Optical assembly, display panel, and method for manufacturing optical assembly

Abstract

Provided is an optical assembly comprising: a light source substrate on which an LED is mounted; and a light source lens covering the LED and having a curved upper surface, wherein the light source lens includes an anisotropic lens of which the length in a first direction is longer than the length in a second direction perpendicular to the first direction.

Description

Optical assembly, display panel and method for manufacturing optical assembly

[0001] The present invention relates to an optical assembly having an improved shape of a light source lens covering an LED, a display device including the same, and a method for manufacturing the optical assembly.

[0002] As the information society develops, the demand for display devices is also increasing in various forms, and in response to this, recent display devices include liquid crystal displays (LCDs), field emission displays (FEDs), plasma display panels (PDPs), and electroluminescence devices.

[0003] The liquid crystal panel of a liquid crystal display device includes a liquid crystal layer and a TFT substrate and a color filter substrate facing each other with the liquid crystal layer in between, and can display images using light provided by a backlight unit. Liquid crystal displays are used in a variety of devices, ranging from televisions, laptop computers, desktop computer monitors, and mobile phones. The backlight unit is a device that is attached to the back of the display panel and forms light provided by a light source into a uniform surface light source and provides it to the liquid crystal panel.

[0004] As a light source, light-emitting diodes (LEDs) are attracting attention as a new material due to their environmental friendliness, ability to display a wide range of colors, and reduced power consumption. Light-emitting diodes (LEDs) are well-known semiconductor light-emitting devices that convert electric current into light. Compared to filament-based LEDs, they offer various advantages, including a long lifespan, low power consumption, excellent initial operating characteristics, and high vibration resistance.

[0005] Recently, the brightness of the backlight unit can be increased by using mini LEDs measuring 100-500 micrometers (μm), which are about one-tenth the size of a regular LED chip.

[0006] However, existing mini LEDs have a limitation in that they have low autonomy in LED arrangement and quantity due to their arrangement close to a square. Therefore, in order to increase the autonomy in LED arrangement, it is necessary to control the shape of light diffusion emitted from a single LED so that it is not square but spreads in a specific direction.

[0007] The purpose of the present invention is to provide an optical assembly capable of diffusion of light in an anisotropic shape by improving the shape of a light source lens covering an LED, and a method for manufacturing a display device and an optical assembly including the same.

[0008] An optical assembly is provided, comprising: a light source substrate on which an LED is mounted; and a light source lens covering the LED and having a curved upper surface, wherein the light source lens includes an anisotropic lens in which a length in a first direction is longer than a length in a second direction perpendicular to the first direction.

[0009] The light source lens may have a diffusion angle in the first direction that is greater than a diffusion angle in the second direction.

[0010] The light source lens may include a concave portion located at the center of the first direction; and a pair of top portions located on both sides of the concave portion in the first direction and having a higher height than the concave portion.

[0011] The second direction length of the above concave portion may be shorter than the second direction length of the above top portion.

[0012] The spacing between the pair of tops may be greater than the length of the first direction of the LED.

[0013] The above pair of tops may have different heights.

[0014] The air layer between the LED and the light source lens can be omitted and sealed.

[0015] The above LED may have a long length in the first direction.

[0016] The length of the light source lens in the first direction may be at least 1.3 times the length in the second direction.

[0017] The above LEDs are arranged in multiple numbers in an array in the first and second directions.

[0018] The plurality of LEDs may have a spacing in the first direction greater than a spacing in the second direction.

[0019] The above light source lens may include at least one of silicone, polymethyl methacrylate (PMMA), or polycarbonate (PC).

[0020] The anisotropic lens positioned at the edge portion of the light source substrate can be arranged so that the first direction faces the edge.

[0021] The above light source lens may include an anisotropic lens disposed adjacent to an edge of the light source substrate; and an isotropic lens disposed at a central portion of the light source substrate.

[0022] A display device is provided, comprising: a display panel; a backlight unit positioned on the back surface of the display panel and emitting light; the backlight unit comprising: a light source substrate on which an LED is mounted; a light source lens covering the LED and having a curved upper surface; and an optical sheet converting light emitted from the LED into a uniform surface light source; and the light source lens including an anisotropic lens having a length in a first direction longer than a length in a second direction perpendicular to the first direction.

[0023] A method for manufacturing a light source, comprising: a step of mounting an LED on a light source substrate; a step of forming a light source lens that covers the LED; and a step of forming the light source lens, wherein the step of dispensing a resin at a first position spaced apart from the LED to one side in a first direction; and a step of dispensing a resin at a second position spaced apart from the light source to the other side in the first direction.

[0024] The distance between the first position and the second position may be longer than the length of the LED in the first direction.

[0025] The step of mounting the above LED may be performed by mounting the LED on the light source substrate so that the longitudinal direction of the LED faces the first direction.

[0026] The step of dispensing resin between the first position and the second position may further be included.

[0027] The optical assembly of the present invention can implement light that is diffused in an anisotropic shape.

[0028] In addition, the optical assembly of the present invention can easily implement a light source lens of an anisotropic shape.

[0029] In addition, the optical assembly of the present invention has the advantage of increasing the degree of freedom in arranging LEDs.

[0030] The effects that can be obtained from the present invention are not limited to the effects mentioned above, and other effects not mentioned can be clearly understood by a person having ordinary skill in the art to which the present invention belongs from the description below.

