Light module of a signalling device for a motor vehicle

Abstract

One aspect of the invention relates to a light module (1) of a signalling device for a motor vehicle, the module comprising: - a printed circuit board (3); - a plurality of selectively controllable light sources (2), each light source including an elementary light generator (21) and a photoluminescent element (22) covering the elementary light generator, each light source being mounted on the printed circuit board via the corresponding elementary light generator, each light source including a plurality of walls (24) made of a white material, each wall coming into contact with a lateral surface of the photoluminescent element. According to the invention, each wall comprises a first portion (24A) and a second portion (24B), the first portion being positioned facing the elementary light generator, the first portion having a thickness smaller than a thickness of the second portion.

Description

DESCRIPTION TITLE: Light module of a motor vehicle signaling device TECHNICAL FIELD OF THE INVENTION

[0001] The technical field of the invention relates generally to automotive lighting and light signaling.

[0002] More specifically, the invention relates to the field of screens integrated into light modules for lighting or signaling of motor vehicles.

[0003] In particular, the invention relates to a light module of a signaling device of a motor vehicle. TECHNOLOGICAL BACKGROUND OF THE INVENTION

[0004] It is common practice to integrate displays into the lighting systems of motor vehicles, for example, in the rear or front lights. These displays are typically made using matrices of numerous light sources, mounted on a printed circuit board and selectively controllable, and whose dimensions are sufficiently small to allow for the display of information, such as messages or pictograms, with satisfactory resolution. This information thus improves vehicle signaling, for example, by contextualizing or accompanying a given signaling function with a message.

[0005] The light sources used in these screens generally include a blue light emitting semiconductor chip, covered with a photoluminescent material adapted to absorb some of this blue light and re-emit, in response, yellow light (by additive synthesis, the light resulting from the composition of the remaining blue light and yellow light being white).

[0006] However, this photoluminescent material has high reflectance. It can therefore significantly reflect the light incident on the screen (such as sunlight or light from external lighting). automotive). This albedo is therefore likely to reduce the screen's contrast and thus impair the visibility of details in messages displayed on the screen.

[0007] Furthermore, due to its properties, the photoluminescent material has a yellow or amber tint, which is visible from outside the screen. Therefore, when the screen is off, it also has a yellow appearance, which is incompatible with the need for a neutral appearance when screens are off.

[0008] Furthermore, given the relative positioning of the light sources, a "crosstalk" effect can be observed. Indeed, the light emitted by one light source can illuminate and reflect off a neighboring light source, resulting in unwanted interference between them. This notably reduces the perceived quality of the screen, particularly its contrast, as a light source that is off can appear on. Moreover, the smaller the light sources and the closer they are to each other, the more pronounced these unwanted effects become.

[0009] It is then known that the structure of this luminous module can be modified to reduce these interference effects between the light sources by creating white walls between them. These walls are then in contact with the photoluminescent material and completely surround it.

[0010] In practice, these walls are obtained by cutting the photoluminescent material, so as to form grooves intended to receive white colored material to form the walls.

[0011] However, this cutting process is delicate because there is a risk of damaging the printed circuit board that houses all the light sources. Accidental cutting of the circuit board (during the wall forming process) can lead to screen reliability issues, particularly by causing corrosion and electromigration defects between the electrodes that power the light sources. SUMMARY OF THE INVENTION

[0012] The present invention therefore proposes a compact luminous module for a motor vehicle signaling device, with effects interference between light sources is limited and in which the integrity of the semiconductor chip carrying the light sources is preserved.

[0013] One aspect of the invention relates to a luminous module of a signaling device for a motor vehicle comprising:

[0014] - a printed circuit board,

[0015] - a plurality of selectively controllable light sources, each light source comprising an elementary light generator and a photoluminescent element covering the elementary light generator, the photoluminescent element being adapted to absorb the light rays emitted by the elementary light generator and to emit, in response, other light rays of a different wavelength, each light source is mounted on the printed circuit board via the corresponding elementary light generator,

[0016] each light source comprising a plurality of walls formed in a white colored material, each wall coming into contact with a lateral surface of the photoluminescent element, the plurality of walls defining an enclosure framing the photoluminescent element of the light source concerned.

[0017] According to the present invention, each wall comprises a first part and a second part, the first part being positioned opposite the elementary lighting generator, the first part having a thickness less than a certain thickness of the second part. It is understood that the first and second parts are arranged along the height of the wall such that a certain thickness of the second part overhangs the first part.

[0018] In the context of this invention, the expression "opposite" therefore designates a specific positioning relationship where the first part of the wall is located on the same side as the elementary light generator, more precisely on the side of the substrate or printed circuit board on which this generator is mounted. This expression is thus equivalent to the expression "at the level of".

