JP7837966B2 - Display device and method for manufacturing the same - Google Patents

Description

This technology relates to a display device and a method for manufacturing the same, and more particularly to a display device and a method for manufacturing the same that eliminates the need for alignment with the light-emitting part when bonding the decorative layer.

In recent years, display devices have been proposed that allow a predetermined design, such as a picture or characters, to be visible when the display is not showing. For example, Patent Document 1 discloses a display device that presents predetermined video information when the display is showing, and allows a predetermined design, such as a decorative film attached to the display surface, to be visible when the display is not showing.

Japanese Patent Publication No. 2020-067564

The technology disclosed in Patent Document 1 involves forming a translucent portion, which is a path for light from the light-emitting portion, and then forming a decorative film. Therefore, when bonding the substrate on which the light-emitting portion is formed with the decorative film, alignment between the translucent portion and the light-emitting portion is required.

This technology was developed in light of these circumstances and aims to provide a display device that eliminates the need for alignment with the light-emitting part when bonding the decorative layer.

The first aspect of this technology is a display device comprising a substrate, a plurality of light-emitting units mounted on the substrate, and a decorative layer formed on the substrate other than the area on which the light-emitting units are mounted, wherein the light-emitting units have a light guide portion in which the area of the bottom portion, which is the connection surface with the substrate, is formed to be larger than the area of the upper portion, which is the light-emitting opening.

In the first aspect of this technology, a substrate is provided, along with a plurality of light-emitting units mounted on the substrate, and a decorative layer formed on the substrate in areas other than those on which the light-emitting units are mounted. Each light-emitting unit is provided with a light guide portion, the area of which is the bottom surface that connects to the substrate is larger than the area of which is the top surface that serves as the light-emitting opening.

The second aspect of this technology is a method for manufacturing a display device, which involves mounting a plurality of light-emitting units on a substrate at a predetermined arrangement pitch, passing the light-guiding portions of the light-emitting units through the decorative layer, and bonding the substrate and the decorative layer together.

In the second aspect of this technology, a plurality of light-emitting units are mounted on a substrate at a predetermined arrangement pitch, and the light-guiding portions of the light-emitting units penetrate the decorative layer, thereby bonding the substrate and the decorative layer together.

The display device may be an independent device or an internal block that constitutes a single device.

This is a cross-sectional view showing an example configuration of one embodiment of the display device according to this disclosure. This is a plan view of the light-emitting section as seen from the top of the circuit board. This is a cross-sectional view illustrating other examples of light guide shapes. This is a cross-sectional view illustrating other examples of the configuration of the light-emitting section. This figure illustrates a method for manufacturing the display device related to this disclosure. This diagram illustrates other methods for bonding the decorative layer to the substrate. This diagram illustrates other methods for bonding the decorative layer to the substrate. This diagram illustrates a method for manufacturing a display device using a packaged light-emitting unit. This is a cross-sectional view of the area around the light-emitting part after it has passed through the light guide. This is a perspective view showing another embodiment of the display device relating to this disclosure. This figure illustrates an example of the use of the display device related to this disclosure. This figure illustrates an example of the use of the display device related to this disclosure. This figure illustrates an example of the use of the display device related to this disclosure.

Hereinafter, embodiments for carrying out the technology of this disclosure (hereinafter referred to as "embodiments") will be described with reference to the attached drawings. In this specification and the drawings, components having substantially the same functional configuration will be denoted by the same reference numerals to avoid redundant explanation. The explanation will be given in the following order.
1. Example of display device configuration 2. Other example of light-emitting section configuration 3. Method of manufacturing a display device 4. Example of display device unit configuration 5. Example of display device application

<1. Example of a display device configuration>
Figure 1 is a cross-sectional view showing an example configuration of one embodiment of the display device according to this disclosure.

The display device 1 in Figure 1 is a device that can display predetermined information as an image when it is emitting light, and can allow a predetermined design to be viewed when it is not emitting light.

The display device 1 comprises a substrate 11, a plurality of light-emitting units 12 mounted on the substrate 11 at a predetermined arrangement pitch P1, and a decorative layer 13 formed on the substrate 11 in areas other than those on which the light-emitting units 12 are mounted.

The substrate 11 is made of, for example, a glass epoxy substrate, a glass polyimide substrate, etc., and the substrate 11 has wiring for control signals and control circuits that control the light emission of the light-emitting unit 12 formed on it.