[0031] Fig. 1 is a perspective view showing an example of a display device of the present invention.

[0032] Figure 2 is an exploded perspective view showing an example of a display device of the present invention.

[0033] Figure 3 is an embodiment of a backlight unit of a display device.

[0034] FIG. 4 is a drawing illustrating another embodiment of a backlight unit of a display device.

[0035] Figure 5 is a drawing illustrating a conventional optical assembly.

[0036] FIG. 6 is a drawing illustrating a first embodiment of the optical assembly of the present invention.

[0037] FIG. 7 is a drawing illustrating a method for manufacturing the optical assembly of FIG. 6.

[0038] FIG. 8 is a drawing illustrating a second embodiment of the optical assembly of the present invention.

[0039] Fig. 9 is a drawing showing the path of light in the light source lens according to the embodiment of Fig. 8.

[0040] Fig. 10 is a drawing illustrating a third embodiment of the optical assembly of the present invention.

[0041] Fig. 11 is a diagram schematically illustrating the features of embodiments of the optical assembly of the present invention.

[0042] Fig. 12 is a graph showing the brightness of an anisotropic lens implemented in embodiments of the optical assembly of the present invention.

[0043] Fig. 13 is a plan view illustrating the optical assembly of the present invention.

[0044] Hereinafter, embodiments disclosed in this specification will be described in detail with reference to the attached drawings. Regardless of the drawing numbers, identical or similar components will be given the same reference numbers, and redundant descriptions thereof will be omitted. The suffixes "module" and "part" used for components in the following description are assigned or used interchangeably only for the convenience of writing the specification, and do not in themselves have distinct meanings or roles. In addition, when describing the embodiments disclosed in this specification, if it is determined that a specific description of a related known technology may obscure the gist of the embodiments disclosed in this specification, a detailed description thereof will be omitted. In addition, the attached drawings are only intended to facilitate easy understanding of the embodiments disclosed in this specification, and the technical ideas disclosed in this specification are not limited by the attached drawings, and should be understood to include all modifications, equivalents, and substitutes included in the spirit and technical scope of the present invention.

[0045] Terms that include ordinal numbers, such as first, second, etc., may be used to describe various components, but the components are not limited by these terms. These terms are used solely to distinguish one component from another.

[0046] When a component is referred to as being "connected" or "connected" to another component, it should be understood that it may be directly connected or connected to that other component, but that there may be other components intervening. Conversely, when a component is referred to as being "directly connected" or "connected" to another component, it should be understood that there are no other components intervening.

[0047] Singular expressions include plural expressions unless the context clearly indicates otherwise.

[0048] In this application, terms such as “include” or “have” are intended to specify the presence of a feature, number, step, operation, component, part or combination thereof described in the specification, but should be understood not to exclude in advance the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts or combinations thereof.

[0049] Meanwhile, the display device (100) described herein is an intelligent display device (100) that adds computer support functions to, for example, a broadcast reception function. While remaining faithful to the broadcast reception function, it can be equipped with an Internet function and other functions, thereby providing a more convenient interface such as a manual input device, touch screen, or space remote control. In addition, it can be connected to the Internet and a computer with support for wired or wireless Internet functions, and can perform functions such as email, web browsing, banking, or games. A standardized, general-purpose operating system (OS) can be used for these various functions.

[0050] Accordingly, the display device (100) described in the present invention can perform various user-friendly functions, for example, since various applications can be freely added or deleted on a general-purpose OS kernel. More specifically, the display device (100) can be, for example, a network TV, HBB TV, smart TV, etc., and in some cases, can also be applied to a smartphone.

[0051] Fig. 1 is a front perspective view illustrating an example of a display device of the present invention. The display device (100) of the present invention may have a rectangular body including a pair of long sides and a pair of short sides. It may include a first long side (First Long Side, LS1), a second long side (Second Long Side, LS2) opposite the first long side (LS1), a first short side (First Short Side, SS1) adjacent to the first long side (LS1) and the second long side (LS2), and a second short side (Second Short Side, SS2) opposite the first short side (SS1).

[0052] Although the long side extending horizontally and the short side extending vertically are depicted in the drawing, the long side and the short side may be of equal length, and the long side may also be arranged vertically.

[0053] For convenience of explanation, the long side is defined as the side extending in the horizontal direction (x-axis direction) and the short side is defined as the side extending in the vertical direction (y-axis direction). However, as mentioned above, the present invention is not limited thereto.

[0054] The first direction (DR1) may be a direction parallel to the long side (LS1, LS2) of the display panel (100), and the second direction (DR2) may be a direction parallel to the short side (SS1, SS2) of the display panel (100). The third direction (DR3) may be a direction perpendicular to the first direction (DR1) and / or the second direction (DR2).

[0055] The side of the display device (100) that displays an image may be referred to as the front or front surface. When the display device (100) displays an image, the side from which the image cannot be observed may be referred to as the rear or back surface. When the display device displays an image, the side from which the image cannot be observed may be referred to as the rearward direction or rear side (rear surface).

[0056] When viewing the display from the front or front, the first long side (LS1) may be referred to as the upper side or upper surface. Similarly, the second long side (LS2) may be referred to as the lower side or lower surface. Similarly, the first short side (SS1) may be referred to as the right side or right surface, and the second short side (SS2) may be referred to as the left side or left surface.