[0019] Thus, advantageously according to the invention, the shape of the walls minimizes the risk of cutting the printed circuit board during wall formation (since the thickness of each wall near the printed circuit board is very small, the cut has a small cross-section near the printed circuit board). This then prevents corrosion phenomena and electromigration can be harmful to the reliability of the light source and may occur when the printed circuit board is damaged.

[0020] This allows the plurality of walls to be formed by cutting as close as possible to the printed circuit board in order to avoid light leaks between the light sources but without damaging the printed circuit board.

[0021] In addition to the characteristics mentioned in the preceding paragraph, the lighting module according to the invention may have one or more additional characteristics from among the following, considered individually or in all technically possible combinations:

[0022] - the first part of each wall has a thickness of less than 75 micrometers;

[0023] - the second part of at least one wall, and preferably of each of the walls, has a variable thickness between a first end of the second part of said wall, and a second end of the second part of said wall, the thickness of the second part of said wall at the first end being greater than the thickness of the second part of said wall at the second end,

[0024] - the second part of each wall has a variable thickness between a first end and a second end, the thickness of the second part of each wall at the first end being greater than the thickness of the second part of each wall at the second end;

[0025] - the thickness of the second part of each wall at the first end is less than 120 micrometers;

[0026] - the first part of each wall has a height of less than 100 micrometers;

[0027] - the second part of each wall has a height of less than 110 micrometers;

[0028] - the first part of each wall is positioned at a distance from the elementary light generator concerned, said distance being less than 150 micrometers;

[0029] - the first part of each wall is positioned at a distance from a first face of the printed circuit board, said distance being less than 50 micrometers;

[0030] - a dielectric layer is provided to be formed on one face of the printed circuit board, the dielectric layer being positioned between the printed circuit board and said plurality of walls;

[0031] - each light source comprises a substrate, the elementary light generator of each light source comprising at least two electrical connection pads through which it is mounted on this substrate, each light source being mounted and interconnected to said printed circuit board via the substrate concerned, the first part of each wall being positioned at a distance from a first face of said substrate, said distance being less than 50 micrometers;

[0032] - a dielectric layer is provided to be formed on the first face of the substrate, the dielectric layer being positioned between the substrate and said plurality of walls;

[0033] - the dielectric layer comprises an epoxy polymer material;

[0034] - the printed circuit board and the dielectric layer comprise the same epoxy polymer material;

[0035] - the dielectric layer has a thickness of less than 50 micrometers;

[0036] - the dielectric layer has a thickness of between 25 and 35 micrometers;

[0037] - another dielectric layer is planned to be formed on the second side of the printed circuit board;

[0038] - the other dielectric layer comprises an epoxy polymer material;

[0039] - the other dielectric layer has a thickness of less than 50 micrometers;

[0040] - the other dielectric layer has a thickness between 25 and 35 micrometers; and

[0041] - the dielectric layer and the other dielectric layer are identical.

[0042] Another aspect of the invention relates to a signaling device for a motor vehicle comprising a light module as previously introduced, said plurality of light sources forming a light screen of said signaling device. BRIEF DESCRIPTION OF THE FIGURES

[0043] Other features and advantages of the invention will become apparent from the description, which can be read in conjunction with the figures. These figures are provided for illustrative purposes only and are not intended to limit the scope of the invention.

[0044] [Fig. 1] Figure 1 represents a partial schematic front view of a light module according to the present invention,

[0045] [Fig. 2] Figure 2 represents a partial schematic cross-sectional view, along plane AA of Figure 1, of a first embodiment of the light module,

[0046] [Fig. 3] Figure 3 shows a partial schematic cross-sectional view, along plane AA of Figure 1, of a second embodiment of the light module,

[0047] [Fig. 4] Figure 4 shows a partial schematic cross-sectional view, along plane AA of Figure 1, of a third embodiment of the light module, and

[0048] [Fig. 5] Figure 5 represents a partial schematic cross-sectional view along plane AA of Figure 1, of a fourth embodiment of the light module according to the invention.

[0049] For clarity, identical or similar elements are identified by identical reference symbols across all figures. DETAILED DESCRIPTION

[0050] The present invention aims to provide a light module for a motor vehicle signaling device with reduced dimensions, whose efficiency is optimal (without parasitic interference effects between light sources) and guaranteeing reliability, particularly electronic, of the whole.

[0051] In this description, the vehicle (not shown) in question is a motor vehicle. The term "motor vehicle" is understood to mean any type of motorized vehicle. Hereafter, the terms "vehicle" and "motor vehicle" are used interchangeably to describe the vehicle covered by this invention.

