TWI845131B - Light emitting unit and backlight module including same - Google Patents

Abstract

The present invention provides a light emitting unit and a backlight module including a plurality of light emitting units. The light emitting unit includes: a base plate with a bearing surface; a light source arranged on the bearing surface; a wall body arranged on the base plate surrounding the light source, wherein the base plate and the wall body jointly define a cavity, and the cavity has an opening above the light source; and a top cover is provided to block the opening. The wall body is at least partially transparent to the light emitted by the light source, and the top cover is at least partially transparent and partially reflective to the light emitted by the light source. The center of the top cover has a thicker thickness than the edge ends of the top cover, and protrudes toward the interior of the cavity. In the light emitting unit, along a virtual cross-section perpendicular to the bearing surface, a lower line defined by the base plate is larger than the upper line defined by the opening in the cross-section of the cavity.

Description

Light-emitting unit and backlight module including the same

The present invention relates to a light-emitting unit and a backlight module including the same. Specifically, the present invention relates to a light-emitting unit including a light-transmissive wall and a backlight module including the same.

In order to adjust the display and light emission more precisely, the design and layout of light-emitting units with characteristics such as local dimming are gradually gaining attention. As mentioned above, the light-emitting unit can have different light patterns or light emission angles according to its design. In order to further improve the light emission efficiency and improve the display with a wide viewing angle, it is better that the light-emitting unit can have a more uniform light pattern and a wider light emission angle within the expected visual range. Therefore, it is necessary to develop a light-emitting unit that can further improve the uniformity of the light pattern and the light emission angle while ensuring the stability and reliability of the structure.

Technical means to solve the problem

To solve the above problems, according to one embodiment of the present invention, a light-emitting unit is proposed, which includes: a bottom plate having a supporting surface; a light source disposed on the supporting surface; a wall body disposed on the bottom plate around the light source, wherein the wall body has at least partial light transmittance relative to the light emitted by the light source, and wherein the bottom plate and the wall body together define a chamber, and the chamber has an opening above the light source; and a top cover, which is disposed to block the opening and has at least partial light transmittance and partial reflectivity relative to the light emitted by the light source. The center of the top cover has a thicker thickness than the edge end, and protrudes toward the inside of the chamber. In addition, along a virtual cross section perpendicular to the supporting surface, the lower bottom defined by the bottom plate in the cross section of the chamber is larger than the upper bottom defined by the opening.

Another embodiment of the present invention provides a backlight module, which includes: a substrate; and a plurality of light-emitting units as described above, which are disposed on the substrate.

Comparison with the efficacy of previous technologies

The light-emitting unit and backlight module provided in accordance with each embodiment of the present invention can reduce or avoid the waste of light in the non-visible range, and guide such light to be emitted from the visible range, thereby improving the light-emitting efficiency at the forward angle, and further increasing the light-emitting angle and uniformity while ensuring the structural stability and reliability of the light-emitting unit. Therefore, the light-emitting unit and backlight module provided in accordance with each embodiment of the present invention can provide a more uniform wide-angle light pattern, and can ensure the structural stability of the light-emitting unit itself and the intensity of the forward light under the trend of thinning of electronic devices.

Various embodiments will be described below, and those with ordinary knowledge in the art should be able to easily understand the spirit and principles of the present invention by referring to the description with accompanying drawings. However, although some specific embodiments will be specifically described in the text, these embodiments are only exemplary and are not to be considered as limiting or exhaustive in all aspects. Therefore, for those with ordinary knowledge in the art, various changes and modifications of the present invention should be obvious and easily achievable without departing from the spirit and principles of the present invention.

Referring to FIG. 1 , a light emitting unit 10 is provided according to an embodiment of the present invention. As mentioned above, the light emitting unit 10 can be applied to various devices or equipment to supply light. For example, as shown in FIG. 1 , a display device DX can have a backlight module 1000, one or more optical films 1500, and a display panel 2000 stacked in sequence along a third direction D3. The backlight module 1000 can include a substrate 800 and a plurality of light emitting units 10 disposed on the substrate 800. For example, a plurality of light emitting units 10 can be arranged on a plane defined by a first direction D1 and a second direction D2 perpendicular to the third direction D3. As mentioned above, the backlight module 1000 configured in this way can supply light to the display panel 2000 through the optical film 1500 based on the light-emitting unit 10 generally facing the third direction D3, and display the expected image through the display panel 2000. However, the configuration of a plurality of light-emitting units 10 as a direct-type backlight module 1000 for use in the display device DX is only an example, and the devices that can be matched with the light-emitting unit 10 according to each embodiment of the present invention and the form of its arrangement are not limited to this.