[0057] The display device may include a display unit (120) that outputs images. The control unit (180) may convert image signals, data signals, OSD signals, control signals, or the like processed by the control unit or received from the interface unit to generate a driving signal. The display unit (150) may include a display panel having a plurality of pixels.

[0058] The plurality of pixels provided on the display panel may have RGB sub-pixels. Alternatively, the plurality of pixels provided on the display panel may have RGBW sub-pixels. The display unit (150) may convert image signals, data signals, OSD signals, control signals, etc. processed by the control unit (180) to generate driving signals for the plurality of pixels.

[0059] The display device (100) includes a display unit (120) that occupies most of the front surface area and a case that covers the rear side of the display unit (120) and packages the display unit (120).

[0060] The display unit (150) can be a PDP (Plasma Display Panel), LCD (Liquid Crystal Display), OLED (Organic Light Emitting Diode), a flexible display, etc., and may also be a 3D display. The 3D display unit (150) can be divided into a glasses-free type and a glasses type.

[0061] LCD displays rely on a backlight unit to supply light, as LCDs are unable to emit light on their own. A backlight unit is a device that evenly distributes light from a light source to the liquid crystal display located at the front. As backlight units become thinner, thinner LCDs can be realized.

[0062] Fig. 2 is an exploded view of the display device of the present invention. Referring to Fig. 2, the display unit (120) of the present invention is an LCD display including a display panel (510) and a backlight unit (520).

[0063] The front cover (110) may cover at least a portion of the front and side surfaces of the display panel (510). The front cover (110) may be divided into a front cover positioned on the front side of the display panel (510) and a side cover positioned on the side surface of the display panel (510). The front cover and the side cover may be configured separately. Either the front cover or the side cover may be omitted.

[0064] A display panel (510) is provided on the front of a display device (100) and can display an image. The display panel (510) can display an image by having a plurality of pixels output RGB (red, green, or blue) according to timing for each pixel. The display panel (510) can be divided into an active area where an image is displayed and a de-active area where an image is not displayed. The display panel (510) can include a front substrate and a rear substrate that face each other with a liquid crystal layer therebetween.

[0065] The front substrate may include a plurality of pixels each composed of red (R), green (G), and blue (B) sub-pixels. The front substrate may output light corresponding to the color red, green, or blue according to a control signal.

[0066] The rear substrate may include switching elements. The rear substrate may switch the pixel electrode. For example, the pixel electrode may change the molecular arrangement of the liquid crystal layer according to an externally applied control signal. The liquid crystal layer may include liquid crystal molecules. The liquid crystal molecules may change their arrangement in response to a voltage difference generated between the pixel electrode and the common electrode. The liquid crystal layer may transmit light provided from the backlight unit (520) to the front substrate or block it.

[0067] The backlight unit (520) may be positioned at the rear of the display panel (510). The backlight unit (520) may include light sources. The backlight unit (520) may be coupled to the frame (130) at the front of the frame (130).

[0068] The backlight unit (520) may be driven in a full driving manner or in a partial driving manner such as local dimming, impulsive, etc. The backlight unit (520) may include an optical sheet (521) and an optical layer (522).

[0069] A guide panel (530) may be included to align the positions of the display panel (510) and the backlight unit (520). The guide panel (530) has a frame shape with four sides, and the display panel (510) and the backlight unit (520) can be mounted on the front.

[0070] The optical sheet (521) can ensure that light from a light source is evenly transmitted to the display panel (510). The optical sheet (521) may be composed of layers. For example, the optical sheet (521) may include a prism sheet, a diffusion sheet, etc.

[0071] The optical sheet (521) may be provided with a coupling portion. The coupling portion may be coupled to the front cover (110), the frame (130), and / or the back cover (120). Alternatively, the coupling portion may be fastened to a structure formed or coupled on the front cover (110), the frame (130), and / or the back cover (120).

[0072] The frame (130) may serve to support components of the display device (100). For example, components such as a backlight unit (520) may be combined with the frame (130). The frame (130) may be made of a metal material such as an aluminum alloy.

[0073] The back cover (120) may be located on the back or rear of the display device (100). The back cover (120) may be coupled to the frame (130) and / or the front cover (110). For example, the back cover (120) may be an injection-molded product made of resin material.

[0074] FIG. 3 is a drawing illustrating one embodiment of a backlight unit (520) of a display device (100).

[0075] The backlight unit (520) may include an optical layer (522) including an optical assembly (524), a reflective sheet (525), and a diffuser plate (526), ​​and an optical sheet (521) positioned on the front side of the optical layer (522).

[0076] This embodiment is characterized in that a direct-type backlight unit (520) is arranged in an array with a light assembly (524) toward the back of a display panel (510). The light assembly (524) may include a light source substrate (5241) and a light source (5242) mounted on the substrate.

[0077] The light source substrate (5241) may be configured in the form of a plurality of straps extending in a first direction and spaced apart at a predetermined interval in a second direction perpendicular to the first direction.

[0078] At least one light source (5242) may be mounted on the light source substrate (5241). An electrode pattern for connecting the adapter and the light source (5242) may be formed on the light source substrate (5241). For example, a carbon nanotube electrode pattern for connecting the light source (5242) and the adapter may be formed on the light source substrate (5241).