[0052] Figure 1 shows a front view of a light module 1; 100; 150 according to an embodiment of the invention. This light module 1; 100; 150 is, for example, intended to be integrated into a front or rear light of the motor vehicle. The light module 1; 100; 150 thus forms a screen. In other words, the light module 1; 100; 150 of the invention forms a display device, visible, for example, from outside the motor vehicle.

[0053] Figure 2 represents a partial cross-sectional view of a first embodiment of the light module 1 (according to the section plane AA visible in Figure 1).

[0054] The light module 1 comprises a plurality of light sources 2 mounted on a support 3. Here, the support 3 is for example formed by a printed circuit board 3.

[0055] In the example described, the light module 1 comprises at least 100 light sources 2, arranged in a matrix (for example, in 10 columns and 10 rows). Preferably, the light module 1 comprises more than 20,000 light sources 2, arranged in a matrix in 256 columns and 80 rows.

[0056] Each light source 2 is here a mini-LED, for example, square-shaped as shown in Figure 1. The dimensions of each light source 2 are, for example, between 100 micrometers (µm) by 100 µm and 600 µm by 600 µm. The light sources 2 are spaced less than 1 millimeter (mm) apart. In this description, the "distance between two light sources" means the distance separating the center of one of these light sources from the center of the other (adjacent) light source.

[0057] Alternatively, the light sources can be arranged on the printed circuit board 3 so that they are spaced between 200 and 400 pm apart, or less than or equal to 300 pm.

[0058] It should be noted that other dimensions of the light sources, other distances between the light sources, and other numbers of light sources or other distributions of light sources, without going outside the scope of the present invention.

[0059] The printed circuit board 3 has a first face 31 and a second face 32 opposite the first face 31. The light sources 2 are mounted on the first face 31 of the printed circuit board 3. This first face 31 faces the outside of the signaling device in which the light module 1 is integrated (the light rays from each light source 2 are therefore directed towards the outside of the signaling device in which the light module 1 is integrated according to the present invention).

[0060] Printed circuit board 3 here comprises a polymer material into which glass fibers are introduced. The polymer material is, for example, an epoxy polymer.

[0061] In practice, the printed circuit board 3 is a so-called multilayer board, meaning that it comprises a stack of layers (not shown), these layers being arranged between the first face 31 and the second face 32. These layers are specifically designed to allow the interconnection of the components mounted on the printed circuit board 3. Each layer may include a plurality of through-hole, blind, or buried vias, arranged within the printed circuit board 3 to be connected to the various interconnection layers. These vias open onto the first face 31 or the second face 32 of the printed circuit board 3 at the level of metal pads to which they are connected.

[0062] In order to control the light sources 2, the light module 1 includes at least one controller 4 configured to selectively control the light sources 2. The light module 1 may include a single controller 4 that controls all the light sources 2 mounted on the printed circuit board 3. Alternatively, the light module may include a plurality of controllers 4, each selectively controlling an array, for example, of 64x64 (i.e., 4096) light sources 2.

[0063] As can be seen in Figure 2, the controller 4 is mounted on the second side 32 of the printed circuit board 3 and is electrically interconnected to the metal pads provided on this second side 32.

[0064] The lighting module may then include an interconnection system linked to the controller and arranged to interconnect the controller to multiple light sources. The interconnection system may, for example, be integrated into the printed circuit board or be a separate component mounted on it. The interconnection system may consist of a connector matrix, such as a ball grid array (BGA) or a land grid array (LGA).

[0065] The light module 1 includes a connector (not shown) for receiving a control instruction for multiple light sources 2. This instruction may be issued by a computer in the motor vehicle or the signaling system to display a logo, message, pattern, or pictogram. For example, it may be an instruction to display a pictogram to inform an outside observer that a door of the motor vehicle has been opened, a pictogram to warn a driver behind the motor vehicle of the presence of black ice on the road, or traffic information.

[0066] The plurality of light sources 2 forms a passive matrix where each row and each column of light sources 2 is associated with a control device (not shown) mounted on the printed circuit board 3 at the location of that row or column to control the power supply provided to the light sources in that row or column. The controller 4 is thus configured to control each of the light sources 2 in the passive matrix according to the control instruction received by the connector, by successively scanning the rows and then the columns of the matrix to control the power supply provided to each of the light sources 2.

[0067] Alternatively, the light module may include a plurality of control devices for the power supply provided to the light sources, each control device being mounted on the second side of the printed circuit board, opposite a light source, to control the power supply provided to the light source concerned, in particular according to an instruction received from the controller intended for it.