The light-emitting section 12 includes a light source 21 and a light guide section 22 formed around it. The light source 21 includes, for example, a light-emitting element that emits red light, a light-emitting element that emits green light, and a light-emitting element that emits blue light, and each light-emitting element is composed of, for example, a light-emitting diode (LED). The size of the light-emitting section 12 (e.g., chip size) is not particularly limited, but it is formed to be a miniature light source, for example, with a size of ¹ mm² or less, or for example, 0.3 ^mm² or less, or for example, 0.1 ^mm² or less. The number of light-emitting elements that emit red, green, and blue light in the light-emitting section 12 may be multiple, not just one each. Also, the number of light-emitting elements may differ depending on the color of light emitted. Furthermore, some or all of the light-emitting section 12 may be provided with light-emitting elements that emit white light, or light-emitting elements that emit yellow, cyan, or magenta light. The arrangement of the multiple light-emitting elements that constitute the light source 21 is also arbitrary.

The light guide portion 22 is formed using a molding resin such as epoxy resin or silicone resin, covering the area including the direction of light emission from the light source 21 (the area shown by the dashed line in Figure 1) and its surroundings. The light guide portion 22 formed on the substrate 11 has a bottom portion S1 area 31, which is the connection surface with the substrate 11, that is larger than the area 32 of the upper portion S2, which is the light emission port. The side walls widen outward from the upper portion S2 towards the bottom portion S1, giving it a tapered shape (inclined shape). The size of the upper portion S2, which is the light emission port, is preferably formed such that (size of upper portion S2) > {(size of light source 21) + 2*TK*tanθ}, i.e., {(size of light source 21) + 2*TK*tanθ} is smaller than the size of the upper portion S2, assuming that the spreading angle in the direction of light emission from the light source 21 is θ and the distance from the light source 21 to the upper portion S2 is the same as the thickness TK of the decorative layer 13. However, this does not apply if the light guide unit 22 has a structure that can extract internally reflected light. The divergence angle θ of the light source 21 is, for example, about 45° for a typical light-emitting diode, and it is even smaller for a narrow-beam light-emitting diode.

The arrangement pitch P1, which is the spacing between multiple light-emitting units 12 (light sources 21) mounted on the substrate 11 in a first direction (e.g., the X direction), is a predetermined value in the range of 0.1 mm to 10 mm, for example, 1.26 mm. The arrangement pitch P2 (not shown) in a second direction (e.g., the Y direction) of the substrate 11 perpendicular to the first direction may match or differ from the arrangement pitch P1 in the first direction. The arrangement pitches P1 and P2 can be appropriately determined according to the resolution, the size of the light-emitting units 12, the required brightness when emitting light, the viewing distance, etc. For example, when determining the arrangement pitch P1 according to the viewing distance, it can be determined by arrangement pitch P1 = viewing distance [m] ÷ 2160. Also, for example, in order to satisfy the required brightness as a display device 1, the arrangement pitch P1 may be determined according to the size of the light-emitting units 12 such that {(arrangement pitch P1) ÷ (size of light-emitting units 12)} < 100.

Now, with reference to Figure 2, the planar shape of the light-emitting section 12 will be described. Figures A to C in Figure 2 are planar views of the light-emitting section 12 as seen from above the substrate 11.

The planar shape of the light guide 22 can be circular, for example, as shown in Figure 2A. Alternatively, if the planar shape of the light source 21 is rectangular, the planar shape of the light guide 22 may be elliptical or rectangular, as shown in Figure 2B or C. Of course, the planar shape of the light guide 22 can also be square.

The diameter (width) of the bottom S1 on the substrate side of the light guide section 22 should be greater than or equal to the diameter (width) of the upper part S2 and less than or equal to the arrangement pitch P1. The diameter (width) of the upper part S2, which is the light emission opening of the light guide section 22, should be greater than or equal to the diameter (width) of the light source 21 and less than or equal to 30% of the arrangement pitch P1. The light transmittance of the light guide section 22 is preferably 80% or more.

Returning to Figure 1, the decorative layer 13 is composed of, for example, fabric (cloth, fiber), leather, decorative panels such as wood grain, wallpaper (including textured materials with uneven surfaces such as plaster), paintings, films with a design layer formed on them, films coated with a thin metal film, etc. The decorative layer 13 allows the observer to see a predetermined design when the light-emitting part 12 is not lit. In addition, the decorative layer 13 provides the observer with a predetermined texture and feel depending on the thickness and unevenness of the decorative layer 13. The decorative layer 13 may have patterns formed on it that include pictures, letters, logos, symbols, codes, marks, emblems, designs, etc.