[0079] The light source substrate (5241) may be composed of at least one of polyethylene terephthalate (PET), glass, polycarbonate (PC), and silicon. The light source substrate (5241) may be a printed circuit board (PCB) on which at least one light source (5242) is mounted.

[0080] On the light source substrate (5241), light sources (5242) may be arranged at a predetermined interval in the first direction. The diameter of the light source (5242) may be larger than the width of the light source substrate (5241). That is, it may be larger than the length of the light source substrate (5241) in the second direction.

[0081] The light source (5242) may be a light emitting diode (LED) chip or a light emitting diode package including at least one light emitting diode chip.

[0082] The light source (5242) may be comprised of a colored LED or a white LED that emits at least one color, such as red (R), blue (B), or green (G). The colored LED may include at least one of a red LED, a blue LED, and a green LED.

[0083] A reflective sheet (525) may be positioned on the front side of the light source substrate (5241). The reflective sheet (525) may be positioned on an area of ​​the light source substrate (5241) excluding an area where a light source (5242) is formed. The reflective sheet (525) may have a plurality of through holes (525a).

[0084] The reflective sheet (525) can reflect light emitted from the light source (5242) toward the front side. In addition, the reflective sheet (525) can re-reflect light reflected from the diffuser plate (526).

[0085] A diffuser supporter (525b) may be further included to maintain a gap between the light source (5242) and the diffuser (526) so that light from the light source (5242) is evenly supplied to the back surface of the diffuser (526).

[0086] The reflective sheet (525) may include at least one of a metal and a metal oxide that is a reflective material. For example, the reflective sheet (525) may include a metal and / or metal oxide having a high reflectivity, such as at least one of aluminum (Al), silver (Ag), gold (Au), and titanium dioxide (TiO2).

[0087] A resin may be deposited on the light source (5242) and / or the reflective sheet (525). The resin may serve to diffuse light emitted from the light source (5242). The diffuser plate (526) may diffuse light emitted from the light source (5242) upward.

[0088] The optical sheet (521) may be positioned in front of the diffuser plate (526). The rear surface of the optical sheet (521) may be in close contact with the diffuser plate (526), ​​and the front surface of the optical sheet (521) may be in close contact with the rear surface of the display panel (510, see FIG. 1).

[0089] The optical sheet (521) may include at least one sheet. Specifically, the optical sheet (521) may include one or more prism sheets and / or one or more diffusion sheets. The plurality of sheets included in the optical sheet (521) may be in an adhesive and / or closely adhered state.

[0090] The optical sheet (521) may be composed of multiple sheets having different functions. For example, the optical sheet (521) may include first to third optical sheets (521a to 521c). For example, the first optical sheet (521a) may be a diffusion sheet, and the second and third optical sheets (521b, 521c) may be prism sheets. The number and / or positions of the diffusion sheets and prism sheets may be changed.

[0091] The diffusion sheet (521) can prevent light from being partially concentrated from the diffusion plate (526), ​​thereby making the light distribution more uniform. The prism sheet can collect light from the diffusion sheet and provide light to the display panel (510).

[0092] The coupling portion may be formed on at least one of the edges or sides of the optical sheet (521). The coupling portion may be formed on at least one of the first to third optical sheets (521a to 521c).

[0093] The bonding portion may be formed on the long side of the optical sheet (521). The bonding portion formed on the first long side and the bonding portion formed on the second long side may be asymmetric. For example, this means that the positions and / or numbers of the bonding portions on the first long side and the bonding portions on the second long side may be different from each other.

[0094] Fig. 4 is a drawing illustrating another embodiment of a backlight unit (520) of a display device (100). The backlight unit (520) of this embodiment is an edge-type backlight unit (520) in which the light assembly (524) exists only in the lateral direction.

[0095] The light source substrate (5241) may be positioned on at least one side of another configuration of the optical layer (522). The light source substrate (5241) may have a light source (5242) and an electrode pattern formed thereon for connecting the adapter and the light source (5242). For example, a carbon nanotube electrode pattern may be formed on the light source substrate (5241) for connecting the light source (5242) and the adapter. For example, the light source substrate (5241) may be a printed circuit board (PCB).

[0096] Light sources (5242) may be arranged at predetermined intervals on the light source substrate (5241). The light sources (5242) may be smaller than the thickness of the light guide plate (528). Therefore, most of the light provided from the light sources (5242) may be transmitted to the light guide plate (528).

[0097] The light source (5242) may be a light emitting diode (LED) chip or a light emitting diode package including at least one light emitting diode chip.

[0098] The light source (5242) may be comprised of a colored LED that emits at least one color, such as red, blue, green, or a white LED.

[0099] The light source included in the light source (5242) may be a COB (Chip On Board) type. The COB type may be a form in which an LED chip, which is a light source, is directly bonded to the light source substrate (5241). Therefore, the process can be simplified. In addition, resistance can be lowered, thereby reducing energy lost as heat. In other words, this means that the power efficiency of the light source (5242) can be increased. The COB type can provide brighter lighting. The COB type can be implemented thinner and lighter than the conventional one.

[0100] The light guide plate (528) can widely spread the light incident from the light source (5242). The reflective sheet (525) can be positioned at the rear of the light guide plate (528). The reflective sheet (525) can reflect the light provided from the light source (5242). The reflective sheet (525) can reflect the light incident from the light guide plate (528) back to the front of the light guide plate (528).