[0068] As shown in Figure 2, each light source 2 comprises a light-emitting semiconductor chip 21, forming an elementary light generator. The semiconductor here is, for example, gallium nitride (or GaN), configured to emit, by electroluminescence and in response to an electric current passing through it, beams of blue light, for example, whose spectrum has a peak centered on a wavelength between 410 nanometers (nm) and 480 nm.

[0069] Each light source 2 also includes a photoluminescent element 22. This photoluminescent element 22, also called a conversion element or phosphor, is adapted to absorb a portion of the light rays emitted by the semiconductor chip 21 and to emit, in response, light rays of a different wavelength. The photoluminescent element 22 is, for example, in the form of a resin comprising a cerium-doped yttrium aluminum garnet (or CE:YAG) adapted to absorb blue light and, through photoluminescence and in response to the excitation produced by this blue light, to emit yellow light rays, for example, whose spectrum has a peak centered on a wavelength between 520 nm and 600 nm.

[0070] The photoluminescent element 22 is arranged on the semiconductor chip 21 such that a portion of the blue light emitted by the semiconductor chip 21 excites this photoluminescent element 22, causing it to emit yellow light by photoluminescence. The remaining portion of the blue light passes through this photoluminescent element 22. Thus, the light source 2, when electrically powered, simultaneously emits blue and yellow light, the resulting light appearing white to the human eye.

[0071] It is understood that the invention is not limited to the colors mentioned herein. In particular, it may be possible to modify the composition of a photoluminescent conversion layer of the photoluminescent element in order to obtain a desired color (other than that described above).

[0072] As can be seen in Figure 2, each light source 2 is mounted and interconnected to the printed circuit board 3 via its semiconductor chip 21. More specifically, the semiconductor chip 21 is provided with electrical connection pads 21a mounted and interconnected directly to the circuit board. printed 3. Thus, the semiconductor chip 21 of each light source 2 is encapsulated between the photoluminescent element 22 and the printed circuit board 3.

[0073] Each light source 2 also comprises a plurality of walls 24 made of a white material. The white material is, for example, a dielectric material with a reflection coefficient between 60 and 99%, preferably around 90%. This white material is, in this case, a silicone resin enriched with titanium dioxide (TiO2).

[0074] Given the white color of these walls 24, light rays emitted by the semiconductor chip 21 from a considered light source 2 towards another adjacent light source 2 are intercepted by these walls 24 and reflected towards the photoluminescent element 22. Due to the white color of these walls, the light rays are reflected within the enclosure defined by the walls and in which the material of the photoluminescent element 22 is located. Advantageously, this avoids parasitic effects and thus increases the efficiency of the light module 1. Furthermore, the edges, or thicknesses, of these white walls 24 contribute to the visible appearance of the light module when off and therefore reduce the influence of the color of the photoluminescent element 22 on this appearance when off.

[0075] In practice, these walls 24 are obtained from grooves formed, for example by laser drilling or by blade cutting (or "blade dicking" according to the commonly used Anglo-Saxon terminology), in the layer of photoluminescent material, to delimit the shape of the photoluminescent element 22. A layer of white colored material is deposited on the layer of photoluminescent material, to fill the grooves, and form the walls 24.

[0076] In the first embodiment shown in Figure 2, each wall 24 extends from the printed circuit board 3 (and more specifically from the first face 31 of the printed circuit board 3), coming into contact with a lateral surface of the photoluminescent element 22, to a top surface of the photoluminescent element 22. The walls 24 thus extend against the photoluminescent element 22 until they are flush with the top surface of the photoluminescent element 22, thereby defining an enclosure framing the photoluminescent element 22 of each light source 2. In other words, like this is visible in figure 2, the walls 24 form a boundary of each light source 2 by surrounding the photoluminescent element 22 of each light source 2.

[0077] Here, each wall 24 comprises a first part 24A and a second part 24B. As can be seen in Figure 2, the first part 24A of each wall 24 is positioned opposite the semiconductor chip 21 of the light source 2 concerned.

[0078] Here, the plurality of walls 24 of each light source 2 is arranged symmetrically with respect to the center of that light source 2.

[0079] Advantageously, according to the invention, the first part 24A has a thickness less than the thickness of the second part 24B. In this description, the term "thickness" refers to a dimension measured in a plane parallel to the first face 31 of the printed circuit board 3. In other words, each wall 24 has a variable thickness, with a thinner thickness at the first part 24A (located opposite the semiconductor chip 21 of the light source in question). This variability in the thickness of each wall 24, with a thinner thickness near the printed circuit board 3, minimizes the risk of cutting the printed circuit board 3 during the formation of the walls 24 (since the thickness of each wall 24 near the printed circuit board is very small, the cut then presents a small cross-section near the printed circuit board 3).This helps to avoid corrosion and electromigration phenomena that are harmful to the reliability of the light source and that may occur when the printed circuit board is damaged.