Next, the light-emitting unit 10 according to the present embodiment will be specifically described below with reference to FIG. 2 which is an enlarged schematic diagram of the light-emitting unit 10 cut along the section line X-X' of FIG. 1 (e.g., perpendicular to the second direction D2 shown in FIG. 1). As mentioned above, the light-emitting unit 10 may include: a bottom plate 100 having a supporting surface 110, a light source 200 disposed on the supporting surface 110, a wall 300 disposed on the bottom plate 100 around the light source 200, and a top cover 400 disposed on the wall 300. The bottom plate 100 and the wall 300 may define a chamber M together, and the chamber M may have an opening OP above the light source 200 to connect the chamber M with the environment outside the chamber M. As mentioned above, the top cover 400 can be disposed to seal the opening OP so that the chamber M is not connected to the external environment.

As shown in FIG. 2 , according to the present embodiment, the center C of the top cover 400 may have a thicker thickness Th1 than the edge end E, and may protrude toward the inside of the chamber M. Specifically, according to the present embodiment, the top cover 400 may have a convex surface N protruding toward the light source 200. The top cover 400 may have a thickness Th1 at the center C, and the thickness Th2 of the top cover 400 may be thinner as it approaches the edge end E. In addition, according to some embodiments, the edge end E of the top cover 400 may have almost no thickness, and may be connected to the top of the wall 300 so that at least a portion of the edge end E of the top cover 400 is supported by the wall 300. As described above, according to this embodiment, the top cover 400 can be more stably disposed on the light source 200 due to the support of the wall 300.

According to the light-emitting unit 10 of the present embodiment, the light L emitted from the light source 200 can be emitted to the wall 300 and the top cover 400. The wall 300 can have at least partial light transmittance relative to the light L emitted from the light source 200, so that at least part of the light L can be emitted through the wall 300. In addition, the top cover 400 has at least partial light transmittance and partial reflectivity relative to the light L emitted from the light source 200, so that at least part of the light L can be emitted through the top cover 400 and at least part of the light L can be reflected by the top cover 400. Therefore, according to this configuration, part of the light L originally emitted to the top cover 400 can be reflected by the top cover 400 and emitted through the wall 300. Thereby, the light with a wide viewing angle can be further enhanced, thereby achieving a better wide viewing angle light emission of the light emitting unit 10.

In addition, according to the present embodiment, along the virtual cross section perpendicular to the supporting surface 110, the lower bottom B1 defined by the bottom plate 100 in the cross section of the chamber M may be larger than the upper bottom B2 defined by the opening OP. In detail, according to the present embodiment, the bottom plate 100 and the wall 300 may be sandwiched by a predetermined angle θm, and the predetermined angle θm is an acute angle. Therefore, the chamber M of the overall light-emitting unit 10 may have a trapezoidal shape in which the lower bottom B1 is larger than the upper bottom B2. With this angle and the trapezoidal structure, the light ray L that is close to being parallel to the bottom plate 100 (for example, along or close to being along the first direction D1) can be further guided to a direction closer to the forward direction for re-emission (for example, at least the angle relative to the first direction D1 becomes larger) while maintaining a wide viewing angle by virtue of the light transmittance of the wall 300. Therefore, according to this embodiment, while maintaining a wide viewing angle, the utilization efficiency of the light L can be further improved. In particular, the light L that may be parallel to or nearly parallel to the bottom plate 100 and cannot be used or observed can be guided back to the forward direction, thereby improving the light extraction efficiency of the entire light emitting unit 10.

As mentioned above, the light-emitting unit 10 according to the present embodiment can be used, for example but not limited to, as a light source of a direct-type backlight module 1000, and due to its wide-angle light emission characteristics, a uniform light emission performance in a wider plane can be achieved based on a configuration with a lower density. However, the above application is only an example, and the present invention is not limited thereto. As mentioned above, according to other embodiments of the present invention, the light-emitting unit 10 can also be applied to other devices as a light source. In addition, the light-emitting unit 10 according to the present embodiment can also be used in combination with other optical molding lenses (Molding Lens) or light guide plates or optical components according to the design to form more diverse light emission changes.

Furthermore, according to some embodiments, in order to further improve the utilization efficiency of the light L, especially when the light source 200 is a 360-degree emitting light source such as an LED, a recessed area 500 may be further provided on the supporting surface 110 of the bottom plate 100, and the light source 200 may be disposed in the recessed area 500. Specifically, the recessed area 500 may have a cross section of a notch R on a virtual cross section. The notch R may be defined by a bottom surface 510 and at least one wall surface 520, and the bottom surface 510 and at least one wall surface 520 may be at an angle θr of a blunt angle. Therefore, if the light source 200 is a 360-degree emitting light source such as an LED, the light L emitted from the back of the top cover 400 may be reflected by the recessed area 500 and emitted in a forward direction from the back of the bottom plate 100. For example, the light L may be reflected and directed by the bottom surface 510 or the wall surface 520, and thus emitted in the forward direction facing away from the bottom plate 100. However, the above is only an example, and according to other embodiments of the present invention, when the light source 200 is not a 360-degree emitting light source, or when the light source 200 itself has sufficient light emitting efficiency, the recessed area 500 may not be provided on the supporting surface 110.