The thickness TK of the decorative layer 13 varies depending on the material. If the material of the decorative layer 13 is fabric (cloth, fiber), for example, a thickness of about 100 to 5000 μm is expected. If the material of the decorative layer 13 is leather or decorative laminate, for example, a thickness of about 500 to 2000 μm is expected. If the material of the decorative layer 13 is wallpaper or painting, for example, a thickness of about 500 to 3000 μm is expected. If the material of the decorative layer 13 is film, for example, a thickness of about 50 to 500 μm is expected.

The decorative layer 13 is bonded to the substrate 11, but it can also be peeled off the substrate 11 and replaced with a new decorative layer 13, for example, one with a different design.

The height of the light-emitting section 12 (distance from the bottom S1 to the top S2) is formed to match the thickness of the decorative layer 13. The display surface of the display device 1 visible to the observer is either the top S2 of the light guide section 22 or the decorative layer 13. Preferably, the area occupied by the top S2 of the light guide section 22 is 20% or less of the area occupied by the decorative layer 13. This allows the decorative layer 13 to be viewed more naturally.

In the display device 1 configured as described above, the side wall of the light guide portion 22 has a tapered shape that widens outward from the upper part S2 to the bottom part S1. By making the three-dimensional shape of the light guide portion 22 such that the upper part S2, which is the tip, is smaller than the bottom part S1, it is unnecessary to align the decorative layer 13 when bonding it to the substrate 11, and to pre-make an opening (hole) at the position of the light-emitting portion 12 of the decorative layer 13.

In other words, as will be described in detail later, before the decorative layer 13 is bonded to the substrate 11, there is no opening (hole) at the position of the light-emitting part 12 of the decorative layer 13. When the decorative layer 13 is bonded to the substrate 11, the light-guiding part 22 of the light-emitting part 12 penetrates the decorative layer 13, resulting in the cross-sectional configuration shown in Figure 1. The three-dimensional shape of the light-guiding part 22 is made into a protruding shape in which the upper part S2, which is the tip, is smaller than the bottom part S1. This makes it easier for the light-emitting part 12 to penetrate the decorative layer 13 and also has the function of reinforcing the base of the light-guiding part 22. The reinforcing part at the base of the light-guiding part 22 prevents the light-emitting part 12 from bending (falling over) when the decorative layer 13 is bonded to the substrate 11.

<2. Other configuration examples of the light-emitting section>
Referring to Figure 3, other configuration examples of the light-emitting unit 12 will be described.

In Figure 3, parts corresponding to those shown in Figure 1 are denoted by the same reference numerals, and explanations of those parts are omitted as appropriate.

Figures 3A to 3C are cross-sectional views showing other examples of the shape of the light guide section 22.

In the basic embodiment shown in Figure 1, the cross-sectional shape of the light guide portion 22 had a tapered shape that increased in size from the upper part S2 to the bottom part S1.

However, if the upper part S2 of the light guide portion 22 is smaller than the lower part S1, the three-dimensional shape of the light guide portion 22 is not limited to a tapered shape.

For example, as shown in Figure 3A, the light guide portion 22 may be formed such that the base side of the bottom portion S1 is formed as a cylindrical shape with a first diameter D1, and the tip side of the upper portion S2 is formed as a cylindrical shape with a second diameter D2 (<D1), so that the upper portion S2 is smaller than the bottom portion S1.

For example, the light guide portion 22 may have a tapered shape, as shown in Figure 3B, where the tip portion including the upper part S2 widens outward towards the bottom portion S1, and from an intermediate height, it may have a cylindrical or prismatic shape with a planar area larger than the planar area of the tapered shape.

Alternatively, the light guide portion 22 may have a shape in which the side walls widen in a stepped manner from the upper part S2 to the bottom part S1 of the light guide portion 22, as shown in Figure 3C.

Including the tapered shape shown in Figure 1, the light guide portion 22 can be divided into a tip portion including an upper part S2 with a smaller diameter (width) in the planar direction, and a base portion including a bottom portion S1 with a larger diameter (width) in the planar direction than the tip portion. The tip portion functions as a penetration aid to facilitate penetration of the decorative layer 13, and the base portion functions as a reinforcing portion to provide resistance to breakage of the protruding light guide portion 22.

Figures 4A to 4C show other configuration examples of the light-emitting unit 12.

In Figure 4, the parts corresponding to those shown in Figure 1 are given the same reference numerals, and explanations of those parts are omitted as appropriate.