[0080] Here, the first section 24A of each wall 24 has a thickness e1 of less than 75 µm. Preferably, the thickness ei of the first section 24A of each wall 24 is between 30 and 70 µm. Even more preferably, this thickness e1 of the first section 24A of the wall 24 is on the order of 50 µm. Such a small thickness then helps to limit any potential risk of cutting the printed circuit board 3.

[0081] Furthermore, the second part 24B of each wall comprises a first end 55 and a second end 56. The second end 56 here corresponds to the end common with the first part 24A. The first end 55 therefore corresponds to the end of each wall 24 present at the level of the outer surface of the light module 1.

[0082] As can be seen in Figure 2, the second part 24B has a variable thickness between its first end 55 and its second end 56. More specifically, the thickness of the second part 24B of each wall 24 is smaller at its second end 56 than at its first end 55.

[0083] Here, the thickness e2 of the second part 24B of each wall 24 at its first end 55 is less than 120 pm. Preferably, this thickness e2 is between 75 and 120 pm. Even more preferably, it is between 75 and 115 pm. Even more preferably, this thickness e2 is on the order of 95 pm. Such values ​​for the thickness e2 of the second part 24B of each wall 24 near the outer surface of the light module 1 ensure the barrier and reflection effect of the white walls as described above, while also contributing to the visible appearance of the light module when off, and thus reduce the influence of the color of the photoluminescent element 22 on this appearance when off.

[0084] At its second end 56, the second part 24B of each part 24 has of course a thickness similar to that of the first part 24A.

[0085] Furthermore, the height h1 of the first part 24A of each wall 24 is less than 100 pm. In this description, the term "height" refers to a dimension of each wall measured perpendicularly to the first face 31 of the printed circuit board 3. Preferably, it is between 60 and 100 pm. Even more preferably, this height h1 is on the order of 80 pm. This makes it possible to avoid damaging the semiconductor chip 21 of each light source 2 during the cutouts used to form the walls 24.

[0086] Regarding the second section 24B of each wall 24, the height h2 is less than 110 pm. Preferably, this height h2 is between 70 and 110 pm. Even more preferably, the height h2 of the second section 24B is approximately 90 pm. Such height dimensions for each wall 24 thus allow for a low overall thickness of the lighting module, while maintaining its lighting and signaling characteristics, and therefore the reliability of the lighting module.

[0087] Furthermore, the first portion 24A of each wall 24 is positioned at a distance from the semiconductor chip 21 of the relevant light source 2. Specifically, this distance d1 is less than 150 pm. Preferably, this distance d1 is less than 125 pm. Such a configuration then limits the potential risk of cutting the semiconductor chip 21 of the relevant light source 2 during the formation of the walls 24.

[0088] As shown in Figures 1 and 2, the set of light sources 2 is encapsulated in a single layer of dark-colored material 5, for example black or gray. Preferably, the layer of dark-colored material 5 has a transmission coefficient in mass of between 50% and 90%, over a thickness of 0.1 mm.

[0089] This dark-colored material layer 5 comprises, for example, a polymer material. This could be, for instance, an epoxy resin or silicone, enriched with carbon particles or black pigments. The carbon particle concentration, that is, the mass of carbon relative to the mass of the polymer material, is, for example, less than 0.05%. This characteristic is particularly suitable when the light module is intended to perform a regulatory signaling function. Alternatively, the carbon particle concentration can be greater than 0.05%, notably to improve the contrast and the appearance of the screen when off.

[0090] This layer of dark-colored material 5 extends between two adjacent light sources 2, coming into contact with the outer lateral surfaces of the walls 24 (i.e., in contact with the lateral surfaces opposite those in contact with the photoluminescent element 22). Given its opacity and color, the layer of dark-colored material 5 further limits interference effects and contributes to improving the appearance of the light module 1 when off and reducing its albedo.

[0091] Furthermore, a thin portion 51 of the dark coloured material layer 5 extends over the walls 24 and the photoluminescent elements 22 of the light sources 2 of the light module 1. This feature further improves the off appearance of the light module and reduces its albedo.

[0092] In practice, portion 51 has a thickness of less than 200 µm. This thickness is preferably between 10 and 200 µm.

