JP7709017B2 - Light source device and lens structure - Google Patents

Description

This application relates to a light source device and a lens structure.

Conventionally, composite molded lenses have been disclosed in which a press-molded lens body and a frame body surrounding the lens body are integrated by injection molding. The upper and lower molds of the composite molded lens die used in the manufacture of this composite molded lens are composed of a lens core, a flange core, and a frame core, each of which is independently movable, but the number of steps required to manufacture the composite molded lens is large (see, for example, Patent Document 1).

JP 2013-202810 A

The objective of this disclosure is to provide a light source device and a lens structure that have good adhesion between the support and the lens.

A light source device according to an embodiment of the present disclosure includes a light source having a light-emitting surface on its upper surface, the light source including a plurality of light-emitting units arranged two-dimensionally; a lens arranged above the light-emitting surface of the light source at a distance from the light source, the lens having an optical function unit and a flange portion arranged along the outer periphery of the optical function unit; and a support body made of a light-shielding member and supporting at least the flange portion of the lens, the optical function unit including a first surface located on the opposite side to the light source and a second surface located on the opposite side to the first surface and facing the light source, the surface area of the first surface being larger than the surface area of the second surface, the first surface and the second surface covering the plurality of light-emitting units in a plan view, the flange portion having a third surface located on the same side as the first surface and a fourth surface located on the same side as the second surface, and the flange portion having at least one first recess on the fourth surface.

A lens structure according to an embodiment of the present disclosure includes a lens having an optical function portion and a flange portion arranged along the outer periphery of the optical function portion, and a support body made of a light-shielding member and supporting at least the flange portion of the lens, the lens and the support body being a two-color molded body, the optical function portion having a first surface and a second surface located opposite the first surface, the surface area of the first surface being larger than the surface area of the second surface, the flange portion having a third surface located on the same side as the first surface and a fourth surface located on the same side as the second surface, and the flange portion having at least one first recess on the fourth surface.

According to one embodiment of the present disclosure, it is possible to provide a light source device and a lens structure that have good adhesion between the support and the lens.

FIG. 1A is a top view of a light source device according to an embodiment of the present disclosure. FIG. 1B is a schematic cross-sectional view taken along line 1B-1B shown in FIG. 1A. FIG. 2A is a schematic top view of a lens structure according to an embodiment. FIG. 2B is a schematic bottom view of the lens structure according to the embodiment. FIG. 2C is a schematic cross-sectional view taken along line 2C-2C shown in FIGS. 2A and 2B. FIG. 3A is a schematic bottom view of a lens in an embodiment. FIG. 3B is a schematic cross-sectional view taken along line 3B-3B shown in FIG. 3A. FIG. 4A is a schematic bottom view showing another lens in the embodiment. FIG. 4B is a schematic bottom view showing still another lens in the embodiment. FIG. 5A is a schematic top view showing a light source in the embodiment. FIG. 5B is a schematic cross-sectional view taken along line 5B-5B shown in FIG. 5A. FIG. 5C is an enlarged schematic cross-sectional view showing a part of the light source. FIG. 6A is a cross-sectional view showing a process for manufacturing the light source device according to the embodiment. FIG. 6B is a cross-sectional view showing a process for manufacturing the light source device according to the embodiment. FIG. 6C is a cross-sectional view showing a process for manufacturing the light source device according to the embodiment. FIG. 6D is a cross-sectional view showing a process for manufacturing the light source device according to the embodiment. FIG. 6E is a cross-sectional view showing a process for manufacturing the light source device according to the embodiment. FIG. 7A is an enlarged schematic bottom view showing a part of the lens of Modification 1. FIG. FIG. 7B is an enlarged schematic cross-sectional view taken along line 7B-7B shown in FIG. 7A. FIG. 8A is an enlarged schematic bottom view showing a part of the lens of Modification 2. FIG. FIG. 8B is an enlarged schematic cross-sectional view taken along line 8B-8B shown in FIG. 8A. FIG. 9A is an enlarged schematic bottom view showing a part of the lens of Modification 3. FIG. FIG. 9B is an enlarged schematic cross-sectional view taken along line 9B-9B shown in FIG. 9A. FIG. 10A is an enlarged schematic bottom view showing a part of the lens of Modification 4. FIG. FIG. 10B is an enlarged schematic cross-sectional view taken along line 10B-10B shown in FIG. 10A. FIG. 11 is a schematic cross-sectional view showing another example of the light source device according to the embodiment.

The following describes an embodiment of the invention with reference to the drawings as appropriate. However, the light source device described below is intended to embody the technical concept of the present invention, and unless otherwise specified, the present invention is not limited to the following. Furthermore, the content described in one embodiment can also be applied to other embodiments and modified examples. Furthermore, the sizes and positional relationships of components shown in the drawings may be exaggerated for clarity of explanation.

In the following description, components having substantially the same functions are indicated by common reference symbols, and descriptions may be omitted. Alternatively, components not referred to in the description may not be assigned reference symbols. In the following description, terms indicating specific directions or positions (for example, "up", "down", "right", "left" and other terms including these terms) may be used. However, these terms are merely used for the sake of clarity of the relative directions or positions in the referenced drawings. As long as the relationship of the relative directions or positions by terms such as "up" and "down" in the referenced drawings is the same, the arrangement may not be the same in drawings other than this disclosure, in actual products, manufacturing equipment, etc. as in the referenced drawings. In this disclosure, "parallel" includes cases where two straight lines, sides, faces, etc. are in the range of about 0° to ±5°, unless otherwise specified. In addition, in this disclosure, "perpendicular" or "orthogonal" includes cases where two straight lines, sides, faces, etc. are in the range of about 90° to ±5°, unless otherwise specified.

In the figures shown below, arrows indicating mutually orthogonal x-axis, y-axis, and z-axis are also shown. The x-direction along the x-axis indicates a predetermined direction in the arrangement plane in which the light source provided in the light source device according to the embodiment is arranged (in other words, in the arrangement plane in which the light emitting units are arranged), the y-direction along the y-axis indicates a direction perpendicular to the x-direction in the arrangement plane of the light source, and the z-direction along the z-axis indicates a direction perpendicular to the arrangement plane. In addition, the direction in which the arrow points in the x-direction is expressed as +x-direction, the direction opposite to the +x-direction is expressed as -x-direction, the direction in which the arrow points in the y-direction is expressed as +y-direction, the direction opposite to the +y-direction is expressed as -y-direction, the direction in which the arrow points in the z-direction is expressed as +z-direction, and the direction opposite to the +z-direction is expressed as -z-direction. In the embodiment, the light source irradiates light in the +z direction as an example. However, this does not limit the orientation of the light source device and the lens structure when used, and the orientation of the light source device and the lens structure is arbitrary.

The following describes an embodiment using as an example a smartphone flashlight having a light source device and a lens structure according to the embodiment.

(Embodiment)
1A and 1B are diagrams showing a light source device 200 according to a first embodiment of the present disclosure. Fig. 1A is a schematic top view of the light source device 200. Fig. 1B is a schematic cross-sectional view of the light source device 200 taken along line 1B-1B shown in Fig. 1A.

The light source device 200 comprises a light source 30, a lens 10, and a support 20.

The light source 30 includes a plurality of light-emitting units 30U arranged two-dimensionally. The lens 10 is disposed above (in the +z direction) the light-emitting surface 30a of the light source 30 and spaced from the light source 30. The lens 10 has an optical function unit 11 and a flange unit 12 disposed along the outer periphery 11P of the optical function unit 11. The support body 20 is made of a light-shielding member and supports at least the flange unit 12 of the lens 10. A structure including the lens 10 and the support body 20 is referred to as a "lens structure."

The optical function unit 11 includes a first surface 11a located on the opposite side to the light source 30, and a second surface 11b located on the opposite side to the first surface 11a and facing the light source 30. In a plan view, the first surface 11a and the second surface 11b cover the multiple light-emitting units 30U. In addition, the surface area of the first surface 11a is larger than the surface area of the second surface 11b.

The flange 12 has a third surface 12a located on the same side as the first surface 11a, and a fourth surface 12b located on the same side as the second surface 11b. The flange 12 has at least one first recess 13 on the fourth surface 12b.

In this embodiment, the lens 10 is formed using a material having translucency. The support 20 is made of a resin member having light blocking properties. For example, a two-color molding method described later can be used as a method for integrally molding different materials such as the lens 10 and the support 20. When the two-color molding method is used, the lens 10 and the support 20 can be integrally molded without using adhesives or the like, even when the support 20 is molded after the lens 10 is molded. The lens 10 and the support 20 may each be made of the same or different base materials, or may have different contained substances in the base materials. According to this embodiment, by providing the first recess 13 on the fourth surface 12b of the flange portion 12 of the lens 10, when the lens 10 is molded as a primary molded body in the two-color molding process described later, the adhesion between the lens 10 and the mold (lower mold) on the lower surface side of the lens 10 can be increased. As a result, when the mold is opened after molding of the lens 10, the lens 10 can be released from the mold (upper mold) on the upper surface side of the lens 10 while the lens 10 is left in the lower mold. Therefore, after molding the lens 10, it is possible to continuously mold the support 20 as a secondary molded body.

In addition, in this embodiment, the first recess 13 is provided in the flange portion 12 located on the outside of the optical function portion 11. This reduces the effect of the first recess 13 on the optical action of the optical function portion 11.

Each component is explained in detail below.