Next, the material arrangement of each component of the light-emitting unit 10 according to an embodiment of the present invention will be further described with reference to FIG. 3 .

As mentioned above, according to an embodiment, a substrate 600 may be filled in the chamber M of the light-emitting unit 10, and the substrate 600 and the top cover 400 may both include a first material Q1 having a predetermined light-transmitting property. For example, the first material Q1 may be silicone, but is not limited thereto. As described above, based on the same first material Q1, the adhesion between the top cover 400 and the substrate 600 may be further enhanced. Therefore, the integrity and structural stability of the overall light-emitting unit 10 may be further improved.

According to some embodiments, in order to set different optical properties, the top cover 400 may be doped with a doping material T1 in addition to the first material Q1, and the base 600 may be doped with a doping material T2 in addition to the first material Q1. As mentioned above, the doping material T1 and the doping material T2 may be different, so that the top cover 400 and the base 600 have different optical properties. For example, when the first material Q1 is silica gel, the base 600 may be further doped with phosphor as the doping material T2, and the top cover 400 may be further doped with TiO ₂ as the doping material T1. Thus, after passing through the fluorescent gel (silicone and fluorescent powder) of the substrate 600, the light L can have a predetermined light color or other light characteristics, and the top cover 400 can have a predetermined reflectivity and light transmittance based on the doped _TiO2 , thereby achieving the characteristics of making part of the light L pass through the top cover 400 and part of the light L reflected by the top cover 400. However, the materials of the top cover 400 and the substrate 600 are only examples, and other embodiments of the present invention are not limited thereto.

In addition, according to some embodiments, the wall 300 can be made of a second material Q2 having a greater light transmittance than the first material Q1 or the entire substrate 600. For example, the wall 300 can be made of Poly Cyclohexylene dimethylene Terephthalate (PCT). In this way, the light transmittance of the wall 300 can be greater than the light transmittance of the substrate 600. Therefore, after the light L emitted from the light source 200 passes through the substrate 600 and is given a predetermined light color or other light characteristics, it can be emitted at least partially or completely through the wall 300. In this way, the light output corresponding to the viewing angle at a wide angle in the forward direction can be further enhanced while the wall 300 supports the substrate 600 to enhance stability and reliability.

According to some embodiments, the required light transmittance of the wall 300 can be adjusted by further doping the wall 300 with a doping material T3 and adjusting its concentration. For example, the doping material T3 can be TiO ₂ . Therefore, the light type of the entire light emitting unit 10 can be further adjusted and changed with the same structure and even size of the light emitting unit 10 .

As mentioned above, the first material Q1, the second material Q2, the doped material T1, the doped material T2 and the doped material T3 can be further adjusted based on the fixed mold for manufacturing the light-emitting unit 10, so as to further adjust the possible light type or light extraction efficiency of the light-emitting unit 10. Therefore, the wall 300 with partial light transmittance can make the whole light-emitting unit 10 more stable and reliable while maintaining a wide viewing angle of light extraction, and different forms can be produced under the same mold based on this change.

Specifically, according to some embodiments, the top cover 400 may be configured to have a light transmittance of 20% to 60%. For example, the top cover 400 may have a light transmittance of 30% to 40%. In addition, the reflectivity of the top cover 400 relative to the light L emitted by the light source 200 may be lower than 70%. For example, the reflectivity of the top cover 400 relative to the light L emitted by the light source 200 may be between 50% and 70%. Thereby, a predetermined degree of light L can be emitted through the top cover 400 to form a frontal light close to the normal line, and a predetermined degree of light L can be reflected by the top cover 400 and directed to the wall 300 and then emitted to form a side light that is relatively deviated from the normal line. In addition, the wall 300 may have a light transmittance of 30% to 100%, and according to some embodiments, may have a light transmittance higher than that of the top cover 400 to improve the light extraction efficiency at a wide viewing angle. For example, the wall 300 may have a light transmittance of 50% to 60%. However, the above is only an example, and under the premise of having a stable structure, the wall 300 may be configured as much as possible to have a higher light transmittance.

According to some embodiments, in order to make the top cover 400 have a predetermined transmittance and reflectivity, the top cover 400 is preferably made of a non-metallic material.

In the following, the specific size details of the above-mentioned structural components will be further explained with reference to FIG. 4.

