 are embedded in the surface microstructures SMS and are equiangularly arranged along the surface microstructure SMS of the second surface 140s2. The microcavities CV3 may be arranged in the refractive units U3-A1 and U3-A2, and the refractive units embedded in different surface microstructures SMS may have different arrangement patterns. For example, in the refractive unit U3-A1 embedded in the surface microstructure SMS closer to the light-emitting element 120, the microcavities CV3 are arranged at approximately equal intervals. However, in the refractive unit U3-A2 embedded in the surface microstructure SMS farther from the light-emitting element 120, the arrangement intervals of the microcavities CV3 gradually increase with increasing distance from the light-emitting element 120. However, the present invention is not limited to this. In other embodiments, the arrangement pattern of the microcavities in the refractive units may be adjusted according to actual light-emitting requirements.

[0063] Fig. 14 is a schematic cross-sectional view of a light source module according to a fifth embodiment of the present invention. Referring to Fig. 14, the light source module 10A of this embodiment differs from the light source module 10 of Fig. 1 in that the light source module 10A of this embodiment further includes a plurality of microparticles disposed in a plurality of microcavities, and the refractive index of the plurality of microparticles is different from the refractive index of the packaging layer.

[0064] For example, in this embodiment, the microcavity CV1 of the reflective unit U1 can be filled with microparticles MP1, the microcavity CV2 of the dimming unit U2 can be filled with microparticles MP2, and the microcavity CV3 of the refractive unit U3 can be filled with microparticles MP3. In this embodiment, the refractive indices of the microparticles MP1, MP2, and MP3 can be approximately the same, but the present invention is not limited thereto. In other embodiments, the refractive indices of the microparticles MP1, MP2, and MP3 can be different from one another. In some embodiments, multiple microparticles in the same reflective unit U1, dimming unit U2, or refractive unit U3 can have different refractive indices.

[0065] It should be noted that in some embodiments, the microparticles can have a gradually varying refractive index distribution in the microcavity, although the invention is not limited thereto, and in other embodiments, the microparticles can have a uniform refractive index distribution in the microcavity.

[0066] In summary, in the light source module of one embodiment of the present invention, the package layer has a first surface directly covering the substrate surface of the circuit board, and a plurality of microcavities are provided in a portion of the package layer adjacent to the first surface, thereby effectively avoiding unexpected light emission caused by poor reflection of part of the light at the first surface of the package layer. [Industrial Applicability]

[0067] The light source module of the present invention can be used as an illumination light source for a non-emissive display panel. [Explanation of symbols]

[0068] 10, 10A, 20, 30, 40: Light source module 100: Circuit board 100s: Substrate surface 110: Solder mask ink layer 120: Light emitting element 120es: Light-emitting surface 140, 140A: Package layer 140s1: 1st surface 140s2: 2nd surface A1, A2, A3, A4: Area CV1, CV2, CV3, CV1-D, CV1-E, CV1-F, CV1-G, CV1-H, CV2-1, CV2-2, CV2-3, CV2a, CV2b, CV2c, CV2d, CV2-D, CV2-E, CV2-F, CV2-G, CV3, CV4: Microcavity CV2s: Cavity surface d1, d2: distance L:Light MP1, MP2, MP3: Microparticles Sc1, Su, Sc2, Sc2a, Sc2b, Sc3, Sc4: Interval SMS: Surface Microstructure t, 140t: thickness U1, U1-A, U1-B, U1-C, U1-D, U1-E, U1-F, U1-G, U1-H: Reflection unit U2, U2-A, U2-B, U2-C, U2-D, U2-E, U2-F, U2-G, U2-H: Dimming unit U3, U3-A, U3-A1, U3-A2, U3-B, U4, U4-A, U4-B, U4-C: Refraction units VP1, VP2, VP3, VP4, VP5: Virtual planes X, Z: direction

Claims

1. A circuit board; a light-emitting element provided on a surface of the circuit board and electrically connected to the circuit board; a package layer that directly covers the substrate surface and the light-emitting surface of the light-emitting element, and has a first surface connected to the substrate surface and a second surface opposite to the first surface; a plurality of microcavities embedded in the package layer, at least a portion of which is adjacent to the first surface and does not overlap with the light emitting surface of the light emitting device along a normal direction of the substrate surface; Including, a light source module, wherein at least some of the plurality of microcavities include a plurality of first microcavities, the plurality of first microcavities being adjacent to the first surface and arranged at intervals in a direction parallel to the first surface to form reflective units, the plurality of reflective units being arranged at intervals along the direction, and the spacing between any two adjacent reflective units of the plurality of first microcavities along the direction being greater than the spacing between any two adjacent reflective units of the plurality of first microcavities along the direction.

2. The light source module according to claim 1 , wherein the distance between any two adjacent ones of the plurality of first microcavities gradually decreases or increases with increasing distance from the light emitting element.

3. The light source module of claim 1 , wherein any two adjacent ones of the plurality of first microcavities are offset from each other along the direction.