1. Lens Structure Fig. 2A is a schematic top view of the lens structure 100. Fig. 2B is a schematic bottom view of the lens structure 100. Fig. 2C is a schematic cross-sectional view taken along line 2C-2C shown in Figs. 2A and 2B.

The lens structure 100 includes a lens 10 and a support 20 made of a light-shielding material. The lens 10 and the support 20 are preferably integrated. The lens 10 and the support 20 may be a single two-color molded body. In this embodiment, a single two-color molded body refers to a molded body made of materials of different colors that are molded together without using an adhesive or the like.

As shown in Figures 1A and 1B, in this embodiment, the support 20 is in the +z direction with respect to the light-emitting surface 30a of the light source 30, and holds the lens 10 at a position where light from the light-emitting surface 30a is incident on the optical function unit 11. The light source device 200 may further include a substrate 40 on which the light source 30 is disposed, and the end of the support 20 on the light source 30 side may be fixed to the first surface 40a of the substrate 40. This allows the lens 10 to be stably held at a predetermined position with respect to the light-emitting surface 30a.

The support 20 may have an opening 25 on the side opposite the light source 30 that exposes at least a portion of the optical function portion 11 of the lens 10. Light incident on the lens 10 from the light source 30 passes through the opening 25 and is emitted from the top surface of the lens 10.

[Lens 10]
FIG. 3A is a schematic top view of the lens 10, and FIG. 3B is a schematic cross-sectional view taken along line 3B-3B shown in FIG. 3A.

In this embodiment, the outer shape of the lens 10 in plan view is approximately circular, and the diameter L1 is preferably 3.0 mm or more and 10.0 mm or less, for example, approximately 6.05 mm. The thickness L2 of the lens 10 is preferably 1.0 mm or more and 5.0 mm or less, for example, approximately 3.2 mm. Note that the outer shape of the lens 10 in plan view is not limited to this. For example, if the lens 10 includes multiple lens portions arranged two-dimensionally, the outer shape of the lens 10 in plan view may be approximately rectangular.

The lens 10 includes an optical function part 11 and a flange part 12 arranged outside the optical function part 11 along the outer periphery 11P of the optical function part 11. The optical function part 11 has a first surface 11a and a second surface 11b located opposite the first surface 11a. The first surface 11a is located opposite the light source, and the second surface 11b is located on the light source side. The flange part 12 has a third surface 12a located on the same side as the first surface 11a and a fourth surface 12b located on the same side as the second surface 11b. The flange part 12 also has at least one first recess on the fourth surface 12b. The flange part 12 may further include an outer surface 12c adjacent to the third surface 12a and the fourth surface 12b.

The lens 10 has an upper surface 10a and a lower surface 10b. The upper surface 10a of the lens 10 includes a first surface 11a of the optical function portion 11 and a third surface 12a of the flange portion 12. The lower surface 10b of the lens 10 includes a second surface 11b of the optical function portion 11 and a fourth surface 12b of the flange portion 12.

The "outer periphery 11P of the optical function part 11" is defined, for example, by the outer edge of the first surface 11a of the optical function part 11 on the upper surface 10a of the lens 10. In the example shown in Figures 3A and 3B, the convex part of the upper surface 10a of the lens 10 is the first surface 11a of the optical function part 11, and the approximately flat part located outside the first surface 11a is the third surface 12a of the flange part 12. Also, the part of the lower surface 10b of the lens 10 that overlaps with the first surface 11a in a plan view is the second surface 11b of the optical function part 11, and the part located outside the second surface 11b is the fourth surface 12b of the flange part 12. The fourth surface 12b includes a substantially flat surface. The fourth surface 12b may include a curved surface that is continuous with the second surface 11b of the optical function part 11.

<Optical function section 11>
The optical function unit 11 refracts the light transmitted through the optical function unit 11 from each light emitting unit 30U of the light source 30 and emits it in a predetermined direction. The optical function unit 11 can function as a convex lens such as a biconvex lens, a plano-convex lens, or a convex meniscus lens, a concave lens such as a biconcave lens, a plano-concave lens, or a concave meniscus lens, a Fresnel lens, or the like.

In this embodiment, the optical function unit 11 functions as a convex lens having one optical axis with respect to the light emitting surface 30a of the light source 30. This allows the light emitted from the light emitting surface 30a to be projected onto an illumination area that is point symmetric with respect to one point on the optical axis. For example, as described below, when multiple light emitting units 30U in the light source 30 are turned on independently of each other (hereinafter referred to as "partial driving"), illumination light having a luminance distribution corresponding to the light emission distribution of the light source 30 can be projected onto the illumination area.

The optical function unit 11 may have multiple optical axes relative to the light-emitting surface 30a of the light source 30. For example, the optical function unit 11 may include multiple lens units having different optical axes. Each of the multiple lens units may be arranged to correspond to one or more of the light-emitting units 30U of the light source 30.

The first surface 11a of the optical function part 11 has a surface area larger than that of the second surface 11b of the optical function part 11. The surface area of the first surface 11a is preferably, for example, two times or more and four times or less than that of the second surface 11b. In this embodiment, the surface area of the first surface 11a is preferably 15.0 ^mm2 or more and 40.0 ^mm2 or less, for example, about 27.9 ^mm2 . The surface area of the second surface 11b is preferably 10.0 ^mm2 or more and 35.0 ^mm2 or less, for example, about 22.1 ^mm2 .

The shapes of the first surface 11a and the second surface 11b are not particularly limited. For example, the first surface 11a and the second surface 11b may each be a convex surface that is curved in a convex shape, or a concave surface that is curved in a concave shape. In this case, the radius of curvature of the first surface 11a, which is a convex or concave surface, may be smaller than the radius of curvature of the second surface 11b, which is a convex or concave surface. Alternatively, the first surface 11a may include a convex surface or a convex surface, and the second surface 11b may be a flat surface. For example, the first surface 11a may be formed with unevenness that functions as a Fresnel lens, and the second surface 11b may be a flat surface.

In the illustrated example, the external shape of the optical function unit 11 in a plan view is approximately circular. The first surface 11a and the second surface 11b of the optical function unit 11 of the lens 10 are both convexly curved convex surfaces, and the optical function unit 11 functions as a convex lens having one optical axis. The optical axis of the convex lens may be parallel to the z-axis. The focal length of the optical function unit 11 is preferably, for example, 3 mm or more and 5 mm or less.

In the illustrated example, the radius of curvature of the first surface 11a is smaller than the radius of curvature of the second surface 11b. The radius of curvature of the first surface 11a is preferably 1.5 mm or more and 3.0 mm or less, for example, 2.4 mm. The radius of curvature of the second surface 11b is preferably 5.0 mm or more and 30.0 mm or less, for example, 10.0 mm.

The lens diameter LD1 of the first surface 11a (the diameter of the first surface 11a in a plan view) is preferably, for example, 3.0 mm or more and 5.0 mm or less, for example, about 4.21 mm. The maximum height HL of the first surface 11a is preferably, for example, 1.0 mm or more and 4.0 mm or less, for example, about 2.34 mm. The maximum height HL of the first surface 11a refers to the length along the z-axis from the third surface 12a to the vertex of the first surface 11a.

As shown in the figure, the lower surface 10b of the lens 10 may be formed with a convex surface having a lens diameter LD2 larger than the lens diameter LD1 of the first surface 11a. In this case, a part of the convex surface formed on the lower surface 10b becomes the second surface 11b of the optical function part 11. The lens diameter LD2 is preferably, for example, 4.0 mm or more and 6.0 mm or less, for example, about 5.3 mm.

<Flange portion 12>
The flange 12 can be disposed along the entire outer periphery 11P of the optical function part 11. In the illustrated example, in a plan view, the outer surface 12c of the flange 12 may extend outside the outer periphery 11P and approximately parallel to the outer periphery 11P. The width w1 of the flange 12 is preferably 0.7 mm or more and 1.1 mm or less, for example, 0.92 mm. The thickness d1 of the flange 12 is preferably 0.3 mm or more and 0.7 mm or less, for example, 0.5 mm. The thickness d1 of the flange 12 refers to the shortest distance in the z-axis direction between the third surface 12a and a portion of the fourth surface 12b where the first recess 13 is not formed and which is on the outer surface 12c side of the flange 12.

The flange portion 12 has at least one first recess 13 on the fourth surface 12b. This increases the contact area between the lower surface 10b of the lens 10 and the lower mold in the two-color molding process described below, and improves adhesion between the lens 10 and the lower mold. This makes it possible to more reliably release the lens 10 from the upper mold while holding the lens 10 on the lower mold when opening the mold after molding the lens 10. Therefore, after molding the lens 10, the support body 20, which is a secondary molded body, can be molded continuously.

In addition, since the first recess 13 is disposed on the flange portion 12, which is on the outside of the optical function portion 11, the influence of the first recess 13 on the optical action of the optical function portion 11 can be suppressed. It is preferable that the first recess 13 is disposed at a distance from the outer periphery 11P of the optical function portion 11. This makes it possible to more reliably suppress the influence of the first recess 13 on the optical action of the optical function portion 11.

The planar shape of the first recess 13 is not particularly limited. The first recess 13 may be a groove extending along the outer periphery 11P of the optical function part 11. Alternatively, it may have a planar shape such as a circle, an ellipse, or a rectangle. The inner surface of the first recess 13 may be approximately perpendicular to the third surface 12a of the flange part 12, or may be inclined with respect to the vertical plane of the third surface 12a. In addition, the corners of the first recess 13 may have a rounded shape (R shape).