As mentioned above, according to one embodiment, the light-emitting unit 10 may have an upper base B2 and a lower base B1 as described above. Specifically, the upper base B2 corresponds to the upper side of the chamber M, and the lower base B1 corresponds to the lower side of the chamber M. The upper base B2 may have an upper base width W2, and the lower base B1 may have a lower base width W1. In addition, the chamber M may have a chamber height H corresponding to the upper base B2 and the lower base B1. As mentioned above, according to some embodiments, along a virtual cross section perpendicular to the supporting surface 110, when a chamber height H of the chamber M is in the range of 10 mm to 0.6 mm, the ratio of the chamber height H: the upper base width W2 of the upper base B2 of the chamber M: the lower base width W1 of the lower base B1 of the chamber M may be 1:1.9~1.1:2.7~1.9. In addition, according to some other embodiments, along a virtual cross-section perpendicular to the supporting surface 110, when the chamber height H of the chamber M is in the range of 0.6 mm to 0.1 mm, the ratio of the chamber height H: the upper bottom width W2 of the upper bottom B2 of the chamber M: the lower bottom width W1 of the lower bottom B1 of the chamber M is 1:3.3~2.5:4.0~3.2.

In addition, according to some embodiments, the thickest top cover thickness Th1 of the top cover 400 along the direction perpendicular to the supporting surface 110 (ie, the third direction D3) may be between 30 μm and 450 μm. For example, according to some embodiments, the top cover thickness Th1 may be between 30 μm and 100 μm.

Continuing to refer to FIG. 4 , according to some other embodiments, the wall 300 surrounding and defining the chamber M in the light-emitting unit 10 may have an inner surface S1 facing the chamber M and an outer surface S2 facing away from the chamber M. Based on the above, the wall thickness K between the inner surface S1 and the outer surface S2 parallel to the bottom plate 100 may be non-fixed. Specifically, the wall thickness K between the inner surface S1 and the outer surface S2 parallel to the bottom plate 100 (i.e., parallel to the first direction D1) is thicker near the bottom plate 100 (e.g., wall thickness K1) than far from the bottom plate 100 (e.g., wall thickness K2). In this way, the emission rate of the light rays L parallel to or close to the bottom plate 100 passing through the wall 300 can be further suppressed, thereby making the overall light pattern more uniform toward the positive angle of the visible range.

As mentioned above, according to some embodiments, the wall thickness K may be between 0.85 mm and 0.09 mm. However, this is only an example, and the wall thickness K of each embodiment of the present invention is not limited thereto under the condition of meeting the expected light transmittance and support. In addition, according to some embodiments, the wall thickness K may gradually become thicker along the third direction D3, but different embodiments of the present invention are not limited thereto.

Furthermore, according to different embodiments of the present invention, the top cover can have various embodiments under the premise that the top cover can have a structure with a thicker center. For example, the top cover 400 can be a plano-convex spherical shape as shown in the above-mentioned reference figures 1 to 4. In addition, referring to Figure 5, according to the light-emitting unit 20 of another embodiment, the top cover 400' can also be a pyramid. As above, the top cover 400' can also have a convex surface N protruding toward the light source 200.

As described above, according to various embodiments of the present invention, the top cover can have various forms, and under the premise that the chamber M has a lower bottom B1 larger than the upper bottom B2, the chamber M according to various embodiments of the present invention can also have various forms. For example, referring to FIG. 6A , according to one embodiment of the present invention, the chamber M1 can be a pyramidal shape formed by truncating the top of a cone. In addition, referring to FIG. 6B , according to another embodiment of the present invention, the chamber M2 can be a pyramidal shape formed by truncating the top of a ridged pyramid. As described above, when the cross section perpendicular to the supporting surface 110 has a lower bottom larger than the upper bottom or the angle between the bottom plate 100 and the wall 300 is a sharp angle, the chamber defined by the light-emitting unit according to each embodiment of the present invention can have various forms.

Next, the light pattern generated by the light emitting unit according to an exemplary embodiment will be described with reference to FIG. 7 .

As described above, according to an exemplary embodiment, in the case of an exemplary light-emitting unit configured as described above, wherein the chamber height H of the chamber M is 0.55 mm, the lower bottom width W1 of the lower bottom B1 is 2 mm, the upper bottom width W2 of the upper bottom B2 is 1.6 mm, and the top cover thickness Th1 of the top cover 400 is 0.1 mm, a light pattern with an angle as shown in FIG. 7 may be provided relative to the normal line perpendicular to the supporting surface 110. In detail, based on the light transmittance of the wall 300 of the light-emitting unit, the light L emitted from the light source 200 may directly pass through the wall 300 or be reflected by the top cover 400 before being emitted through the wall 300, so that the light emission at a wide angle relative to 0 degrees from the normal line is enhanced. However, since the top cover 400 itself also has a certain light transmittance, the light output close to the normal 0 degree can also be maintained. In addition, according to each embodiment of the present invention, since the predetermined angle θm between the bottom plate 100 and the wall 300 is lower than 90 degrees, and the light L emitted close to parallel to the bottom plate 100 (for example, approximately falling at an angle of 70 degrees to 90 degrees as shown in Figure 7) can be guided and emitted at least partially along a relatively positive direction (for example, approximately falling at an angle of 0 degrees to 80 degrees as shown in Figure 7). As mentioned above, this arrangement maintains a wide viewing angle of light output, so that the light output at an excessively large angle (for example, the closer to 90 degrees) and that may not be used is guided back to a usable viewing angle. Therefore, according to various embodiments of the present invention, the light output at a wide viewing angle and the light output close to the normal line can be maintained while protecting the chamber M with the wall 300, and the utilization rate of ineffective light at a large angle can be further guided and improved.