[0101] The reflective sheet (525) may include at least one of a metal and a metal oxide that is a reflective material. For example, the reflective sheet (525) may include a metal and / or metal oxide having a high reflectivity, such as at least one of aluminum (Al), silver (Ag), gold (Au), and titanium dioxide (TiO2).

[0102] The reflective sheet (525) may be formed by depositing and / or coating a metal or metal oxide. The reflective sheet (525) may be printed with ink containing a metal material. The reflective sheet (525) may have a deposition layer formed using a vacuum deposition method such as a thermal deposition method, an evaporation method, or a sputtering method. The reflective sheet (525) may have a coating layer and / or a printed layer formed using a printing method, a gravure coating method, or a silk screen method.

[0103] A diffuser plate (not shown) may be further included on the front of the light guide plate (528). The diffuser plate may diffuse light emitted from the light guide plate (528) forward.

[0104] An air gap may be positioned between the light guide plate (528) and the optical sheet (521). The air gap may disperse light emitted from the light source (5242).

[0105] The optical sheet (521) may be positioned in front of the light guide plate (528). The back side of the optical sheet (521) may face the light guide plate (528), and the front side of the optical sheet (521) may face the back side of the display panel (510).

[0106] The optical sheet (521) may include at least one sheet. The optical sheet (521) may include one or more prism sheets and / or one or more diffusion sheets. The plurality of sheets included in the optical sheet (521) may be in a state of being adhered and / or in close contact with each other.

[0107] For example, the optical sheet (521) may include first to third optical sheets (521a to 521c). The first optical sheet (521a) may be a diffusion sheet, and the second and third optical sheets (521b, 521c) may be prism sheets. The number and / or positions of the diffusion sheets and prism sheets may be changed.

[0108] The diffusion sheet (521a) can prevent light from being partially concentrated from the light guide plate (528) to ensure uniform light distribution. The prism sheets (521b, 521c) can collect light from the diffusion sheet (521a) and provide light toward the display panel (510).

[0109] Fig. 5 is a drawing illustrating a conventional optical assembly (524). Fig. 5 (a) is a plan view, (b) is a bb cross-sectional view of (a), and (c) is a cc cross-sectional view of (a).

[0110] A light source lens (5243) covering the upper surface of the light source may be included so that the light emitted from the LED (5242), which is the light source of the light assembly (524), can be widely diffused. Here, the upper surface may refer to the direction in which the light source emits light, i.e., the surface of the light source substrate (5241) on which the light source is mounted. Since an LED (5242) can be used as the light source, the light source may be expressed as an LED (5242) hereinafter.

[0111] The light source lens (5243) covers the LED (5242) and can be configured to have a dome shape. The conventional light source lens (5243) for a backlight unit was manufactured separately and then attached to the upper surface of the LED (5242).

[0112] However, as the size of the LED (5242) became smaller, the size of the lens also became smaller, making it difficult to manufacture and attach the lens separately. Therefore, a light source lens (5243) could be manufactured by dispensing resin (R) onto the LED (5242). Here, dispensing refers to a method of applying a small amount of liquid by dropping it in the form of water droplets.

[0113] The resin (R) dispensed on the upper surface of the LED (5242) forms a dome shape due to surface tension and is positioned on the light source substrate (5241). When the resin is cured in the dome shape, a solid light source lens (5243) can be implemented. The conventional light source lens (5243) dispensed the resin directly above the LED (5242) and used an isotropic light source lens (5243) with the same shape in all directions, as shown in Fig. 5.

[0114] The isotropic light source lens (5243) forms an array, and the multiple LEDs (5242) arranged therein are limited to a grid arrangement close to a square. When the isotropic light source lens (5243) is used, the degree of freedom in the design of the light source substrate (5241) is reduced, and the amount of light source substrate (5241) used increases, which causes an increase in component costs. In addition, there is also a problem that a dark area occurs in the center of the square grid arrangement of the multiple LEDs (5242).

[0115] Accordingly, the present invention requires the application of an anisotropic light source lens (5243) to the light assembly (524) so ​​that the light emitted from the LED (5242) can be further diffused in a desired direction, thereby increasing the degree of freedom in the arrangement of the LED (5242).

[0116] Fig. 6 is a drawing illustrating a first embodiment of the optical assembly (524) of the present invention. Fig. 6 (a) is a plan view, (b) is a bb cross-sectional view of (a), and (c) is a cc cross-sectional view of (a).

[0117] The optical assembly (524) according to the embodiment illustrated in FIG. 6 includes an elliptical light source lens (5243) whose length in the first direction (D1) is longer than that in the second direction (D2) perpendicular to the first direction (D1). The length in the first direction may be 1.3 times or more the length in the second direction. Here, the first direction (D1) and the second direction (D2) may mean directions in both directions that are parallel to each other, such as the x-axis direction and the y-axis direction, but not both.

[0118] In the past, anisotropic light source lenses were manufactured as oval-shaped lenses using a separate mold rather than by applying resin, and these were then attached to an LED (5242).

[0119] However, the attachment method creates an air layer between the LED (5242) and the light source lens. Since the refractive index of air is 1, which is significantly different from the refractive index of 1.84 of the sapphire glass of the LED (5242), the light source lens of the attachment method has the problem of reduced light emission effect.