The flange 12 may have a plurality of first recesses 13. The arrangement method, arrangement pitch, etc. of the plurality of first recesses 13 are not limited. For example, the plurality of first recesses 13 may be arranged at intervals along the outer periphery 11P of the optical function part 11. If the width w1 of the flange 12 is sufficiently large, two or more first recesses 13 may be arranged in the width direction of the flange 12. From the viewpoint of suppressing the traction phenomenon (a phenomenon in which the lens 10 remains on the upper mold side when the mold is opened after the formation of the lens 10) described later, it is preferable that the plurality of first recesses 13 are arranged at approximately equal intervals around the entire circumference of the flange 12.

3A and 3B, the first recess 13 is a groove surrounding the optical function part 11 in a plan view. The inner surface of the first recess 13 includes, for example, a first side surface 13s1 along the outer periphery 11P of the optical function part 11, and a second side surface 13s2 facing the first side surface 13s1 and positioned closer to the optical function part 11 than the first side surface 13s1. By providing a groove surrounding the optical function part 11 as the first recess 13, it is possible to improve adhesion with the lower mold over the entire flange part 12 of the lens 10 in the first mold opening process.

The width w2 of the first recess 13 is preferably 1/2 or less, more preferably 1/3 or less, of the width w1 of the flange 12. The width w2 of the first recess 13 is preferably, for example, 0.25 mm or more and 0.60 mm or less, for example, about 0.30 mm. The depth d2 of the first recess 13 from the fourth surface 12b (in other words, the maximum length in the z-axis direction) is preferably 1/2 or more of the thickness d1 of the flange 12. From the viewpoint of the strength of the lens 10, the depth d2 of the first recess 13 can be set to 4/5 or less of the thickness d1 of the flange 12. The depth d2 of the first recess 13 is preferably, for example, 0.25 mm or more and 0.40 mm or less.

Figures 4A and 4B are bottom views of the lens 10 to explain other examples of the first recesses 13. As shown in Figures 4A and 4B, a plurality of first recesses 13 may be arranged at intervals on the fourth surface 12b of the flange portion 12. These first recesses 13 may be arranged, for example, at approximately equal intervals along the outer periphery 11P.

In the example shown in FIG. 4A, each first recess 13 is a groove extending along a part of the outer periphery 11P of the optical function part 11 in a plan view. The inner surface of each first recess 13 includes, for example, a first side surface 13s1 and a second side surface 13s2 that are substantially parallel to the outer periphery 11P in a plan view, and a third side surface 13s3 and a fourth side surface 13s4 that extend in a direction intersecting the outer periphery 11P in a plan view. By including multiple side surfaces that extend in different directions in a plan view, the inner surface of the first recess 13 can improve adhesion between the lower surface 10b of the lens 10 and the lower mold. As shown in FIG. 4B, each first recess 13 may have a circular planar shape.

The shape, arrangement, and number of the first recesses 13 are not limited to the structures exemplified in Figures 3A, 3B, 4A, and 4B. As described below, the first recesses 13 may have at least one convex portion and/or at least one second recess on the inner surface. This can further increase the adhesion between the lower surface 10b of the lens 10 and the lower mold when the mold is opened after molding the lens 10 in the two-color molding process described below, thereby more effectively suppressing the occurrence of the traction phenomenon.

Furthermore, a plurality of first recesses 13 having different shapes may be provided on the fourth surface 12b of the flange portion 12. For example, the plurality of first recesses 13 may include an annular first recess (groove) 13 as shown in Figs. 3A and 3B and a circular (or rectangular) first recess 13 as shown in Fig. 4B in a plan view.

The lens 10 can be formed using a resin material having optical transparency, such as a thermoplastic resin. Examples of the thermoplastic resin that can be used include polycarbonate, acrylic, cyclic polyolefin, polyethylene terephthalate, and polyester. Thermoplastic resin materials are preferred because they can be efficiently manufactured by injection molding. Of these, it is preferable to use polycarbonate, which is highly transparent and inexpensive. Alternatively, the lens 10 may be formed using a thermosetting resin, such as a silicone resin or an epoxy resin.

[Support 20]
2A to 2C, the support 20 supports at least the flange 12 of the lens 10. The support 20 may be in contact with at least a part of the third surface 12a and/or at least a part of the outer surface 12c of the flange 12.

In this embodiment, the support 20 has a contact surface 20S that contacts at least a portion of the third surface 12a of the flange 12. The support 20 may contact the entire third surface 12a of the flange 12. It is preferable that the support 20 covers the entire third surface 12a and the outer surface 12c of the flange 12. This allows the support 20 to stably support the lens 10 (specifically, the flange 12 of the lens 10).

The support 20 may be arranged so as to at least partially overlap the first recess 13 in the flange 12 of the lens 10 in a plan view. That is, the contact surface 20S of the support 20 that contacts the third surface 12a of the flange 12 and at least one first recess 13 of the flange 12 may overlap each other. This allows the first recess 13 to be arranged in a position that does not affect the optical function of the optical function unit 11. As shown in the figure, it is preferable that the contact surface 20S of the support 20 covers the entire first recess 13 in a plan view.

When the flange portion 12 has multiple first recesses 13, the contact surface 20S of the support body 20 may cover at least some of the first recesses 13 in a plan view, but it is preferable that the contact surface 20S covers all of the first recesses 13.

In the illustrated example, the support 20 includes a first hood portion 21, a second hood portion 22, a support first flange portion 23, and a support second flange portion 24.

The first hood portion 21 and the second hood portion 22 have a cylindrical, e.g., tubular, outer shape tapered toward the direction in which the light is emitted. That is, the first hood portion 21 and the second hood portion 22 are inclined so as to approach the optical axis of the convex lens as they approach the +z direction. The first hood portion 21 extends from the third surface 12a of the flange portion 12 to the side opposite the light source. It is preferable that the first hood portion 21 has a shape tapered in the +z direction. The second hood portion 22 extends from the outer surface 12c of the flange portion 12 toward the light source side. The second hood portion 22 may be fixed to a substrate on which the light source is disposed.

In plan view, the first hood portion 21 preferably overlaps at least partially with the first recess 13 of the flange portion 12, and more preferably overlaps with the entire first recess 13. In addition, the first recess 13 is preferably disposed inside the second hood portion 22 in plan view. Furthermore, it is preferable that the support body 20 including the first hood portion 21 and the second hood portion 22 is not in contact with at least one first recess. This allows the support body 20 to stably support the lens 10 (specifically, the flange portion 12 of the lens 10). In addition, it is possible to prevent light from the light source 30 from leaking outside the support body 20 (specifically, outside the ±x direction or ±y direction of the first hood portion 21 and the second hood portion 22).

In a plan view, the outer surface of the first hood section 21 may be located inside the outer surface of the second hood section 22. In this case, the support 20 may have a support first flange section 23 outside the first hood section 21 and above the second hood section 22 (in the +z direction). The support first flange section 23 surrounds the first hood section 21 in a plan view. The upper surface of the support first flange section 23 is approximately flat, and the side surface of the support first flange section 23 may be continuous with the outer side surface of the second hood section 22.

The second flange 24 of the support 20 covers the edge of the first surface 11a of the optical function unit 11. In this embodiment, the inner edge of the second flange 24 of the support defines an opening 25 of the support 20. The second flange 24 of the support may be located between the first hood unit 21 and the optical function unit 11. The second flange 24 of the support can act as an aperture for the optical function unit 11.

In this embodiment, the maximum width S1 of the support 20 is preferably, for example, 4.0 mm or more and 15.0 mm or less, for example, about 6.9 mm, and the height S2 of the support 20 is preferably, for example, 1.5 mm or more and 7.0 mm or less, for example, 4.03 mm. The maximum width S1 of the support 20 refers to the maximum width of the outer shape of the second hood section 22. The height S2 of the support 20 refers to the length in the z-axis direction from the lower end of the second hood section 22 to the upper end of the first hood section 21.

The height H1 of the first hood portion 21 can be set, for example, to be approximately the same as the maximum height HL of the first surface 11a of the optical function portion 11 or greater than the maximum height HL. The height H1 of the first hood portion 21 refers to the length along the z-axis from the third surface 12a to the upper end of the first hood portion 21. The height H1 of the first hood portion 21 is preferably 1.1 mm or more and 4.1 mm or less, and may be, for example, 2.44 mm.

The height H2 of the second hood portion 22 is set so that a predetermined space is formed between the second surface 11b of the optical function portion 11 and the light emitting surface 30a of the light source 30. The height H2 of the second hood portion 22 refers to the length along the z-axis from the third surface 12a. The height H2 of the second hood portion 22 is preferably, for example, 0.5 mm or more and 3.0 mm or less, and may be, for example, 1.59 mm.

The thickness H3 of the second flange 24 of the support from the third surface 12a of the flange 12 is preferably, for example, 0.1 mm or more and 0.5 mm or less, for example, 0.3 mm.

The configuration of the support 20 is not limited to the above configuration. The support 20 may not have one or both of the first hood portion 21 and the second hood portion 22. Depending on the shape of the outer surface of the support 20, the support first flange portion 23 may not be formed. In addition, the support 20 may not have the support second flange portion 24.

The support 20 is formed, for example, from a resin material colored in a dark color. The support 20 may contain a resin as a base material and a colorant dispersed in the resin. The base material may contain a thermoplastic resin. As the thermoplastic resin, polycarbonate, acrylic, cyclic polyolefin, polyethylene terephthalate, polyester, etc. can be used. Preferably, polycarbonate resin is used. The resin material as the base material of the support 20 and the resin material of the lens 10 may be the same or different. By using the same resin material as the lens 10, the adhesion between the lens 10 and the support 20 can be improved. Note that, when the lens 10 is formed using a thermosetting resin, the support 20 may also contain a thermosetting resin as a base material.