[0093] Alternatively (not shown), each wall 24 is positioned at a distance from the printed circuit board 3. More specifically, the end 57 of each wall 24 is positioned at a distance from the first face 31 of the printed circuit board 3. This distance is, for example, less than 50 µm here. This allows for a margin to be maintained so as not to damage the printed circuit board during the cutting of the grooves used to form the walls 24, while also limiting light leakage between the light sources 2.

[0094] Figure 5 shows a partial cross-sectional view of an alternative embodiment of the first embodiment described. The elements common to this first embodiment are not described in detail again here. The main difference lies in the fact that the light sources 2 are mounted on the support 3 via a substrate 23 called the "interposer 23". In practice, the interposer 23 is also in the form of a printed circuit board.

[0095] As can be seen in Figure 5, the semiconductor chip 21 is mounted, via the electrical connection pads 21a, on a first face 23a of the interposer 23.

[0096] Each wall 24 extends here from the first face 23a of the interposer 23 to the upper surface of the photoluminescent element 22. The walls 24 thus also extend here against the photoluminescent element 22 until they come flush with the upper surface of the photoluminescent element 22, thus defining an enclosure framing the photoluminescent element 22.

[0097] Furthermore, each light source 2 is mounted and interconnected to the printed circuit board 3 via the interposer 23. As shown in Figure 5, the interposer 23 has two electrical connection pads 23c (extending from a second face 23b of the interposer 23). Each light source 2 is therefore mounted on the first face 31 of the printed circuit board 3 and is electrically interconnected to electrical traces provided on this first face 31. In practice, the electrical connection pads 23c are separated from each other by a distance of at least 80 µm.

[0098] This arrangement of the electrical connection pads 23c is made possible by the increased surface area of ​​the interposer 23, due to the walls 24. The electrical connection pads 23c can then be more easily positioned by a machine on a given location on the printed circuit board 3, thus improving assembly accuracy. Furthermore, thermal conduction between the printed circuit board 3 and each light source 2 is improved, and the increased spacing between the two electrical connection pads 23c prevents corrosion and electromigration phenomena that could compromise the reliability of the light source 2.

[0099] Using an interposer for each light source makes it easier to assemble each of the light sources 2 on the printed circuit board 3, and therefore improves the efficiency and reliability of the light module.

[0100] Alternatively (not shown), each wall 24 is positioned at a distance from the interposer 23. More specifically, the end 57 of each wall 24 is positioned at a distance from the first face 23a of the interposer 23. This distance is, for example, less than 50 pm. This allows for a margin to be maintained so as not to damage the interposer during the cutting of the grooves used to form the walls 24, while also limiting light leakage between the light sources 2.

[0101] Figure 3 shows a partial cross-sectional view of a second embodiment of the light module 100 (along the section plane AA visible in Figure 1). The elements common to the first embodiment described previously (and shown in Figure 2) are not described again in detail hereafter.

[0102] In this second embodiment, the light module 100 includes a dielectric layer 25. This dielectric layer 25 is formed on the first face 31 of the printed circuit board 3. More specifically, the dielectric layer 25 is positioned between the printed circuit board 3 and the walls 24. This dielectric layer 25 thus forms a protective layer that protects the printed circuit board 3, particularly during the formation of the plurality of walls 24. This prevents corrosion and electromigration phenomena that are detrimental to the reliability of the light source and that can occur when the printed circuit board is damaged. This dielectric layer is electrically insulating, It allows the interconnection between each light source 2 and the printed circuit board 3 to be maintained.

[0103] In practice, as can be seen in Figure 3, the dielectric layer 25 comprises a plurality of portions, allowing in particular to maintain, for each light source 2, the interconnection between the semiconductor chip 21 and the printed circuit board 3 (via the electrical connection pads 21a).

[0104] Here, the dielectric layer 25 comprises a polymer material, preferably an epoxy polymer material. This epoxy polymer material is, for example, homogeneous, i.e., without fiber reinforcement (e.g., without glass, acrylic, or aramid fibers). In one variant, the printed circuit board 3 and the dielectric layer both comprise the same epoxy polymer material.

[0105] Advantageously, the dielectric layer 25 has a thickness of less than 50 µm. Preferably, the thickness of the dielectric layer 25 is between 25 and 35 µm. This allows for a low overall thickness of the light module and preserves its characteristics and properties.

[0106] Alternatively (not shown), the light module according to this second embodiment may also include an interposer as described above, on which the semiconductor chip 21 of each light source 2 is mounted and interconnected.

[0107] In this variant, the dielectric layer 25 is formed on the first face 23a of the interposer 23. Each wall 24 extends here from the dielectric layer 25 formed on the interposer 23, to the upper surface of the photoluminescent element 22.