Next, further referring to FIG. 8 , different light-emitting units similarly configured based on different data as in the embodiment of FIG. 7 described above may have similar light patterns. As mentioned above, according to the light-emitting units of different embodiments of the present invention, the light pattern emitted after passing through the wall and the top cover may have a shape close to an inverted triangle or a gold ingot shape. In detail, the light pattern of the light emitted by the light-emitting units of each embodiment of the present invention may be close to an inverted triangle, and thus may reduce ineffective light emission at excessively large angles, ensure sufficient front-facing 0-degree angle light emission, and improve light emission intensity and uniformity at a wide angle within the visible range.

According to some embodiments, the light-emitting unit described above can also have excellent forward light intensity and wide-angle light uniformity when the device is thinned. Continuing from the above, Figures 9A to 9C are actual photos of the light output performance of multiple light-emitting units configured in the above embodiments at OD10 (Figure 9A), OD7 (Figure 9B) and OD5 (Figure 9C), respectively. As shown in the figure, it can be seen that even in the case of thinning OD5, the light output performance of the light-emitting unit according to the embodiment of the present invention can still have considerable forward light intensity and wide-angle light uniformity, and can maintain the uniformity and integrity of the overall light emission and reduce or avoid the generation of local dark spot defects.

As described above, referring to FIG. 10 , the light emitting unit 30 having a structure similar to or identical to the light emitting unit disclosed in the above-mentioned embodiments can emit light L’. According to some embodiments, when a normal line perpendicular to the supporting surface 110 is defined as a reference line P, the light intensity of the light emitting unit 30 at 30 to 60 degrees relative to the reference line P can be greater than the light intensity of the light emitting unit 30 at 60 to 90 degrees relative to the reference line P. In detail, the light L originally parallel to or nearly parallel to the bottom plate 100 emitted by the light source 200 is guided by the structure of the light emitting unit 30, and thus can be emitted in a direction with a smaller angle relative to the reference line P. Therefore, the light L' emitted by the light-emitting unit 30 can reduce or avoid the waste of light in a large non-visible range (e.g., close to 90 degrees). In addition, the light L' can be guided to emit light from the visible range, thereby further improving the light intensity at other angles. Therefore, according to the embodiment of the present invention, the efficiency of the light-emitting unit 30 can be effectively improved, and the uniformity and intensity of the light emitted in the visible range can be further improved.

Next, an exemplary process of preparing a light-emitting unit having the same or similar structure as above according to one embodiment of the present invention will be described with reference to Figures 11 to 16. However, a person skilled in the art should understand that this is only an example, and the preparation method of other embodiments of the present invention is not limited thereto if the same structure can be achieved.

As described above, as shown in FIG. 11, according to an embodiment of the present invention, the manufacturing method 50 of the light-emitting unit includes step S100, step S200, step S300, and step S400 in sequence. In particular, referring to FIG. 12 together with FIG. 11, in step S100, the bottom plate 100 and the wall 300 on the bottom plate 100 can be first set to make a main structure similar to a cup body, thereby defining the space of the chamber M and the opening OP connected to the outside. As described above, the bottom plate 100 and the wall 300 are set at a predetermined angle θm, and the predetermined angle θm is less than 90 degrees. In addition, optional structures such as a recessed area 500 can also be set on the bottom plate 100 in advance. Furthermore, although not specifically shown in the above embodiments, in this step, the required perforations G and other structures may be provided in advance on the bottom plate 100 or the wall 300 for purposes such as but not limited to electrical connection. As mentioned above, these contents should be understood by those with ordinary knowledge in the relevant technical field and will not be elaborated here.

As mentioned above, according to the present embodiment, referring to FIG. 13 together with FIG. 11, after the chamber M is constructed, a die bonding process (die bonding) can be performed in step S200 to place the light source 200 on the bottom plate 100 in the chamber M and supported by the supporting surface 110. As mentioned above, the light source 200 can be a source that can generate light such as LED, micro LED, mini LED, etc., and is not limited to the specific examples given here.