As a colorant to be added to the resin that is the base material, various dyes and pigments are suitably used, specifically, Cr ₂ O ₃ , MnO ₂ , Fe ₂ O ₃ , carbon black, etc. can be mentioned.

[Positional Relationship Between Lens Structure 100 and Light Source 30]
1A and 1B, in a plan view, the opening 25 of the lens 10 at least partially overlaps with the light-emitting surface 30a. Preferably, in a plan view, the entire light-emitting surface 30a is located inside the opening 25 of the lens 10. This allows the light emitted from the light-emitting surface 30a to be irradiated from the opening 25 more efficiently.

The shortest distance D between the light emitting surface 30a of the light source 30 and the second surface 11b of the optical function section 11 of the lens 10 is preferably 0.1 mm or more and 0.7 mm or less, for example, 0.4 mm. Between the light emitting surface 30a of the light source 30 and the lower surface 10b of the lens 10, there may be a cavity (air layer). Alternatively, a light-transmitting resin may be disposed between the light emitting surface 30a and the lower surface 10b of the lens 10.

In plan view, the size of the opening 25 is set to be, for example, equal to or larger than the size of the light-emitting surface 30a. The area A1 of the opening 25 in plan view may be 1.3 times or more and 2.3 times or less than the area A2 of the light-emitting surface 30a. In this embodiment, in plan view, the opening 25 is a circle with a diameter of 4.21 mm, and the area A1 of the opening 25 is 13.92 ^mm2 . The area A2 of the light-emitting surface 30a is 7.68 ^mm2 (3.12 mm x 2.46 mm). Therefore, in plan view, the area ratio (A1/A2) of the opening 25 to the light-emitting surface 30a is 1.81. Note that the suitable area ratio (A1/A2) may vary depending on the shortest distance D between the light-emitting surface 30a and the second surface 11b of the optical function unit 11.

Furthermore, when the first surface 11a is a convex surface having one optical axis, the surface area A3 of the portion of the first surface 11a of the lens 10 located within the opening 25 (in other words, the portion not covered by the support 20) may be 2.5 to 4.5 times the area A2 of the light-emitting surface 30a of the light source 30 in a plan view. In this embodiment, the surface area A3 of the portion of the first surface 11a located within the opening 25 is 26.0 ^mm2 , and the area A2 of the light-emitting surface 30a is 7.68 ^mm2 . Therefore, the ratio (A3/A2) of the surface area A3 of the first surface 11a to the area A2 of the light-emitting surface 30a is 3.39.

2. Light Source Fig. 5A is a schematic plan view of the light source 30, and Fig. 5B is a schematic cross-sectional view taken along line 5B-5B shown in Fig. 5A.

In the configuration illustrated in Figures 5A and 5B, the light source 30 has a generally rectangular shape. Each side of the rectangular shape is parallel to the x-axis or y-axis shown in the figure. Note that the outer shape of the light source 30 in a plan view does not have to be rectangular.

The light source 30 is disposed, for example, on a first surface of a substrate 40 having wiring 42. The outer shape of the substrate 40 in a plan view is, for example, substantially rectangular. Note that the substrate 40 may have other shapes, such as a circle.

The light source 30 has a light-emitting surface 30a on the upper surface. The light source 30 includes a plurality of light-emitting units 30U arranged two-dimensionally. In other words, the light-emitting surface 30a of the light source 30 is divided into a plurality of unit areas corresponding to the plurality of light-emitting units 30U.

The multiple light-emitting units 30U are, for example, two-dimensionally arranged along the x-axis and y-axis directions, with the arrangement pitch in the x-axis direction being equal to the arrangement pitch in the y-axis direction. The arrangement direction of the light-emitting units 30U is not limited to this. The arrangement pitch in the x-axis direction and the y-axis direction may be different, and the two directions of the arrangement may not be orthogonal. Furthermore, the arrangement pitch is not limited to being equal, and may be unequal.

The number of light-emitting units 30U, i.e., the number of divisions of the light-emitting surface 30a, is preferably, for example, 16 or more. This allows for more precise control of the luminance distribution of the light-emitting surface 30a. On the other hand, if the number of light-emitting units 30U is 15 or less, an increase in the size of the light source 30 can be suppressed.

When the light source device 200 is applied to a camera flashlight, the light emitting surface 30a may be divided taking into consideration the aspect ratio of the image. When the aspect ratio is 4:3, for example, it may be divided into 9 light emitting sections 30U in the x-axis direction and 7 in the y-axis direction (represented as "9 x 7") for a total of 63 light emitting sections 30U, or into 7 x 5 light emitting sections 30U for a total of 35 light emitting sections 30U.

In the illustrated example, the light source 30 has a total of 63 light-emitting units 30U arranged in a matrix of 9 x 7. For example, the length LX of the light-emitting surface 30a of the light source 30 in the x-axis direction is 3.12 mm, and the length LY of the light-emitting surface 30a is 2.46 mm. The arrangement pitches Px, Py of each light-emitting unit 30U in the x-axis direction and y-axis direction are, for example, 330 μm, respectively. The thickness (length in the z-axis direction) of the light source 30 is, for example, 230 μm.

The multiple light-emitting units 30U may be capable of being turned on independently of each other. This allows only selected light-emitting units of the multiple light-emitting units 30U to be turned on and the other light-emitting units to be turned off (partial driving). By partially driving the multiple light-emitting units 30U, it is possible to irradiate (project) light having a desired luminance distribution. As a result, for example, when the light source device 200 of this embodiment is used as a flashlight for a camera, the luminance distribution of the illumination light can be controlled according to information on the area to be irradiated (such as the position and distance of the subject), thereby suppressing crushed shadows and blown-out highlights and allowing for clearer photographs to be taken.

Depending on the application of the light source device, some or all of the multiple light-emitting units 30U may be used in a constantly lit state.

Various known surface-emitting light sources can be used as the light source 30. Preferably, the light source 30 has a structure in which a plurality of light-emitting elements 50, such as light-emitting diodes, are arranged two-dimensionally. The plurality of light-emitting elements 50 are arranged corresponding to the plurality of light-emitting units 30U. Each of the plurality of light-emitting units 30U includes one or more corresponding light-emitting elements among the plurality of light-emitting elements 50. By lighting one or more light-emitting elements 50 in each light-emitting unit 30U independently of each other, partial driving of the light-emitting unit 30U can be realized, and the luminance distribution of the light-emitting surface 30a can be controlled.

In this embodiment, the light source 30 has a plurality of light-emitting elements 50, a plurality of wavelength conversion layers 60, a plurality of diffusion layers 70, and a light reflecting member 80. Each component of the light source 30 will be described below.

[Light-emitting element 50]
The plurality of light-emitting elements 50 are arranged two-dimensionally in a plan view. In the present embodiment, one light-emitting element 50 is arranged in each light-emitting section 30U. Note that two or more light-emitting elements 50 may be arranged in each light-emitting section 30U.

In the illustrated example, multiple (here, 63) light-emitting elements 50 are arranged at intervals in two mutually orthogonal directions, i.e., the x-axis direction and the y-axis direction, in a plan view. The arrangement pitch of the light-emitting elements 50 means the distance between the midpoints of two adjacent light-emitting elements in a plan view. In this example, one light-emitting element 50 is arranged in each light-emitting section 30U, so the arrangement pitch of the light-emitting elements 50 is the same as the arrangement pitches Px, Py of the light-emitting section 30U described above (e.g., 330 μm).

The arrangement pitch of the light-emitting elements 50 in the x-axis direction and the y-axis direction may be the same or different, and the two directions of the arrangement may not be perpendicular to each other. The arrangement pitch is not limited to being equal, and may be unequal. For example, the light-emitting elements 50 may be arranged so that the spacing between them increases from the center of the substrate 40 toward the periphery.

Figure 5C is an enlarged cross-sectional view showing a portion of the light source 30, showing a portion including three of the multiple light-emitting elements 50.

As shown in FIG. 5C, each light-emitting element 50 has a light-emitting surface 50a that mainly extracts light, an electrode-forming surface 50b located on the opposite side to the light-emitting surface 50a, a side surface 50c located between the light-emitting surface 50a and the electrode-forming surface 50b, and at least a pair of positive and negative electrodes 51 located on the electrode-forming surface 50b. The electrodes 51 are electrically connected to the wiring 42 on the substrate 40. For example, a wavelength conversion layer 60 is disposed on the light-emitting surface 50a of the light-emitting element 50.

As the light-emitting element 50, various types of light-emitting elements such as a semiconductor laser and a light-emitting diode can be used. In this embodiment, the light-emitting element 50 is a light-emitting diode. The wavelength of light emitted by the light-emitting element 50 can be selected arbitrarily. For example, as the blue and green light-emitting elements, light-emitting elements using semiconductors such as nitride-based semiconductors (In _x Al _y Ga _1-x-y N, 0≦X, 0≦Y, X+Y≦1), ZnSe and GaP can be used. As the red light-emitting element, light-emitting elements using semiconductors such as GaAlAs and AlInGaP can be used. Semiconductor light-emitting elements made of other materials can also be used. The composition, emission color, size, number, etc. of the light-emitting element used can be appropriately selected according to the purpose. The light-emitting layer of the light-emitting element 50 preferably includes a nitride semiconductor (In _x Al _y Ga _1-x-y N, 0≦X, 0≦Y, X+Y≦1) capable of emitting light of a short wavelength that can efficiently excite the wavelength conversion material contained in the wavelength conversion layer 60. The emission wavelength can be selected from various wavelengths depending on the material of the semiconductor layer and/or the degree of mixed crystal thereof. The positive and negative electrodes may be on the same surface, or on different surfaces.