Figure 4A shows a first modified example of the light-emitting unit 12.

The light-emitting unit 12 shown in Figure 4A further comprises a light distribution control unit 41 and a light reflection unit 42 or an intensity enhancement unit 43, in addition to the configuration of the light-emitting unit 12 shown in Figure 1.

The light distribution control unit 41 is provided at the upper part S2, which is the light output port of the light guide unit 22, and has the function of spreading the light emitted from the light output port. The light distribution control unit 41 is composed of, for example, a bumpy structure that is repeated at a period of less than or equal to the wavelength of visible light, or a randomly formed bumpy structure. Alternatively, the light distribution control unit 41 may be formed by a structure in which fine particles with different refractive indices are dispersed. The light distribution control unit 41 scatters the light emitted from the light source 21, thereby improving the viewing angle of the display device 1.

The light-reflecting section 42 is constructed by forming a predetermined film on the tapered side wall and bottom S1 of the light-guiding section 22, reflecting the light emitted from the light source 21 and causing it to exit from the upper part S2 of the light-guiding section 22. The light-reflecting section 42 is composed of, for example, a metal film, a dielectric multilayer film, or a film with a high refractive index (high refractive index film). The light-reflecting section 42 can improve the efficiency of extracting light emitted from the light source 21.

The reinforcement section 43 is constructed by forming a predetermined film on the tapered side wall and bottom S1 of the light guide section 22, thereby reinforcing the light guide section 22 by coating its surface. The reinforcement section 43 is composed of, for example, an inorganic insulating film, a metal film, or a high-hardness resin film. By providing the reinforcement section 43, the scratch resistance of the surface of the light guide section 22 can be improved.

The tapered side walls and bottom S1 of the light guide portion 22 may be coated with a film that is specialized for either a light-reflecting portion 42 or a strength-enhancing portion 43, or a film that has the functions of both a light-reflecting portion 42 and a strength-enhancing portion 43 may be formed. For example, by forming a metal film on the tapered side walls and bottom S1 of the light guide portion 22, it is possible to provide both the functions of a light-reflecting portion 42 and a strength-enhancing portion 43.

Figure 4B shows a second modified example of the light-emitting unit 12.

The light-emitting section 12 shown in Figure 4B has a configuration in which a high refractive index layer 45, which serves as a light-collecting optical system, is further provided in a part of the light-guiding section 22. The configuration other than the high refractive index layer 45 is the same as that of the light-emitting section 12 shown in Figure 1.

Specifically, a high refractive index layer 45 is formed in the light emission direction (forward) of the light source 21, with a refractive index higher than that of the molding resin surrounding the light guide portion 22. The high refractive index layer 45 may be a resin with a refractive index higher than that of the molding resin surrounding the light guide portion 22, or it may be an optical fiber, etc. Due to the difference in refractive index between the high refractive index layer 45 and the surrounding resin layer, the light emitted from the light source 21 undergoes total internal reflection by the high refractive index layer 45, allowing the light from the light source 21 to be efficiently output forward.

Figure 4C shows a third modified example of the light-emitting unit 12.

The light-emitting unit 12 shown in Figure 4C has a configuration that further includes a reflector (mirror) 46 as a light-collecting optical system within the light-guiding unit 22. The configuration other than the reflector 46 is the same as that of the light-emitting unit 12 shown in Figure 1.

Specifically, a roughly hemispherical reflector 46 is formed within the light guide section 22 so as to surround the light source 21 and the direction of light emission (forward). The reflector 46 is made of, for example, a metal plate or a resin plate with a metal film deposited on its surface. By totally reflecting the light emitted from the light source 21 by the reflector 46, the light from the light source 21 can be efficiently output forward.

The light-emitting section 12 in Figures A to C has a configuration that adds at least one of the following to the configuration of the light-emitting section 12 shown in Figure 1: a light distribution control unit 41, a light reflection unit 42, an intensity enhancement unit 43, a high refractive index layer 45, or a reflector 46. It goes without saying that the same additions can be made to the light guide unit 22 with the shapes shown in Figures A to C. Furthermore, the same can be applied regardless of which of the shapes in Figures A to C the planar shape of the light guide unit 22 is used. Multiple light distribution control units 41, light reflection units 42, intensity enhancement units 43, high refractive index layers 45, and reflectors 46 of Figures A to C may be arranged in appropriate combinations.

<3. Method for manufacturing a display device>
Next, with reference to Figure 5, the manufacturing method of the display device 1 will be described.