Next, referring to FIG. 14 together with FIG. 11, after the light source 200 is set, a wire bonding process may be performed in step S300 to set the relevant circuit configuration. As mentioned above, components such as wires W may be connected and configured corresponding to the light source 200, for example but not limited to, and the above-mentioned pre-set through-hole G and other structures may be used accordingly. These contents should be understood by those with ordinary knowledge in the relevant technical field, and will not be elaborated here.

Further, referring to FIG. 15 together with FIG. 11 , after the above configuration is completed, the matrix 600 may be filled in the chamber M in step S400. Specifically, as shown in FIG. 15 , a plastic fluid material Q (e.g., a mixed material of the first material Q1 and the doping material T1 described above) as the matrix 600 may be injected into the chamber M through the opening OP. As described above, after the matrix 600 is filled in the chamber M, it may be supported by the bottom plate 100 and the wall 300 , and based on the configuration of the chamber M, the unsupported central portion may naturally sink and cohere to form a groove V. Next, before the base 600 is completely formed, in step S400, a plastic fluid material Q' (for example, a mixed material of the first material Q1 and the doping material T2 described above) serving as the top cover 400 is injected into the above-mentioned sunken groove V through the opening OP. In this way, the shape of the top cover 400 can be formed by the above-mentioned naturally cohesive sunken groove V, and the groove V of a predetermined size and configuration can be set according to the preset size design by injecting a certain amount of fluid material Q, thereby forming a top cover 400 with a preset size and configuration. In addition, since the top cover 400 and the base 600 can selectively have part of the same material, and the fluid material Q' of the top cover 400 is injected onto the fluid material Q of the base 600 before being solidified, the adhesion of the formed top cover 400 and the base 600 can be further improved. In addition, the top cover 400 and the base 600 completed in this way can be supported and protected by the wall 300, reducing or avoiding the possibility of deterioration due to direct contact with the external environment, thereby further improving its stability and integrity.

In addition, according to the present embodiment, since the adhesion between the top cover 400 and the base 600 is improved, the integrity of the overall structure can be further improved, and the defects of peeling or falling off at the junction of the top cover 400 and the base 600 can be reduced or avoided. In particular, when the finished product needs to be moved separately, the separation between the top cover 400 and the base 600 during holding and the peeling and loss of materials can be reduced.

According to some embodiments, the end edge of the top cover 400 supported by both the base 600 and the wall 300 can be directly connected to the wall 300 with almost no thickness. In detail, by enhancing the adhesion between the top cover 400 and the base 600, the width of the top of the wall 300 to be set can be correspondingly reduced, and the end edge of the top cover 400 with almost no thickness can still be stably connected and supported, thereby reducing or avoiding the installation space of the top cover 400 that needs to be set in advance and occupied on the wall 300 while ensuring the support of the top cover 400. However, this is only an example, and the present invention is not limited thereto.

Finally, referring to FIG. 16 , after the above-mentioned steps S100, S200, S300 and S400 of glue dispensing molding are completed, a light-emitting unit 40 having a predetermined angle θm filled with a base 600 and a top cover 400 attached to the top can be formed. As described above, the top cover 400 has reflectivity and transmittance, and the wall 300 has transmittance, and since the chamber M can have a configuration in which the lower bottom B1 is larger than the upper bottom B2, the light-emitting unit 40 can thereby have a light-shaped feature close to an inverted triangle. Specifically, for example, a portion of the light L1 emitted by the light source 200 to the top cover 400 can penetrate the top cover 400 and be emitted as light L1', and a portion can be reflected by the top cover 400 and be light L2'. In addition, for example, the light ray L2 emitted by the light source 200 parallel to or close to the bottom plate 100 and reaching the wall 300 can be at least partially directed to a more positive angle and emitted as the light ray L3'. As mentioned above, the light ray L3' can at least partially deviate from the emission angle parallel to or close to the bottom plate 100 to emit from other positive wide angles or even positive angles on the normal.

According to some embodiments, the light emitting unit 40 may be further processed by other known processes, such as but not limited to testing, packaging, transferring, arranging and assembling in other devices, etc. As mentioned above, these contents should be well known to those with ordinary knowledge in the relevant technical field and will not be elaborated here.