The light-emitting element 50 has a light-transmitting substrate such as sapphire, and a semiconductor laminate structure laminated on the light-transmitting substrate. The semiconductor laminate structure includes a light-emitting layer, and an n-type semiconductor layer and a p-type semiconductor layer sandwiching the light-emitting layer, and positive and negative electrodes 51 are electrically connected to the n-type semiconductor layer and the p-type semiconductor layer, respectively. The bottom surfaces of the positive and negative electrodes 51 are electrically connected to the wiring 42 of the substrate 40.

The electrode 51 is made of a known metal material that can be electrically connected to the semiconductor laminate. For example, metals such as Ni, Pt, Cu, Au, Ag, and AuSn can be used as the material of the electrode 51. Cu is preferably used. The electrode 51 may have a single-layer structure or a laminate structure. A terminal protective film may be formed so as to cover the electrode 51. For example, as the terminal protective film, a Ni film (thickness: for example, 5 nm) may be formed on the surface of the electrode 51 made of Cu, and an Au film (thickness: for example, 25 nm) may be further formed on the Ni film.

The shape of the light-emitting element 50 in a plan view is, for example, rectangular. There is no particular limit to the size of the light-emitting element 50. The length and width of the light-emitting element 50 are, for example, 1000 μm or less, preferably 500 μm or less. It is even more preferable that they are 300 μm or less. By using light-emitting elements 50 of such a size, it is possible to increase the number of divisions of the light-emitting surface 30a while ensuring the light amount of each light-emitting element 50. Therefore, when the light source 30 is partially driven, it is possible to generate light and dark contrast in smaller units in the illuminated area.

In this embodiment, the light-emitting element 50 has a square shape with sides of 220 μm in plan view. The thickness of the light-transmitting substrate and semiconductor laminate structure in the light-emitting element 50 is, for example, 120 μm, and the thickness of the electrode 51 is, for example, 40 μm. As described above, the arrangement pitch of the light-emitting element 50 in the x-axis direction and the y-axis direction is, for example, 330 μm.

[Wavelength conversion layer 60]
The wavelength conversion layer 60 is disposed above (in the +z direction) the light emission surface 50a of the light emitting element 50, and covers the light emission surface 50a of the light emitting element 50. The wavelength conversion layer 60 absorbs at least a portion of the light emitted by the light emitting element 50, and emits light having a wavelength different from the wavelength of the light emitted from the light emitting element 50.

The wavelength conversion layer 60 has an upper surface 60a and a lower surface 60b that faces the upper surface 60a and is located on the light emitting element 50 side of the upper surface 60a. The lower surface 60b of the wavelength conversion layer 60 may be bonded or adhered to the light emission surface 50a of the light emitting element 50.

The wavelength conversion layer 60 may have a substantially rectangular shape in plan view. In plan view, the wavelength conversion layer 60 is preferably larger than the light emission surface 50a of the light emitting element 50 and covers the entire light emission surface 50a. This allows the light emitted from the light emitting element 50 to be efficiently incident on the wavelength conversion layer 60, thereby converting the wavelength of the light emitted from the wavelength conversion layer 60. In addition, it is possible to prevent a decrease in luminance in the portions of the light emitting surface 30a located between the light emitting elements.

In this embodiment, the wavelength conversion layer 60 has a square shape with a side length of 305 μm in a plan view. The thickness of the wavelength conversion layer 60 in the z-axis direction is, for example, 40 μm.

In this embodiment, a wavelength conversion layer 60 is provided for each light-emitting element 50, but a common wavelength conversion layer may be provided for multiple light-emitting elements 50.

The wavelength conversion layer 60 includes, for example, a resin as a base material and a wavelength conversion substance dispersed in the resin. For example, an epoxy resin, a silicone resin, a resin mixture of these, or a light-transmitting material such as glass can be used as the base material. From the viewpoint of light resistance and ease of molding, it is preferable to select a silicone resin as the base material of the wavelength conversion layer 60. In particular, it is preferable that the base material contains a phenyl silicone resin as the main component. The wavelength conversion layer 60 may be mainly made of ceramics or glass and contain a wavelength conversion substance.

The wavelength conversion material is excited by the light emitted by the light emitting element 50 and emits light of a different wavelength from the light emitted by the light emitting element 50 . Examples of wavelength conversion materials include cerium-activated yttrium aluminum garnet (YAG) phosphors (e.g., Y ₃ (Al,Ga) ₅ O ₁₂ :Ce), cerium-activated lutetium aluminum garnet (LAG) phosphors (e.g., Lu ₃ (Al,Ga) ₅ O ₁₂ :Ce), terbium aluminum garnet phosphors (e.g., Tb ₃ (Al,Ga) ₅ O ₁₂ :Ce), nitrogen-containing calcium aluminosilicate (CaO-Al ₂ O ₃ -SiO ₂ ) phosphors activated with europium and/or chromium, silicate ((Sr,Ba) ₂ SiO ₄ ) phosphors activated with europium, and β-sialon phosphors (e.g., (Si,Al) ₃ (O,N) ₄ :Eu), α-sialon phosphors (for example, _Mz (Si,Al) ₁₂ (O,N) ₁₆ (where 0<z≦2, and M is Li, Mg, Ca, Y, and lanthanoid elements excluding La and Ce)), nitride phosphors such as CASN phosphors (for example, _CaAlSiN3 :Eu) or SCASN phosphors (for example, (Sr,Ca) _AlSiN3 :Eu), fluoride phosphors such as KSF _phosphors (for example, _K2SiF6 :Mn4 ⁺ ) or MGF phosphors (for example _{, 3.5MgO.0.5MgF2.GeO2} :Mn), sulfide phosphors, perovskite, chalcopyrite, quantum dots, etc. Phosphors other than these phosphors that have similar performance, action, and effect can also be used. The wavelength conversion layer 60 may contain one of the wavelength conversion materials alone, but preferably contains multiple types of wavelength conversion materials. For example, the wavelength conversion layer 60 preferably contains a LAG-based phosphor that produces greenish light and a CASN-based phosphor that produces reddish light. This makes it possible to realize a light source 30 capable of emitting white light. In addition, by containing multiple types of wavelength conversion materials, it is possible to widen the wavelength band and suppress the occurrence of wavelength regions with weak emission intensity. The content of the wavelength conversion material (phosphor) in the wavelength conversion layer 60 is, for example, 10 to 80% by weight. In this specification, weight % means the ratio of the weight of the contained material to the total weight including the base material and the contained material (here, the wavelength conversion material).

The wavelength conversion material may be arranged in any manner within the wavelength conversion layer 60. For example, the wavelength conversion material may be distributed substantially uniformly within the wavelength conversion layer 60, or may be unevenly distributed in a portion of the layer. "Unevenly distributed in a portion of the layer" includes, for example, the wavelength conversion material being arranged so that its concentration is higher on the upper surface 60a or the lower surface 60b of the wavelength conversion layer 60. Alternatively, it includes the wavelength conversion material being arranged so that its concentration is higher near the center or near the periphery of the wavelength conversion layer 60 in a plan view. The wavelength conversion layer 60 may also be formed by stacking multiple layers each containing a wavelength conversion material.

The wavelength conversion layer 60 may contain a material other than the wavelength conversion substance. For example, a material having a refractive index different from that of the base material may be dispersed in the wavelength conversion layer 60. For example, particles having a light diffusing effect, such as titanium oxide or silicon oxide, may be dispersed in the base material of the wavelength conversion layer 60.

[Diffusion layer 70]
The diffusion layer 70 is disposed above (in the +z direction) the wavelength conversion layer 60. The diffusion layer 70 diffuses the light emitted from the light emitting element 50.

The diffusion layer 70 has an upper surface 70a and a lower surface 70b that corresponds to the upper surface 70a and is located on the wavelength conversion layer 60 side of the upper surface 70a. In this embodiment, the upper surface 70a of the diffusion layer 70 is the upper surface of the light source 30 and is the light emitting surface 30a of the light source 30.

The diffusion layer 70 may have a substantially rectangular shape in plan view. In plan view, the diffusion layer 70 is preferably larger than the light exit surface 50a of the light-emitting element 50 and covers the entire light exit surface 50a. The size of the diffusion layer 70 may be substantially the same as the size of the wavelength conversion layer 60. In the light source 30, the light exit surface 50a of each light-emitting element 50 tends to be bright, and the area between the light exit surfaces 50a of two adjacent light-emitting elements 50 (in the illustrated example, the light reflecting member 80 is disposed in this area) tends to be dark (brightness unevenness). In addition, in the white light source 30, when a blue light-emitting element 50 is used, for example, the light exit surface 50a may shine blue, and yellow light may leak from the area between the two adjacent light exit surfaces 50a (color unevenness). By disposing the diffusion layer 70 above the wavelength conversion layer 60 (in the +z direction), the light emitted from the light emission surface 50a of the light emitting element 50 can be diffused, thereby suppressing such uneven brightness and color.