First, as shown in Figure 5A, the light source 21 is mounted at a predetermined position on the substrate 11. Although Figure 5 shows a single light source 21, in reality, as described above, multiple light sources 21 are mounted on the substrate 11 at a predetermined arrangement pitch P1 or P2.

Next, as shown in Figure 5B, a light guide portion 22 is formed around the light source 21, for example, using epoxy resin. The light guide portion 22 is molded into a tapered shape, for example, with the side walls widening outward from the top S2 to the bottom S1. The light-emitting portion 12 is completed when the light guide portion 22 is formed around the light source 21. When forming a light-reflecting portion 42 or a strength-enhancing portion 43, the light-reflecting portion 42 or strength-enhancing portion 43 is formed on the upper surface of the substrate 11 before the light guide portion 22 is formed, or on the side wall after the light guide portion 22 is formed. Also, when forming a light distribution control portion 41, the light distribution control portion 41 is formed on the upper part S2 of the light guide portion 22 after it has been formed.

Next, as shown in Figure 5C, the decorative layer 13 is mechanically pressed onto the substrate 11 using a roller 51 or other component, thereby bonding the decorative layer 13 to the upper surface of the substrate 11. An adhesive layer is provided on at least one or both of the back surface of the decorative layer 13 (the lower surface on the substrate 11 side) and the upper surface of the substrate 11. The decorative layer 13 does not have any openings (holes) before bonding, and as the decorative layer 13 is bonded to the upper surface of the substrate 11, the light guide portion 22 of the light-emitting portion 12 penetrates the decorative layer 13, completing the cross-sectional structure shown in Figure 1.

The adhesive strength between the back surface of the decorative layer 13 and the top surface of the substrate 11 is set to be strong enough to allow for peeling, so that the decorative layer 13 can be replaced.

Referring to Figures 6 and 7, another method for bonding the decorative layer 13 and the substrate 11, corresponding to C in Figure 5, will be described.

For example, as shown in Figure 6A, the decorative layer 13 and the substrate 11 can be bonded together by applying pressure from above to below with hot air from a dryer 52, or, as shown in Figure 6B, by using vacuum suction between the decorative layer 13 and the substrate 11.

Furthermore, as shown in Figure 6C, a method may be employed to bond the decorative layer 13 and the substrate 11 using a magnet 53N bonded to the decorative layer 13 and a magnet 53S bonded to the substrate 11. In this case, the arrangement density of the magnets 53N and 53S can be made sparser than the arrangement density of the light source 21. That is, the arrangement pitch of the magnets 53N and 53S in the planar direction can be set to be larger than the arrangement pitch P1 or P2 of the light source 21.

Alternatively, as shown in Figure 7, the decorative layer 13 and the substrate 11 may be bonded together by pressing the decorative layer 13 from above toward the substrate 11 using a jig 54 with a recess corresponding to the light-emitting portion 12.

In the various manufacturing method examples described above, the light guide 22 was formed after mounting the light source 21 on the substrate 11. However, it is also possible to use a light-emitting unit 12 in which the light guide 22 is packaged integrally with the light source 21. Surface-mount type light-emitting diodes (LEDs), generally called SMDs (Surface Mount Devices), correspond to such a packaged light-emitting unit 12.

Figure 8 illustrates a method for manufacturing the display device 1 when using a light-emitting unit 12 in which the light source 21 and the light guide unit 22 are packaged together.

First, as shown in Figures 8A and 8B, the packaged light-emitting unit 12 is mounted at a predetermined position on the substrate 11. The arrangement pitch P1 or P2 of the light-emitting unit 12 is the same as in the manufacturing method described above.

Next, as shown in Figure 8C, the decorative layer 13 is mechanically pressed onto the substrate 11 using a roller 51 or other component, thereby bonding the decorative layer 13 to the upper surface of the substrate 11. The decorative layer 13 does not have any openings (holes) before bonding. As the decorative layer 13 is bonded to the upper surface of the substrate 11, the light guide portion 22 of the light-emitting portion 12 penetrates the decorative layer 13, completing the cross-sectional structure shown in Figure 1.

If a light-emitting unit 12 is used in which the light guide unit 22 is packaged integrally with the light source 21, the step of forming the light guide unit 22 can be omitted, making it easier to manufacture the display device 1.

According to the various manufacturing methods described above, the decorative layer 13 before bonding does not have an opening at the position of the light-emitting part 12 after bonding. By bonding the decorative layer 13, the light-guiding part 22 penetrates the decorative layer 13, thereby manufacturing a display device 1 in which the light-emitting part 12 is arranged with respect to the decorative layer 13 at a predetermined arrangement pitch P1 or P2.