In summary, the light-emitting unit and the device using the same, such as a backlight module, proposed in each embodiment of the present invention can ensure the integrity of the overall light-emitting unit structure and reduce or avoid the exposure and damage and peeling of the interfaces between the components of the light-emitting unit. In particular, the light-emitting unit proposed in the present embodiment can reduce or avoid the peeling and separation of the top cover or the exposure and contamination of the chamber based on the protection and support of the wall. In addition, since the chamber is defined by the wall without the need for a cutting process, according to the present invention, the chamber and its contents can be reduced or avoided. Unexpected deviations, damage and contamination during the cutting process can be reduced or avoided. For example, but not limited to wet gas erosion in wet cutting and high-speed friction carbonization in dry cutting. In addition, the configuration and angle design of the chamber of the light-emitting unit according to each embodiment of the present invention can reduce or avoid the defect that the light close to parallel light or parallel light cannot be used in the visible range. Continuing from the above, based on this structure and the preset reflectivity and transmittance of the top cover and the preset transmittance of the wall, the light-emitting unit and the device using the same according to each embodiment of the present invention can improve the light type and uniformity of the light output at a wide angle, while ensuring the predetermined intensity of the forward light output on the normal line and reducing or avoiding the halo effect. In particular, even when the device layer is thinned to below OD5, the light-emitting unit and the device using the same according to each embodiment of the present invention can still greatly improve the possible defect of the dark spot of the forward light output on the lamp. Therefore, the light-emitting unit and the device using the same according to the embodiments of the present invention can realize more uniform wide-angle light emission and forward light emission with thinner device layers and lower arrangement density. As mentioned above, the light-emitting unit and the device using the same according to the embodiments of the present invention can improve the efficiency of light emission, and are more stable and reliable and have a longer life.

The above descriptions are only some of the preferred embodiments of the present invention. It should be noted that the present invention can be subjected to various changes and modifications without departing from the spirit and principles of the present invention. A person with ordinary knowledge in the relevant technical field should understand that the present invention is defined by the scope of the attached patent application, and that various possible substitutions, combinations, modifications and conversions are within the scope of the present invention as defined by the scope of the attached patent application in accordance with the intent of the present invention.

10, 20, 30, 40: light emitting unit

50:Production method

100: Base plate

110: Loading surface

200: Light source

300: Wall

400, 400’: Top cover

500: Depression

510: Bottom

520: Wall

600: Base

800: Substrate

1000:Backlight module

1500:Optical film

2000: Display Panel

B1: Bottom

B2: Upper bottom

C: Central

D1: First direction

D2: Second direction

D3: Third direction

DX: Display Device

E: Edge end

G: Perforation

H: Chamber height

K, K1, K2: wall thickness

L, L’, L1, L2, L1’, L2’, L3’: light

OP: Open mouth

M, M1, M2: Chamber

N: Convex

P: Baseline

Q, Q’: fluid material

Q1: First Material

Q2: Second Material

R: Notch

S1: Inner surface

S2: Outer surface

S100, S200, S300, S400: Steps

T1, T2, T3: mixed materials

Th1, Th2: thickness

V: Groove

W:Wire

W1: bottom width

W2: Upper base width

θm: Predetermined angle

θr: Angle

FIG. 1 is a three-dimensional schematic diagram of a display device having a backlight module with a light-emitting unit according to an embodiment of the present invention.

FIG2 is a schematic cross-sectional view of a light-emitting unit taken along the X-X section line of FIG1 according to an embodiment of the present invention.

FIG3 is a schematic diagram showing the material properties of various structural parts of a light-emitting unit according to an embodiment of the present invention.

FIG4 is a schematic diagram showing the size configuration of each structural part of a light-emitting unit according to an embodiment of the present invention.

FIG5 is a schematic diagram showing a top cover of a light-emitting unit according to another embodiment of the present invention.

FIG. 6A and FIG. 6B are schematic diagrams showing the state of the chamber of the light-emitting unit according to different embodiments of the present invention.

FIG. 7 is a schematic diagram showing an example of a light pattern generated by a light-emitting unit according to an embodiment of the present invention.

FIG8 is a schematic diagram showing examples of light patterns generated by light-emitting units according to different embodiments of the present invention.

9A to 9C are example photographs of luminescence performance generated by a plurality of light-emitting units under different OD configurations according to an embodiment of the present invention.

FIG10 is a diagram showing the distribution of light emitted by a light-emitting unit in various angle ranges according to an embodiment of the present invention.

FIG. 11 is a schematic diagram of a process for preparing a light-emitting unit according to an embodiment of the present invention.

FIG. 12 is a schematic diagram showing a main structure of a light-emitting unit and a chamber defined by the main structure prepared according to an embodiment of the present invention.

FIG. 13 is a schematic diagram showing a die bonding process for setting a light source according to an embodiment of the present invention.

FIG. 14 is a schematic diagram showing a wire bonding process to set up a related circuit configuration according to an embodiment of the present invention.

FIG. 15 is a schematic diagram showing an encapsulation process for setting a base and a top cover according to an embodiment of the present invention.