In this embodiment, the diffusion layer 70 is, for example, a square with a side length of 305 μm in plan view. The thickness of the diffusion layer 70 in the z-axis direction is, for example, 30 μm.

In this embodiment, the diffusion layer 70 is provided for each light-emitting element 50, but a common diffusion layer 70 may be provided for multiple light-emitting elements 50. When a common diffusion layer 70 is provided for multiple light-emitting elements 50, the thickness of the diffusion layer 70 in the z-axis direction may not be uniform. As shown in FIG. 11, for example, the portion of the diffusion layer 70 located between adjacent light-emitting elements 50 in a plan view may be thinner than the portion overlapping each light-emitting element 50. In other words, the diffusion layer 70 may have a groove 71 on the lower surface 70b in the region between adjacent light-emitting elements 50. The thickness of the diffusion layer 70 in the z-axis direction (in other words, the thickness from the upper surface 70a to the lower surface 70b of the diffusion layer 70) is, for example, 30 μm, and the depth of the groove 71 in the Z-axis direction (in other words, the depth of the groove from the lower surface 70b of the diffusion layer 70) is greater than 0 μm, and is, for example, 2/3 or less of the thickness of the diffusion layer 70 in the z-axis direction.

The diffusion layer 70 includes a resin as a base material and a diffusion material dispersed in the resin. As the base material, a light-transmitting material such as epoxy resin, silicone resin, a mixture of these, or glass can be used. From the viewpoint of light resistance and ease of molding, it is preferable to select a silicone resin as the base material of the diffusion layer 70. In particular, it is preferable that the base material is mainly composed of phenyl silicone resin. In addition, by using the same resin as that of the wavelength conversion layer 60 as the base material of the diffusion layer 70, the adhesion between the wavelength conversion layer 60 and the diffusion layer 70 can be improved. Note that the diffusion layer 70 may be mainly made of ceramics or glass and contain a diffusion material.

The diffusion material is a material with high light reflectance, such as white fillers such as titanium oxide, silicon oxide, alumina, and zinc oxide. The concentration of the diffusion material is preferably 0.1% by weight or more and 3.0% by weight or less. The diffusion layer 70 may also contain a glass filler or the like to suppress thermal expansion and contraction of the resin base material. The concentration of the glass filler is preferably 50% by weight or more and 80% by weight or less. The concentrations of the diffusion material, glass filler, and the like are not limited to this. The diffusion layer 70 preferably contains titanium oxide and glass filler.

[Light reflecting member 80]
The light reflecting member 80 is disposed on the first surface 40a of the substrate 40, and covers the first surface 40a of the substrate 40 and the side surfaces 50c of the plurality of light emitting elements 50. The light reflecting member 80 may further cover the side surfaces of the wavelength conversion layer 60 and the diffusion layer 70. The light reflecting member 80 may be formed so as to cover the side surfaces of the electrodes 51 and to fill the gap between the electrode forming surface 50b of the light emitting element 50 and the first surface 40a of the substrate 40. However, an underfill resin may be filled in the gap between the electrode forming surface 50b of the light emitting element 50 and the first surface 40a of the substrate 40. The underfill resin can reduce stress that may be caused by the difference in thermal expansion coefficient between the light emitting element 50 and the substrate 40, and can improve heat dissipation.

The light reflecting member 80 exposes the lower surface of the electrode 51 of each light emitting element 50 and the upper surface 70a of each diffusion layer 70. The lower surface of the electrode 51 is electrically connected to the wiring 42 of the substrate 40. If the diffusion layer 70 is not formed, the upper surface 60a of the wavelength conversion layer 60 may be the light emitting surface 30a of the light source 30.

By disposing the light reflecting member 80 between the light emitting units 30U, the propagation of light between the light emitting units 30U can be suppressed, thereby reducing color unevenness. In addition, when performing the partial driving described above, the contrast between the lit light emitting units 30U and the unlit light emitting units 30U can be improved.

In this embodiment, the light reflecting member 80 seals and holds the multiple light emitting elements 50 together. Note that the light reflecting member 80 may be separated for each light emitting element 50.

The light reflecting member 80 protects the multiple light emitting elements 50. The light reflecting member 80 also reflects light emitted from the side surface 50c of the light emitting element 50 and guides the light upward (+z direction) of the light emitting element 50. Furthermore, by providing the light reflecting member 80 between the electrode forming surface 50b of the light emitting element 50 and the substrate 40, the light traveling from the electrode forming surface 50b of the light emitting element 50 toward the substrate 40 can be reflected by the light reflecting member 80 and guided upward (+z direction) of the light emitting element 50. This improves the efficiency of use of the light emitted from the light emitting element 50.

The light reflecting member 80 includes, for example, a resin as a base material and a light reflecting substance dispersed in the resin. As the base material, an epoxy resin, a silicone resin, a resin mixture of these, or a light-transmitting material such as glass can be used. From the viewpoint of light resistance and ease of molding, it is preferable to select a silicone resin as the base material of the wavelength conversion layer 60. In particular, it is preferable that the base material contains dimethyl silicone resin or phenyl silicone resin as the main component. In addition, by using the same resin as the wavelength conversion layer 60 and the diffusion layer 70 as the base material of the light reflecting member 80, the adhesion to the wavelength conversion layer 60 and the diffusion layer 70 can be improved.

As the light-reflecting material, titanium oxide, silicon oxide, zirconium oxide, yttrium oxide, yttria-stabilized zirconia, potassium titanate, alumina, aluminum nitride, boron nitride, mullite, etc. can be used. This makes it possible to more effectively suppress light leakage in the ±x direction, ±y direction, and -z direction of each light-emitting unit 30U. The concentration of the light-reflecting material in the light-reflecting member 80 is preferably 10% by weight or more and 70% by weight or less. In addition, the light-reflecting member 80 may contain a glass filler or the like in order to suppress thermal expansion and contraction of the resin of the base material. The concentration of the glass filler is preferably greater than 0% by weight and less than 30% by weight, and more preferably greater than 5% by weight and 20% by weight or less. The concentration of the light-reflecting material, glass filler, etc. is not limited to this. The light-reflecting member 80 preferably contains titanium oxide and glass filler.

3. Substrate 40
The light source 30 including a plurality of light emitting elements 50 is disposed on the substrate 40. The substrate 40 has a first surface 40a and a second surface 40b opposite to the first surface 40a.

In the example shown in FIG. 5C, the substrate 40 includes a plate-shaped base 41, wiring 42 formed on a first surface 40a of the base 41, and an external terminal 43 formed on a second surface 40b of the base 41. The first surface 40a of the substrate 40 may be the first surface 40a of the base 41, and the second surface 40b of the substrate 40 may be the second surface 40b of the base 41. The wiring 42 is electrically connected to the electrode 51 of the light-emitting element 50. The wiring 42 is electrically connected to the external terminal 43, for example, via a via hole and a via conductor provided in the base 41.

Materials for the base 41 include insulating materials such as glass epoxy, resin, and ceramics, and metal materials whose surfaces are covered with insulating materials. In particular, it is preferable to use ceramics with high heat resistance and weather resistance as the material for the base 41. Examples of ceramic materials include alumina, aluminum nitride, and mullite. These ceramic materials may be combined with insulating materials such as bismaleimide triazine resin (BT resin), glass epoxy, and epoxy-based resin.

The wiring 42 and the external terminal 43 can be formed, for example, from metals such as Cu, Al, Au, Ag, Pt, Ti, W, Pd, Fe, Ni, etc., or alloys containing these metals.

The substrate 40 may be a substrate (wiring substrate) equipped with wiring on which light-emitting elements such as LEDs and various electric elements can be mounted. Since a wiring pattern can be provided in advance on the wiring substrate, it is possible to provide more complex wiring necessary for driving (partial driving) the multiple light-emitting units 30U to light up independently of each other.

(Method of Manufacturing Lens Structure 100)
An example of a method for manufacturing the lens structure 100 using a two-color molding process will now be described with reference to the drawings.

In this embodiment, after molding a lens as the primary molded body, a support is molded as the secondary molded body. To mold the lens, which is the primary molded body, a lower mold (hereinafter, a "common mold") corresponding to the lower surface of the lens and an upper mold (hereinafter, a "primary molding mold") corresponding to the upper surface of the lens are used. The common mold is used in common for molding the primary molded body and the secondary molded body. To mold the support, which is the secondary molded body, the common mold and a mold having a different shape from the primary molding mold (hereinafter, a "secondary molding mold") are used.

Figures 6A to 6E are cross-sectional views illustrating steps in the manufacturing method of the lens structure 100.

First, as shown in FIG. 6A, a common mold 110 having a fifth surface 110a and a primary molding mold 120 having a sixth surface 120a are prepared.

The fifth surface 110a of the common mold 110 is a surface that forms the bottom surface of the lens, and includes a surface that corresponds to the second surface of the optical function portion and the fourth surface of the flange portion. The fifth surface 110a includes a convex portion 112 for forming the first concave portion of the flange portion. The sixth surface 120a of the primary molding mold 120 is a surface that forms the top surface and side surface of the lens, and includes a surface that corresponds to the first surface of the optical function portion of the lens, the third surface of the flange portion, and the outer surface of the flange portion.

The common mold 110 and the primary molding mold 120 are held so that the fifth surface 110a of the common mold 110 and the sixth surface 120a of the primary molding mold 120 face each other (mold clamping). This forms a first cavity 121 between the common mold 110 and the primary molding mold 120. The first cavity 121 is a space for molding a lens, which is the primary molded body.