4. 2. The light source module of claim 1, wherein the plurality of microcavities further include a plurality of second microcavities arranged on one side opposite the first surface of the plurality of first microcavities and spaced apart along the direction to form a refractive unit, and the distance between the refractive unit and the first surface or the second surface in the normal direction of the substrate surface is equal to or greater than the thickness of the refractive unit.

5. The light source module according to claim 4 , wherein the interval between any two adjacent ones of the plurality of second microcavities gradually decreases or increases with increasing distance from the light emitting element.

6. The light source module according to claim 4 , wherein any two adjacent ones of the plurality of second microcavities are offset from each other along the direction.

7. The light source module according to claim 4 , wherein a portion of the refractive unit overlaps the reflecting unit in the normal direction of the substrate surface, and the refractive unit and the reflecting unit are offset from each other.

8. 2. The light source module of claim 1, wherein the plurality of microcavities further include a plurality of second microcavities arranged on one side of the light-emitting surface of the light-emitting element, and in the normal direction of the substrate surface, a dimming unit formed by the plurality of second microcavities overlaps the light-emitting surface.

9. 9. The light source module of claim 8, wherein the plurality of second microcavities are arranged along a plurality of imaginary planes parallel to the light-emitting surface, the plurality of imaginary planes are arranged at intervals along a normal direction of the light-emitting surface, and the number of the plurality of second microcavities arranged in each of the plurality of imaginary planes gradually increases or decreases with increasing distance from the light-emitting surface.

10. The light source module according to claim 9 , wherein two portions of each of the second microcavities arranged along any two adjacent ones of the plurality of imaginary planes are offset from each other in the normal direction of the light-emitting surface.

11. 9. The light source module of claim 8, wherein the plurality of second microcavities are arranged along a plurality of imaginary planes parallel to the light-emitting surface, the plurality of imaginary planes are arranged at intervals along the normal direction of the light-emitting surface, and the number of imaginary planes installed in each of the plurality of second microcavities is the same.

12. 12. The light source module of claim 11, wherein the plurality of second microcavities further include a first second microcavity, a second second microcavity, and a third second microcavity arranged along each of the plurality of imaginary planes, the first second microcavity and the second second microcavity being arranged adjacent to each other along the direction at a first interval, and the second second microcavity and the third second microcavity being arranged adjacent to each other along the direction at a second interval, and the first interval being different from the second interval.

13. 9. The light source module of claim 8, wherein the plurality of second microcavities are respectively arranged along a plurality of imaginary planes parallel to the light-emitting surface, the plurality of imaginary planes being arranged at intervals along a normal direction of the light-emitting surface, the plurality of second microcavities including a first second microcavity provided on one imaginary plane of the plurality of imaginary planes and a second second microcavity provided on another imaginary surface of the plurality of imaginary planes, and the structural shape of the first second microcavity is different from the structural shape of the second second microcavity.

14. 14. The light source module of claim 13, wherein one of the plurality of imaginary planes is located between another of the plurality of imaginary planes and the light-emitting element, the structural shape of the first of the plurality of second microcavities includes a spherical shape, a conical shape, an elliptical shape, or a rectangular shape, and the structural shape of the second of the plurality of second microcavities includes an asymmetric conical shape or an irregular shape.

15. 9. The light source module of claim 8, wherein the plurality of second microcavities are respectively arranged along a plurality of imaginary planes parallel to the light-emitting surface, the plurality of imaginary planes being arranged at intervals along a normal direction of the light-emitting surface, the plurality of second microcavities including a first second microcavity provided in one imaginary plane of the plurality of imaginary planes and a second second microcavity provided in another imaginary plane of the plurality of imaginary planes, the package layer having a first cavity surface defining the first second microcavity and a second cavity surface defining the second second microcavity, and the surface roughness of the first cavity surface being different from the surface roughness of the second cavity surface.

16. 9. The light source module of claim 8, wherein the plurality of second microcavities are respectively arranged along a plurality of imaginary planes parallel to the light-emitting surface, the plurality of imaginary planes being arranged at intervals along a normal direction of the light-emitting surface, the plurality of second microcavities including a first second microcavity and a second second microcavity provided in each of the plurality of imaginary planes, the package layer having a first cavity surface defining the first second microcavity and a second cavity surface defining the second second microcavity, and the surface roughness of the first cavity surface being different from the surface roughness of the second cavity surface.

17. A light source module as described in claim 1, wherein the plurality of microcavities further include a plurality of second microcavities, which are arranged adjacent to the second surface and spaced apart in a direction parallel to the second surface to form a refractive unit.

18. 18. The light source module of claim 17, wherein the second surface of the packaging layer is provided with a surface microstructure, and the plurality of second microcavities are embedded in the surface microstructure and are equiangularly arranged along a portion of the second surface that defines the surface microstructure.

19. The light source module of claim 1 , further comprising a plurality of microparticles filled in the plurality of microcavities, the refractive index of the plurality of microparticles being different from the refractive index of the packaging layer.

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