[0120] Accordingly, the light source lens (5243) of the present invention can be configured to be tightly attached without an air layer between the LED (5242) and the light source lens (5243) by dispensing a liquid resin (R) containing at least one of silicone, polymethyl methacrylate (PMMA), or polycarbonate (PC).

[0121] However, since an isotropic light source lens (5243) is formed when dispensing on the upper surface of the LED (5242) as in the embodiment of FIG. 5 described above, the present invention manufactures an anisotropic light source lens (5243) of FIG. 6 in a different manner.

[0122] FIG. 7 is a drawing illustrating a method for manufacturing the light assembly (524) of FIG. 6. As illustrated in (a) of FIG. 7, a light source substrate (5241) on which an LED (5242) is mounted is provided, and a resin (R) can be applied at a position spaced apart from the center of the LED (5242) on both sides in the first direction (D1).

[0123] It may include a step of dispensing resin (R) at a first location (①) spaced apart from a light source to one side in a first direction (D1) and a step of dispensing resin (R) at a second location (②) spaced apart from the light source to the other side in the first direction (D1). Dispensing of resin (R) at the first location (①) and the second location (②) may be performed sequentially, but may also be performed simultaneously as illustrated in (b) of Fig. 7.

[0124] The first position (①) and the second position (②) may be the same or different from the center of the LED (5242). The amount of resin (R) dispensed may be the same or different. If the first position (①) and the second position (②) dispense the same amount of resin (R) at the same distance from the center of the LED (5242), a light source lens (5243) that is symmetrical in the first direction (D1) can be implemented.

[0125] When the amount or distance of the resin (R) is different, an asymmetric light source lens (5243) is provided in the first direction (D1), and in this case, the light emitted from the LED (5242) can be asymmetric in the first direction (D1). For example, in the case of the LED (5242) located at the edge, in order to induce more light in the opposite direction than the edge direction, an asymmetric light source lens (5243) in the first direction (D1) can be used.

[0126] However, in the present invention, the amorphous light source lens (5243) having different shapes in the first direction (D1) and the second direction (D2) of the light source lens (5243) is a more preferred feature. Hereinafter, the light source lens (5243) having symmetry in the first direction (D1) and symmetry in the second direction (D2), but having different shapes in the first direction (D1) and the second direction (D2) will be described based on the light source lens (5243).

[0127] The size of the light source lens (5243) may vary depending on the amount of the resin (R) droplet being dispensed. If the amount of the resin (R) droplet is large, the size may increase not only in the first direction (D1) but also in the second direction (D2). Therefore, even if the resin (R) is dispensed at the same location, the size and shape of the light source lens (5243) may vary depending on the size (amount) of the resin (R) droplet.

[0128] In the step (b) of FIG. 7, when the distance between the first position (①) and the second position (②) is within 1 / 3 of the length of the first direction (D1) of the light source lens (5243), an elliptical light source lens (5243) as in FIG. 6 can be provided.

[0129] When dispensing resin (R) at the first position (①) and the second position (②) at a pitch (interval) of 1 mm, an oval-shaped light source lens (5243) having a length of 3.4 mm in the first direction (D1) as shown in Fig. 6 can be obtained.

[0130] At this time, the size of the LED (5242) may have a size of 0.5 mm in the long direction, and the LED (5242) may be arranged so that the long direction faces the first direction (D1). In order to implement light that spreads more in the first direction (D1), the shape of the light source lens (5243) may also be implemented so that it is longer in the first direction (D1), and the long direction of the LED (5242) may be arranged so that it faces the first direction (D1).

[0131] If the distance between the first position (①) and the second position (②) is too close, it becomes close to the isotropic light source lens of FIG. 5, so the distance between the first position (①) and the second position (②) may be at least larger than the size of the first direction of the LED (5242).

[0132] The length of the LED (5242) in the longitudinal direction is about 0.5 mm, the distance between the first position (①) and the second position (②) is greater than the size of the LED (5242) in the first direction (D1), and the first position (①) and the second position (②) may not overlap with the LED (5242).

[0133] Fig. 8 is a drawing illustrating a second embodiment of the light assembly (524) of the present invention. When the distance between the first position (①) and the second position (②) exceeds 1 / 3 of the length of the light source lens (5243) in the first direction (D1), the light source lens (5243) may have a peanut-shaped shape as illustrated in Fig. 8.

[0134] The overlapping area between the first resin (R) droplet dispensed at the first position (①) and the second resin (R) droplet dispensed at the second position (②) is small, so that the amount of resin (R) in the central portion in the first direction is small, resulting in a concave shape. According to the embodiment of Fig. 8, the resin (R) droplet can be applied so that the first position (①) and the second position (②) have a pitch of 2 mm, and the length of the light source lens (5243) in the first direction (D1) can be 5 mm.

[0135] In order to implement the peanut-shaped light source lens (5243) of the embodiment of Fig. 8, the interval between the first position (①) and the second position (②) may have a pitch of about 40% of the total length of the light source lens (5243). Looking more specifically at the light source lens (5243) of the embodiment of Fig. 8, (a) of Fig. 8 is a plan view, (b) is a bb cross-sectional view of (a), and (c) is a cc cross-sectional view of (a).

[0136] The center of the first direction (D1) may include a concave portion (52431) that is concave in both a plan view and a cross-section. As illustrated in FIG. 8(b), the highest peak portion (52432) may be positioned at a predetermined distance from the concave portion (52431) on both sides of the first direction (D1) (h2>h1). The heights of the pair of peak portions (52431) are illustrated as being the same, but may be different. Even if the heights of the pair of peak portions (52432) are different, the concave portion (52431) may be positioned between the pair of peak portions (52432) by being higher than the center.