Next, as shown in FIG. 6B, the lens 10 is molded as a primary molded body (primary molding process). First, a first resin is injected into the first cavity 121 from the first resin injection port 122 provided at the position where the flange of the lens of the primary molding die 120 is to be formed. For example, a thermoplastic transparent resin material with polycarbonate as a base material is used as the first resin. Next, the first resin in the first cavity 121 is solidified by cooling. When a thermosetting resin is used as the first resin, the first resin is hardened by heating. In this way, the lens 10 is formed from the first resin. The lens 10 has an optical function part 11 and a flange part 12. A first recess 13 corresponding to the surface shape of the protrusion part 112 of the common die 110 is formed on the lower surface of the flange part 12.

Next, as shown in FIG. 6C, one of the common mold 110 and the primary molding mold 120 is moved away from the other to perform the first mold opening process. At this time, as shown in the figure, the lens 10, which is the primary molded body, is released from the primary molding mold 120 and remains on the common mold 110. In this embodiment, since the first recess 13 is provided on the lower surface 10b of the lens 10, the contact area between the lower surface 10b of the lens 10 and the fifth surface 110a of the common mold 110 is larger than when the first recess 13 is not provided on the lower surface 10b of the lens 10, and therefore the adhesion between the lens 10 and the common mold 110 is improved. Therefore, the lens 10 can be released from the primary molding mold 120 while being held on the common mold 110.

After that, as shown in FIG. 6D, a secondary molding die 130 having a seventh surface 130a is prepared. Next, the secondary molding die 130 is placed on the common die 110 holding the lens 10, and the die is clamped. As a result, a second cavity 131 is formed between the common die 110, the lens 10, and the secondary molding die 130. The second cavity 131 is a space for molding the support body, which is the secondary molded body. A part of the upper surface 10a of the lens 10 contacts the seventh surface 130a of the secondary molding die 130. In the illustrated example, the space between the edge of the first surface 11a of the optical function part 11 of the lens 10, the third surface 12a and the outer surface 12c of the flange part 12, the seventh surface 130a of the secondary molding die 130, and the side surface 110b of the common die 110 becomes the second cavity 131.

Next, as shown in FIG. 6E, the support 20 is molded as a secondary molded body (secondary molding process). First, the second resin is injected into the second cavity 131 from the second resin injection port 132 provided at the position where the first flange of the support is to be formed in the secondary molding die 130. For example, a thermoplastic resin material colored in a dark color is used as the second resin. Next, the second resin in the second cavity 131 is solidified by cooling. When a thermosetting resin is used as the second resin, the second resin is hardened by heating. As a result, the support 20 is molded from the second resin. The support 20 and the lens 10 are integrated by the support 20 contacting the edge of the first surface 11a of the optical function part 11 of the lens 10, the third surface 12a of the flange part 12, and the outer surface 12c. In this manner, the lens structure 100 is obtained. In addition, in Figures 6D and 6E, the second resin injection port 132 is provided at the position where the first flange of the support body of the secondary molding die 130 is formed, taking into consideration the filling property of the second resin, but the position where the second resin injection port 132 is provided is not limited to this. For example, the second resin injection port 132 may be provided at the position where the second hood portion of the secondary molding die 130 is formed.

The support 20 is in contact with at least a portion of the upper surface 10a of the lens 10. As shown in the figure, the support 20 may cover the outer surface of the lens 10 (i.e., the outer surface 12c of the flange portion 12). In this embodiment, the support 20 is molded with the lower surface 10b of the lens 10 in contact with the common mold 110, so the support 20 does not come into contact with the lower surface 10b of the lens 10.

Next, the secondary molding die 130 and the common die 110 are opened (hereinafter referred to as the "second mold opening step"). As a result, the lens structure 100 is released from the secondary molding die 130 while being held on the common die 110. The lens structure 100 is then released from the common die 110, and the lens structure 100 is removed. In this embodiment, as described above, the first hood portion 21 and the second hood portion 22 of the support 20 are inclined toward the optical axis of the lens 10 as they move toward the +z direction, and the first hood portion 21 has a tapered shape in the +z direction, which makes it easier to open the secondary molding die 130 and the common die 110.

In this embodiment, the lens 10 is molded as the primary molded body, and then the support 20 is molded as the secondary molded body. If the support 20 is molded first (the support 20 is the primary molded body), when the lens 10 is subsequently molded (the lens 10 is the secondary molded body), the presence of the support 20 makes it impossible to inject the resin material from the side of the mold. If the resin were injected from anywhere other than the side of the mold, the resin injection port would be located in the area of the optical function part 11 of the lens 10, which could affect the optical function. Therefore, it is preferable to mold the lens 10 in the primary molding process and the support 20 in the secondary molding process.

Conventionally, when manufacturing a lens structure by a two-color molding process, if the contact area between the upper surface of the lens and the upper mold is larger than the contact area between the lower surface of the lens and the lower mold, there is a risk of the lower surface of the lens coming off the lower mold and the lens remaining in the upper mold (trailing phenomenon) occurring during mold opening. In contrast, according to this embodiment, by providing the first recess 13 on the lower surface 10b of the lens 10, the contact area between the lens 10 and the common mold 110 is increased, and the adhesion between the lower surface 10b of the lens 10 and the fifth surface 110a of the common mold 110 can be improved. Therefore, the trailing phenomenon in the first mold opening process can be suppressed, and the lens 10 can be more easily released from the primary molding mold 120. As a result, after the first mold opening process, the support 20, which is a secondary molded body, can be continuously molded on the lens 10. According to this embodiment, when molding the lens structure 100, no complex mold structure is required, and the traction phenomenon can be suppressed by using only three types of molds: a common mold 110, a primary molding mold 120, and a secondary molding mold 130.

The adhesion between the lens 10 and the common mold 110 can be adjusted by the contact area between the lower surface 10b of the lens 10 and the fifth surface 110a of the common mold 110, as well as the planar shape of the first recesses 13, the inclination angle, position, number, etc. of the inner surface of the first recesses 13.

(Modification)
The following describes modified examples of the lens according to the present disclosure. The modified lens is different from the lens shown in Figures 3A and 3B in that it has a convex portion or a second concave portion on the inner surface of the first concave portion. Below, the differences from the first concave portion shown in Figures 3A and 3B are mainly described, and the description of the similar structure is omitted. In addition, in each drawing showing the modified example, for ease of understanding, the same reference numerals are given to the same components as those shown in Figures 3A and 3.

In Modifications 1 to 4, the first recess is an annular groove in plan view. However, the planar shape of the first recess is not limited to annular.

Figure 7A is a schematic enlarged plan view showing a portion of the flange 12 of the lens 10 of modified example 1, and Figure 7B is a schematic enlarged cross-sectional view taken along line 7B-7B in Figure 7A. Figure 8A is a schematic enlarged plan view showing a portion of the flange 12 of the lens 10 of modified example 2, and Figure 8B is a schematic enlarged cross-sectional view taken along line 8B-8B in Figure 8A.

As shown in the figure, the inner surface of the first recess 13 includes a first side surface 13s1 that is provided along the outer periphery of the optical function part, and a second side surface 13s2 that faces the first side surface 13s1 and is located closer to the optical function part than the first side surface 13s1.

In the first modification, the first recess 13 has one second recess 14 on the first side surface 13s1 that extends along the first side surface 13s1. By providing the second recess 14, the adhesion between the lower surface of the lens 10 and the common mold can be more effectively increased in the first mold opening process. The second recess 14 may extend along the entire first side surface 13s1, for example, so as to surround the optical function portion in a plan view. By forming the second recess 14 around the entire circumference of the first side surface 13s1, the traction phenomenon can be more effectively suppressed.

In the second modification, the first recess 13 has a plurality of second recesses 14 on the first side surface 13s1. The second recesses 14 are arranged at intervals from each other in a plan view. For example, when a single second recess 14 that is annular in a plan view and extends along the first side surface 13s1 is provided on the first side surface 13s1 as in the first modification, the adhesion between the lower surface of the lens 10 and the common mold may be too strong depending on the material of the lens 10. Therefore, by selecting the size, number, arrangement pitch, etc. of the second recesses 14, the strength of adhesion between the lower surface of the lens 10 and the common mold can be adjusted. This makes it possible to more easily release the lens structure 100 from the common mold 110 after the secondary molding process while suppressing the traction phenomenon in the first mold opening process.

In Modification 1 and Modification 2, the depth w3 of the second recess 14 (in other words, the maximum width in the xy plane) is preferably, for example, 1/3 to 1/2 of the width w2 of the first recess 13, e.g., 0.1 mm. The length d3 of the second recess 14 in the z-axis direction is preferably, for example, 1/3 to 2/3 of the depth d2 of the first recess 13, e.g., 0.2 mm.

Figure 9A is a schematic enlarged plan view showing a portion of the flange 12 of the lens 10 of modified example 3, and Figure 9B is a schematic enlarged cross-sectional view taken along line 9B-9B in Figure 9A. Figure 10A is a schematic enlarged plan view showing a portion of the flange 12 of the lens 10 of modified example 4, and Figure 10B is a schematic enlarged cross-sectional view taken along line 10B-10B in Figure 10A.

In the third modification, the first recess 13 has one protrusion 15 on the first side surface 13s1 that extends along the first side surface 13s1. This makes it possible to more effectively improve the adhesion between the lower surface of the lens 10 and the common mold during the mold opening process. The protrusion 15 may extend along the entire first side surface 13s1, for example, so as to surround the optical function portion in a plan view. By forming the protrusion 15 around the entire circumference of the first side surface 13s1, the traction phenomenon can be more effectively suppressed.