[0108] Figure 4 shows a partial cross-sectional view of a third embodiment of the light module 150 (along the section plane AA visible in Figure 1). The elements common to the second embodiment described previously (and shown in Figure 3) are not described again in detail hereafter.

[0109] In this third embodiment, the light module 150 includes another dielectric layer 26 which is formed on the second face 32 of the board printed circuit board 3. In other words, this other dielectric layer 26 is formed on the face of the printed circuit board 3 opposite to that bearing the dielectric layer 25. Advantageously, this other dielectric layer 26 makes it possible to ensure a symmetrical structure, at the level of the printed circuit board 3, for the light module 150, thus improving its reliability.

[0110] In practice, as can be seen in Figure 4, the other dielectric layer 26 is formed on the second face 32 of the printed circuit board 3, around the controller 4. This allows the correct connection of the light sources 2 to the controller 4 to be maintained, in order to ensure proper control.

[0111] As previously described for the dielectric layer 25 in the second embodiment presented, the other dielectric layer 26 comprises a polymer material, preferably an epoxy polymer material. According to one variant, the printed circuit board 3 and the other dielectric layer both comprise the same epoxy polymer material. In a further variant, the dielectric layer and the other dielectric layer comprise the same epoxy polymer material.

[0112] Advantageously, the other dielectric layer 26 has a thickness of less than 50 µm. Preferably, the thickness of the other dielectric layer 26 is between 25 and 35 µm. This allows for a low overall thickness of the light module, without altering its characteristics and properties.

[0113] Preferably, the dielectric layer 25 and the other dielectric layer 26 have the same thickness.

[0114] Preferably, in order to ensure a symmetry characteristic for the light module, the dielectric layer and the other dielectric layer are identical (in material and thickness in particular).

[0115] Alternatively (not shown), the light module 150 according to this second embodiment of the invention may also include an interposer as described above, on which the semiconductor chip 21 of each light source 2 is mounted and interconnected.

[0116] An example of a manufacturing process for a light source 2 of a light module 1; 100; 150 according to the embodiments of figures 1 to 4 is described below.

[0117] In a first step, the light-emitting semiconductor chip 21, in the form of a "die", is assembled to the printed circuit board 3. In practice, the pads 21a are, for example, soldered, brazed or glued to the first face 31 of the printed circuit board 3.

[0118] In an optional second step (for the second and third embodiments introduced previously), the dielectric layer 25 is deposited on the first face 31 of the printed circuit board 3, around the light-emitting semiconductor chip 21. In practice, this is implemented, for example, by masking the light-emitting semiconductor chip 21. The other dielectric layer 26 can also be formed during this optional second step.

[0119] Then, in a third step, a layer of photoluminescent material is deposited, for example by molding, onto the light-emitting semiconductor chip 21 and onto the printed circuit board 3 (or onto the dielectric layer 25 in the case of the second and third embodiments).

[0120] In a fourth step, grooves are then formed, for example by laser drilling or by blade cutting, in this layer of photoluminescent material, to delimit the shape of the photoluminescent element 22.

[0121] Then, in a fifth step, a layer of white colored material is deposited on the layer of photoluminescent material, to fill the grooves, and form the walls 24.

[0122] Finally, in a sixth step, the excess white material, protruding from the grooves, is polished so that the levels of the layers of white material and photoluminescent material are identical.

[0123] Finally, advantageously according to the present invention, the shape of the walls 24 minimizes the risk of cutting the printed circuit board 3 during the formation of the walls 24 (since the thickness of each wall 24 near the printed circuit board is very small, the cut has a small cross-section near the printed circuit board 3). This then avoids phenomena corrosion and electromigration are harmful to the reliability of the light source and may occur when the printed circuit board is damaged.

[0124] Furthermore, in the case of the second and third embodiments, the presence of the dielectric layer 25 provides additional protection for the printed circuit board 3, particularly during the formation of the plurality of walls 24.

[0125] Alternatively, in the case of the use of the interposer23, another example of a manufacturing process for a light source 2 of a light module 1; 100; 150 according to the embodiment of figure 5 is described below.

[0126] In a first step, the light-emitting semiconductor chip 21, in the form of a "die", is assembled to the interposer 23. In practice, the pads 21a are for example soldered, brazed or glued to the first face 23a of the interposer 23.

[0127] In an optional second step, the dielectric layer 25 is deposited on the first face 23a of the interposer 23, around the light-emitting semiconductor chip 21. In practice, this is implemented, for example, by masking the light-emitting semiconductor chip 21. Optionally, the other dielectric layer 26 can also be formed during this second step.

[0128] Then, in a third step, a layer of photoluminescent material is deposited, for example by molding, onto the light-emitting semiconductor chip 21 (and onto the dielectric layer 25 if it is formed).