[0137] Alternatively, the dispensing positions can be set to three locations to implement an anisotropic light source lens (5243) having three peaks (52432) and two concave portions (52431).

[0138] The position of the top portion (52432) may correspond to the first position (①) and the second position (②) for dispensing the resin (R), and therefore, the interval between the pair of top portions (52432) may be greater than the first direction length of the LED (5242).

[0139] The length (y1) of the second direction (D2) of the concave portion (52431) is shorter than the length (y2) of the second direction (D2) of the top portion (52432), so that the concave portion (52431) can have a concave shape not only in the height direction but also in the second direction (D2).

[0140] Even though the light source lens (5243) of this embodiment has a concave shape at the center, the cross-section in the first direction (Fig. 8(b)) and the cross-section in the second direction (Fig. 8(c)) have different shapes. The concave portion (52431) of the light source lens (5243) of this embodiment may have a shape like a valley located between mountain peaks.

[0141] The cross-section in the first direction (D1) may have a shape that protrudes on both sides and is concave in the center, as shown in (b) of FIG. 8, even if the position of the cross-section changes in the second direction (D2), and the cross-section in the second direction may have a semicircular shape, as shown in (c) of FIG. 9 is a drawing showing the path of light in the light source lens (5243) according to the embodiment of FIG. 8. The concave portion (52431) is further configured to spread light upward, and the light is totally reflected within the concave portion (52431) and completely spreads laterally. In this embodiment, the amount of light emitted upward can be reduced and spread widely laterally.

[0142] Fig. 10 is a drawing illustrating a third embodiment of the optical assembly (524) of the present invention. The embodiment of Fig. 10 can dispense resin (R) at three locations. Dispensing can be performed at a first location (①) and a second location (②) that are offset from the center of the LED (5242) to either side of the first direction (D1), and dispensing can be performed at a third location between the first location (①) and the second location (②), thereby dispensing three times. The third location may be a location overlapping the LED (5242).

[0143] When dispensing three times, an elliptical light source lens (5243) having a long length in the first direction (D1) can be obtained. The distance between the first position (①) and the third position and between the third position and the second position (②) can have a value within 1 / 3.

[0144] In this embodiment, the resin (R) was dispensed so that the interval (pitch) between each position was 1.5 mm, and the length of the light source lens (5243) in the first direction (D1) can be 5.15 mm. Since the resin (R) is dispensed three times, the length in the second direction (D2) can be longer than the first and second embodiments of FIGS. 6 and 8.

[0145] Fig. 11 is a diagram schematically illustrating the features of embodiments of the optical assembly (524) of the present invention. It is a diagram illustrating the shape of the light source lens (5243) and the shape of light of the first to third embodiments.

[0146] The first embodiment is a light source lens (5243) manufactured by dispensing resin (R) twice at a first position (①) and a second position (②) with a 1 mm interval, and can implement a light source lens (5243) having a slightly longer length in the first direction (D1).

[0147] The second embodiment is a light source lens (5243) manufactured by dispensing resin (R) twice at a first position (①) and a second position (②) with a 2 mm interval, and has a peanut shape, so it can be confirmed that the shape of light is greatly biased toward the first direction (D1). As seen in Fig. 9, total reflection occurs at the concave portion (5243a) in the center and spreads to both sides in the first direction (D1), so that the light can spread more outward in the first direction (D1) at the top portion (5243b).

[0148] In the third embodiment, the shape of the light may have a similar elliptical shape, with a size in the first direction (D1) being larger than that of the first embodiment.

[0149] Fig. 12 is a graph showing the luminance of an anisotropic lens (5243) implemented by embodiments of the optical assembly (524) of the present invention. It shows the luminance in the first direction (D1) (x-axis) and the second direction (D2) (y-axis). In the drawing, the horizontal direction is the first direction (D1) and the vertical direction is the second direction (D2).

[0150] Since the isotropic lens exhibits the same form of light diffusion in the first direction (D1) and the second direction (D2), the luminance graph is also the same, and the y:x luminance ratio is 1:1. Since the light source lens (5243) (anisotropic lens 1) of the first embodiment is longer in the first direction (D1), light is further spread in the first direction (D1), and the luminance in the first direction (D1) can be 1.3 times greater.

[0151] The light source lens (5243) of the second embodiment (anisotropic lens 2) spreads the most in the second direction (D2) and exhibits a luminance ratio of 1.8 times. It has a value greater than 1.6 times that of the light source lens (5243) of the third embodiment (anisotropic lens 3), and the light source lens (5243) of the second embodiment has the best effect of spreading light in the first direction (D1).

[0152] Fig. 13 is a drawing illustrating an example of the arrangement of a light source lens of an optical assembly (524) of the present invention. One optical assembly (524) includes a plurality of LEDs (5242), and the shape of the light source lens (5243) can vary depending on the position of the LEDs (5242). As illustrated in Fig. 13, both an isotropic lens (5243a) and anisotropic lenses (5243b, 5243c) can be used.

[0153] The central portion of the light assembly (524) can achieve uniform brightness by light supplied from the neighboring LED (5242), but the LED (5242) located at the edge portion of the light assembly (5244) has a problem in that the brightness is relatively low because there is no neighboring LED (5242) toward the end of the light source substrate (5241).