In the fourth modification, the first recess 13 has a plurality of protrusions 15 on the first side surface 13s1. The plurality of protrusions 15 are arranged at intervals from each other in a plan view. For example, when a single protrusion 15 that is annular in a plan view and extends along the first side surface 13s1 is provided on the first side surface 13s1 as in the third modification, the adhesion between the lower surface of the lens 10 and the common mold may be too strong depending on the material of the lens 10. Therefore, the strength of adhesion between the lower surface of the lens 10 and the common mold can be adjusted by selecting the size, number, arrangement pitch, etc. of the protrusions 15. This makes it possible to more easily release the lens structure 100 from the common mold 110 after the secondary molding process while suppressing the traction phenomenon in the first mold opening process.

In the third and fourth modifications, the height w4 of the protrusion 15 (in other words, the maximum width in the xy plane) is preferably, for example, 1/3 to 1/2 of the width w2 of the first recess 13, e.g., 0.1 mm. The length d4 of the protrusion 15 in the z-axis direction is preferably, for example, 1/3 to 2/3 of the depth d2 of the first recess 13, e.g., 0.2 mm.

It is preferable that the second recess 14 or the protrusion 15 has an R-shape. This makes it easier to release the two-color molded body (lens structure 100) from the common mold after the secondary molding process. As a result, deformation of the secondary molded body during demolding can be suppressed.

The size, number, shape, etc. of the second recess 14 or the protrusion 15 provided in the first recess 13 are not limited to the example shown in the figure. The shape of the second recess 14 and the protrusion 15 in a cross-sectional view in the xy plane may be rectangular. In addition, both the protrusion and the second recess may be formed in one first recess 13.

In variants 1 to 4, the second recess 14 or protrusion 15 is provided on the first side 13s1 of the first side 13s1 and the second side 13s2 of the first recess 13, which is the side farther from the optical function unit 11. This makes it possible to more reliably suppress the effect of the second recess 14 or protrusion 15 on the optical action of the optical function unit 11.

In addition, the second recess 14 or the protrusion 15 is preferably provided on the first side surface 13s1 of the first recess 13. In this embodiment, by providing the first recess 13 in the flange 12, the portion of the flange 12 located closer to the outer side surface 12c than the first recess 13 becomes more easily deformed by external forces, etc. In detail, when the lens structure 100 is released from the common mold while being deflected after the secondary molding process, the portion of the flange 12 located closer to the optical function unit 11 than the first recess 13 is less likely to deform because it is adjacent to the optical function unit 11, but the above portion of the flange 12 has room (i.e., space) for deformation and is therefore more likely to deform. Therefore, by providing the second recess 14 or the convex portion 15 on the first side surface 13s1 of the first recess 13, the second recess 14 or the convex portion 15 is arranged in a portion of the flange portion 12 that is easily deformed, and the obtained lens structure 100 is easier to release from the common mold after the secondary molding process than when the second recess 14 or the convex portion 15 is arranged on the second side surface 13s2.

The second recess 14 or the protrusion 15 may be provided on the second side surface 13s2 of the first recess 13. In this case, it is preferable that the second recess 14 or the protrusion 15 is arranged so as not to overlap the optical function section 11 in a plan view. This can reduce the effect on the optical action of the optical function section 11.

When multiple second recesses 14 or multiple protrusions 15 are provided in one first recess 13, some of the second recesses 14 or some of the protrusions 15 may be provided on the first side surface 13s1 of the first recess 13, and the remaining second recesses 14 or some of the remaining protrusions 15 may be provided on the second side surface 13s2.

The light source device and lens structure disclosed herein can be suitably used in light source devices for various applications, such as lighting, camera flashlights, and vehicle headlights. In particular, they are suitable for use in flashlights for small cameras mounted on mobile phones and the like.

10 Lens 10a Upper surface of lens 10b Lower surface of lens 11 Optical function part 11a First surface 11b Second surface 11P Outer periphery of optical function part 11 12 Flange part 12a Third surface 12b Fourth surface 12c Outer surface 13 First recess 13s1 First side surface 13s2 Second side surface 14 Second recess 15 Convex part 20 Support body 20S Contact surface 21 First hood part 22 Second hood part 23 Support body first flange part 24 Support body second flange part 25 Opening 30 Light source 30a Light emitting surface 30U Light emitting part 40 Substrate 40a First surface of substrate 40b Second surface of substrate 41 Base 42 Wiring 43 External terminal 50 Light emitting element 50a Light emitting surface 50b Electrode forming surface 50c Side surface 51 Electrode 60 Wavelength conversion layer 70 Diffusion layer 60a, 70a Upper surfaces 60b, 70b Lower surface 80 Light reflecting member 100 Lens structure 110 Common mold 110a Fifth surface 110b Side surface 112 Convex portion 120 Primary molding mold 120a Sixth surface 121 First cavity 122 First resin injection port 130 Second molding mold 130a Seventh surface 131 Second cavity 132 Second resin injection port 200 Light source device

Claims (20)

A light source having a light emitting surface on an upper surface thereof, the light source including a plurality of light emitting units arranged two-dimensionally;
a lens disposed above the light emitting surface of the light source and spaced from the light source, the lens having an optical function portion and a flange portion disposed along an outer periphery of the optical function portion;
a support member that is made of a light-shielding member and that supports at least the flange portion of the lens;
the optical function unit includes a first surface located on an opposite side to the light source and a second surface located on an opposite side to the first surface and facing the light source, a surface area of the first surface is larger than a surface area of the second surface, and the first surface and the second surface cover the plurality of light emitting units in a plan view;
the flange portion has a third surface located on the same side as the first surface and a fourth surface located on the same side as the second surface,
The flange portion has at least one first recess in the fourth surface,
A light source device , wherein the at least one first recess is exposed to a cavity located between a light emitting surface of the light source, the second surface of the optical function portion, and the fourth surface of the flange portion . the support body has a contact surface in contact with at least a portion of the third surface of the flange portion,
The light source device according to claim 1 , wherein the contact surface of the support body and the at least one first recess of the flange portion overlap each other in a plan view. The light source device according to claim 1 or 2, wherein the lens is a convex lens in which the first surface and the second surface are convexly curved. The light source device according to claim 3, wherein the radius of curvature of the first surface is smaller than the radius of curvature of the second surface. The light source device according to claim 4, wherein the radius of curvature of the first surface is 1.5 mm or more and 3.0 mm or less, and the radius of curvature of the second surface is 5.0 mm or more and 30.0 mm or less. The light source device according to any one of claims 1 to 5, wherein the at least one first recess includes a groove that surrounds the optical function part in a plan view. The light source device according to any one of claims 1 to 6, wherein the at least one first recess includes a plurality of recesses arranged at intervals. The light source device according to any one of claims 1 to 7, wherein the at least one first recess has at least one protrusion and/or at least one second recess on the inner surface. the inner surface of the at least one first recess includes a first side surface provided along the outer periphery of the optical function portion, and a second side surface opposed to the first side surface and located closer to the optical function portion than the first side surface,
The light source device according to claim 8 , wherein the at least one protrusion and/or the at least one second recess is disposed on the first side surface. The light source device according to any one of claims 1 to 9, wherein the support and the lens are two-color molded bodies. The light source device according to any one of claims 1 to 10, wherein the support is not in contact with the at least one first recess. the flange portion includes an outer surface adjacent to the third surface and the fourth surface,
The support is
a first hood portion extending from the third surface of the flange portion to a side opposite the light source;
a second hood portion extending from the outer surface of the flange portion toward the light source,
The light source device according to claim 1 , wherein the at least one first recess overlaps the first hood portion in a plan view and is disposed inside the second hood portion. The light source device further includes a substrate.
The light source device according to claim 12 , wherein the light source is disposed on a first surface of the substrate, and the second hood portion is fixed to the substrate. The light source device according to any one of claims 1 to 13, wherein the support further covers an edge portion of the first surface of the optical function portion. The light source device according to claim 14, wherein, in a plan view, the surface area of the portion of the first surface of the lens that is not covered by the support is 2.5 to 4.5 times the area of the light-emitting surface of the light source. A light source device according to any one of claims 1 to 15, wherein the lens has one optical axis with respect to the light emitting surface. The light source device according to any one of claims 1 to 16, wherein the plurality of light-emitting elements can be turned on independently of one another. The light source is
A plurality of light-emitting elements are arranged two-dimensionally, and each of the plurality of light-emitting sections includes one or more corresponding light-emitting elements among the plurality of light-emitting elements;
The light source device according to claim 1 , further comprising: a wavelength conversion layer covering light emission surfaces of the plurality of light emitting elements. A lens having an optical function portion and a flange portion disposed along an outer periphery of the optical function portion;
A lens structure including a support body made of a light-shielding member and supporting at least the flange portion of the lens,
the lens and the support are a single two-color molded body;
The optical function portion has a first surface and a second surface located opposite to the first surface, and a surface area of the first surface is larger than a surface area of the second surface,
the flange portion has a third surface located on the same side as the first surface and a fourth surface located on the same side as the second surface,
The flange portion has at least one first recess in the fourth surface,
The at least one first recess is in contact with an air space . the support body has a contact surface in contact with at least a portion of the third surface of the flange portion,
The lens structure according to claim 19 , wherein, in a plan view, the contact surface of the support and the at least one first recess of the flange overlap each other.