FIG16 is a schematic diagram of a light-emitting unit and its light emission after filling and packaging according to an embodiment of the present invention.

without

10: Light-emitting unit

100: Base plate

110: Loading surface

200: Light source

300: Wall

400: Top cover

500: Depression area

510: Bottom

520: Wall

B1: Bottom

B2: Upper bottom

C:Central

D1: First direction

D2: Second direction

D3: Third direction

E: Edge end

L: Light

OP: Open your mouth

M: Chamber

N: convex

R: Notch

Th1, Th2: thickness

θm: Predetermined angle

θr: angle

Claims (26)

A light-emitting unit comprises: a bottom plate having a supporting surface; a light source disposed on the supporting surface, wherein a recessed area is provided on the supporting surface and the light source is disposed in the recessed area; a wall body disposed on the bottom plate around the light source, wherein the wall body has at least partial light transmittance relative to the light emitted by the light source, and wherein the bottom plate and the wall body jointly define a chamber, and the chamber has an opening above the light source; and a top cover disposed to block the opening and relative to the light source. The light emitted by the source is at least partially transparent and partially reflective, wherein the center of the top cover is thicker than the edge end, and protrudes toward the inside of the chamber, wherein, along a virtual cross section perpendicular to the supporting surface, a lower bottom defined by the bottom plate in the cross section of the chamber is larger than an upper bottom defined by the opening, and wherein the recessed area has a notched cross section on the virtual cross section, the notch is defined by a bottom surface and at least one wall surface, and the bottom surface and the at least one wall surface form a blunt angle. The light-emitting unit as described in claim 1, wherein the base plate and the wall are arranged at a predetermined angle, and the predetermined angle is a sharp angle. The light-emitting unit as described in claim 1, wherein the chamber is filled with a substrate, and both the substrate and the top cover contain a first material. The light-emitting unit as described in claim 3, wherein the light transmittance of the wall is greater than the light transmittance of the substrate. The light-emitting unit as described in claim 3, wherein the first material is silicone. The light-emitting unit as described in claim 3, wherein the substrate is further doped with phosphor, and the top cover is further doped with TiO ₂ . The light-emitting unit as described in claim 1, wherein the wall is made of polyethylene terephthalate. The light-emitting unit as described in claim 7, wherein the wall is further doped with TiO ₂ . The light-emitting unit as described in claim 1, wherein the top cover has a light transmittance of 20% to 60%. The light-emitting unit as described in claim 9, wherein the top cover has a light transmittance of 30% to 40%. The light-emitting unit as described in claim 1, wherein the wall has a light transmittance of 30% to 100%. The light-emitting unit as described in claim 1, wherein the wall has an inner surface facing the chamber and an outer surface facing away from the chamber, and the thickness of a wall parallel to the bottom plate between the inner surface and the outer surface is thicker near the bottom plate than far from the bottom plate. The light-emitting unit as described in claim 12, wherein the wall thickness is between 0.85 mm and 0.09 mm. The light-emitting unit as described in claim 1, wherein the top cover is pyramidal or plano-convex spherical and has a convex surface protruding toward the light source. The light-emitting unit as described in claim 1, wherein the chamber is a conical shape formed by truncating the top of a cone or a ridged pyramid. The light-emitting unit as described in claim 1, wherein the thickness of the thickest top cover in the direction perpendicular to the supporting surface is between 30μm and 450μm. A light-emitting unit as described in claim 16, wherein the thickness of the top cover is between 30 μm and 100 μm. The light-emitting unit as described in claim 1, wherein, along the virtual cross section perpendicular to the supporting surface, when a chamber height of the chamber is in the range of 10 mm to 0.6 mm, the ratio of the chamber height: the upper bottom width of the upper bottom of the chamber: the lower bottom width of the lower bottom of the chamber is 1:1.9~1.1:2.7~1.9. The light-emitting unit as described in claim 1, wherein, along the virtual cross section perpendicular to the supporting surface, when a chamber height of the chamber is in the range of 0.6 mm to 0.1 mm, the ratio of the chamber height: the upper bottom width of the upper bottom of the chamber: the lower bottom width of the lower bottom of the chamber is 1:3.3~2.5:4.0~3.2. The light-emitting unit as described in claim 1, wherein at least a portion of the edge end of the top cover is supported by the wall. A light-emitting unit as described in claim 1, wherein the light pattern of the light emitted by the light-emitting unit is close to an inverted triangle. The light-emitting unit as described in claim 1, wherein when a normal line perpendicular to the supporting surface is defined as a reference line, the light-emitting unit has a light intensity at 30 to 60 degrees relative to the reference line greater than the light intensity at 60 to 90 degrees relative to the reference line. A light-emitting unit as described in claim 1, wherein the top cover is made of non-metallic material. The light-emitting unit as described in claim 1, wherein the reflectivity of the top cover relative to the light emitted by the light source is less than 70%. The light-emitting unit as described in claim 24, wherein the reflectivity of the top cover relative to the light emitted by the light source is between 50% and 70%. A backlight module, comprising: a substrate; and a plurality of light-emitting units as described in claim 1, disposed on the substrate.