[0154] The problem of reduced brightness at the edge of the light assembly (524) can be solved by applying an anisotropic lens (5243b, 5243c) to the edge of the light assembly (524). As illustrated in Fig. 13, the light source lens (5243) positioned at the edge of the light source substrate (5241) can use an anisotropic lens (5243b, 5243c). The anisotropic lens (5243b, 5243c) can be arranged so that the first direction in which the length thereof is long faces the edge, thereby enabling more light to be supplied toward the edge.

[0155] Referring to the enlarged view of the corner portion of the light assembly (524) of Fig. 13, the light source lens located at the corner can be arranged so that the longitudinal direction (first direction) of the anisotropic shape faces the corner.

[0156] In particular, when using the peanut-shaped light source lens (5243) of Fig. 8, it can be implemented to have an asymmetrical shape in the first direction. Like the anisotropic light source lens (5243c) illustrated on the right side of Fig. 13, a light source lens (5243c) can be used in which the size of the lens in the part facing the edge or corner is implemented to be larger in order to supply more light supplied from the LED (5242) toward the edge of the light assembly (524).

[0157] As described above, the optical assembly (524) of the present invention can implement light that is diffused in an anisotropic shape through an anisotropic dome-shaped light source lens (5243).

[0158] In addition, the optical assembly (524) of the present invention can easily implement an anisotropically shaped light source lens (5243).

[0159] In addition, the optical assembly (524) of the present invention has the advantage of increasing the degree of freedom in the arrangement of the LED (5242).

[0160] The above detailed description should not be construed as limiting in any respect and should be considered illustrative only. The scope of the present invention should be determined by a reasonable interpretation of the appended claims, and all modifications within the equivalent scope of the present invention are intended to be included within the scope of the present invention.

[0161] With respect to various embodiments for implementing the present invention, duplicate descriptions are omitted as they have been described above in the previous table of contents, Best Mode for Carrying Out the Invention.

[0162] Since the present invention can be applied to display devices in various fields, its industrial applicability is recognized.

Claims

1. A light source substrate with an LED mounted on it; and Includes a light source lens that covers the above LED and has a curved upper surface, An optical assembly characterized in that the light source lens includes an anisotropic lens in which a length in a first direction is longer than a length in a second direction perpendicular to the first direction.

2. In paragraph 1, The above light source lens An optical assembly characterized in that the diffusion angle in the first direction is greater than the diffusion angle in the second direction.

3. In paragraph 1, The above light source lens A concave recess located in the center of the first direction; An optical assembly characterized in that it includes a pair of top portions located on both sides of the first direction in the concave portion and having a height higher than the concave portion.

4. In paragraph 3, An optical assembly characterized in that the second direction length of the concave portion is shorter than the second direction length of the top portion.

5. In paragraph 3, The spacing between the above pair of peaks is An optical assembly characterized in that the length of the LED in the first direction is greater than that of the LED.

6. In paragraph 3, The above pair of summits An optical assembly characterized by different heights.

7. In paragraph 1, An optical assembly characterized in that the air layer between the LED and the light source lens is omitted and the two are tightly sealed.

8. In paragraph 1, An optical assembly characterized in that the LED has a long length in the first direction.

9. In paragraph 1, An optical assembly characterized in that the length of the light source lens in the first direction is at least 1.3 times the length in the second direction.

10. In paragraph 1, The above LEDs are arranged in multiple numbers in an array in the first and second directions. An optical assembly characterized in that the plurality of LEDs have a spacing in the first direction greater than a spacing in the second direction.

11. In paragraph 1, An optical assembly characterized in that the light source lens comprises at least one of silicone, polymethyl methacrylate (PMMA), or polycarbonate (PC).

12. In paragraph 1, The anisotropic lens located at the edge portion of the light source substrate An optical assembly characterized in that the first direction is arranged so as to face the edge.

13. In paragraph 1, The above light source lens The anisotropic lens is placed at a portion adjacent to the edge of the light source substrate; and An optical assembly characterized by including an isotropic lens arranged in the central portion of the light source substrate.

14. Display panel; It includes a backlight unit located on the back of the display panel and emitting light, The above backlight unit, Light source board with mounted LED; A light source lens having a curved upper surface that covers the above LED; It includes an optical sheet that converts light emitted from the LED into a uniform surface light source, A display device characterized in that the light source lens includes an anisotropic lens in which a length in a first direction is longer than a length in a second direction perpendicular to the first direction.

15. Step of mounting LED on light source substrate; Including a step of forming a light source lens covering the above LED, The step of forming the above light source lens is: A step of dispensing resin at a first position spaced apart from the LED in the first direction; and A method for manufacturing an optical assembly, comprising the step of dispensing a resin at a second location spaced apart from the light source in the first direction.

16. In paragraph 15, A method for manufacturing an optical assembly, characterized in that the distance between the first position and the second position is longer than the length of the LED in the first direction.

17. In paragraph 15, The steps for mounting the above LED are A method for manufacturing an optical assembly, characterized in that the LED is mounted on the light source substrate so that the longitudinal direction of the LED faces the first direction.

18. In paragraph 15, A method for manufacturing an optical assembly, characterized in that it further comprises a step of dispensing resin between the first position and the second position.

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