[0129] In a fourth step, grooves are then formed, for example by laser drilling or by blade cutting, in this layer of photoluminescent material, to delimit the shape of the photoluminescent element 22.

[0130] Then, in a fifth step, a layer of white colored material is deposited on the layer of photoluminescent material, to fill the grooves, and form the walls 24.

[0131] In a sixth step, the excess white material, protruding from the grooves, is polished so that the levels of the layers of white material and photoluminescent material are identical.

[0132] In a seventh step, each light source 2 is positioned on the first face 31 of the printed circuit board 3. More specifically, the electrical connection pads 23c are mounted and interconnected on the first face 31 of the printed circuit board 3.

[0133] Finally, in an eighth step, the light sources are encapsulated in a single layer of dark-colored material 5 to form the light module. In practice, this step is implemented in such a way as to also obtain the thin portion 51 of the layer 5 that extends over the walls 24 and the photoluminescent elements 22 of the light sources.

Claims

DEMANDS

1. Light module (1; 100; 150) of a motor vehicle signaling device comprising: - a printed circuit board (3), - a plurality of selectively controllable light sources (2), each light source (2) comprising an elementary light generator (21) and a photoluminescent element (22) covering the elementary light generator (21), the photoluminescent element (22) being adapted to absorb the light rays emitted by the elementary light generator (21) and to emit, in response, other light rays of a different wavelength, each light source (2) is mounted on the printed circuit board (3) via the corresponding elementary light generator (21), each light source (2) comprising a plurality of walls (24) formed from a white colored material, each wall (24) coming into contact with a lateral surface of the photoluminescent element (22), the plurality of walls (24) defining an enclosure framing the photoluminescent element (22) of the light source (2) concerned,characterized in that each wall (24) comprises a first part (24A) and a second part (24B), the first part (24A) being positioned at the level of the elementary luminaire generator (21), the first part (24A) having a thickness less than the thickness of the second part (24B).

2. Light module (1; 100; 150) according to claim 1, wherein the first part (24A) of each wall (24) has a thickness of less than 75 micrometers. [Claims] Light module (1; 100; 150) according to claim 1 or 2, wherein the second part (24B) of at least one wall (24), and preferably of each of the walls (24), has a variable thickness between a first end (56) of the second part (24B) of said wall (24), and a second end (55) of the second part (24B) of said wall (24), the thickness of the second part (24B) of said wall (24) at the first end (55) being greater than the thickness of the second part (24B) of said wall (24) at the second end (56).

4. Light module (1; 100; 150) according to claim 3, wherein the thickness of the second part (24B) of each wall (24) at the first end (55) is less than 120 micrometers. [Claims] Light module (1; 100; 150) according to any one of claims 1 to 4, wherein the first part (24A) of each wall (24) has a height of less than 100 micrometers. [Claims] Light module (1; 100; 150) according to any one of claims 1 to 5, wherein the second part (24B) of each wall (24) has a height of less than 110 micrometers.

7. Light module (1; 100; 150) according to any one of claims 1 to 6, wherein the first part (24A) of each wall (24) is positioned at a distance from the relevant elementary light generator (21), said distance being less than 150 micrometers. [Claims] Light module (1; 100; 150) according to any one of claims 1 to 7, wherein the first part (24A) of each wall (24) is positioned at a distance from a first face (31) of the printed circuit board (3), said distance being less than 50 micrometers.

9. Light module (100; 150) according to any one of claims 1 to 8, wherein a dielectric layer (25) is provided formed on a first face (31) of the printed circuit board (3), the dielectric layer (25) being positioned between the printed circuit board (3) and said plurality of walls (24).

10. Light module (100) according to any one of claims 1 to 7, wherein each light source comprises a substrate (23), the elementary light generator (21) of each light source (2) comprising at least two electrical connection pads (21a) through which it is mounted on this substrate (23), each light source (2) being mounted and interconnected to said printed circuit board (3) via the substrate (23) concerned, the first part (24A) of each wall (24) being positioned at a distance from a first face (23a) of said substrate (23), said distance being less than 50 micrometers.

11. A light module (100) according to claim 10, wherein a dielectric layer (25) is provided, formed on the first face (23a) of the substrate (23), the dielectric layer (25) being positioned between the substrate (23) and said plurality of walls (24).

12. A light module (100; 150) according to claim 9 or 11, wherein the dielectric layer (25) comprises an epoxy polymer material.

13. A signaling device for a motor vehicle comprising a light module (1; 100; 150) according to any one of claims 1 to 12, said plurality of light sources (2) forming a light screen of said signaling device.

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