Since there is no need to pre-prepare an opening in the decorative layer 13 at the position where the light-emitting part 12 will be inserted, there is no need to process the decorative layer 13 specifically for the display device 1. Because no prior processing is required for the decorative layer 13, a general decorative material can be used as the decorative layer 13, and the display device 1 can be realized at a low cost.

Furthermore, since the decorative layer 13 has no openings, alignment with the light-emitting part 12 is unnecessary when bonding, making bonding easy. In a manufacturing method where an opening is provided in the decorative layer 13 corresponding to the position of the light-emitting part 12, and the decorative layer 13 is bonded to the substrate 11 while aligning, if a misalignment occurs, a portion will be created that blocks the light from the light source 21, resulting in a narrower viewing angle. If the opening is made larger with a margin to prevent deterioration of the viewing angle, the natural visibility of the decorative layer 13 will be impaired.

According to the manufacturing method of the display device 1, the decorative layer 13 does not have any pre-existing openings. Since the openings are formed in the decorative layer 13 by passing the light guide portion 22 through the decorative layer 13, there is no margin for the openings relative to the size of the light-emitting portion 12. This makes it possible to reduce the area ratio of the light-emitting portion 12 on the display surface of the display device 1, thereby improving the visibility of the decorative layer 13.

Furthermore, since no misalignment occurs, it is possible to prevent a decrease in viewing angle characteristics due to vignetting caused by the decorative layer 13.

Since there are no pre-existing openings in the decorative layer 13, when the area around the light-emitting part 12 that penetrates the decorative layer 13 is magnified, as shown in Figure 9, the end (cut) of the decorative layer 13 that was opened by the penetration of the light guide part 22 curls up and covers the area around the light guide part 22. This curled-up, deformed portion of the decorative layer 13 around the light guide part 22 also functions as a protective part that protects the area around the light guide part 22 that protrudes from the decorative layer 13.

In the example described above, no pre-existing openings were provided in the decorative layer 13. However, there should be no openings corresponding to the size of the light-emitting part 12, specifically, no openings larger than the size of the light-emitting part 12 (for example, the size of the upper part S2), but smaller openings may be present. For example, small holes, approximately 1/2 to 1/10 the size of the light-emitting part 12, may be provided at even intervals as penetration aids to assist in penetration. The presence of penetration aids makes it easier for the light guide part 22 to penetrate when bonding the decorative layer 13. The penetration aids do not have to be openings (holes); they may also be indentations or cross-shaped cuts.

<4. Example of a display device unit configuration>
Figure 10 is a perspective view showing another embodiment of the display device according to the present disclosure.

The display device 1 in Figure 1 can be formed to have a large display size on its own, but as shown in Figure 10, it may also be constructed by having a display device 1 that has a relatively small display size on its own, and arranging multiple of these small display devices 1 in a two-dimensional matrix to realize a display device 100 with a large display size.

In other words, the display device 100 in Figure 10 is constructed by arranging multiple display devices 1 from Figure 1 as display device units in a two-dimensional matrix. The display device 100 is constructed by arranging multiple display devices 1 in a tile-like pattern and displays a single image. Each display device 1 works in conjunction with other display devices 1 arranged in the same array to display a portion of a single image.

In Figure 10, the boundaries between the tiled display devices 1 are shown for illustrative purposes, but in reality, they are arranged so close together that the boundaries are not visible. Also, in the example in Figure 10, the display device 100 is configured with 4 in the vertical direction (Y direction) and 3 in the horizontal direction (X direction), for a total of 4 x 3 = 12 display devices 1, but the number of tiled display devices 1 is arbitrary, and the display size is scalable.

The front surface of the display device 100 (display device 1) is a display surface to which the decorative layer 13 is attached. When multiple light-emitting units 12, which are mounted at a predetermined arrangement pitch, emit light, predetermined information is displayed as an image. On the other hand, when the multiple light-emitting units 12 are not emitting light, the display device 100 allows the user to view a predetermined design formed by the decorative layer 13.

<5. Examples of Display Device Applications>
The following describes examples of applications for the display device 1 or 100.

<Spatial Display>
The display device 1 or 100 can be installed as a spatial display on the walls, ceilings, floors, etc., of buildings, company entrances, luxury hotels, restaurants, residences, etc.

For example, as shown in Figure 11, a display device 100 is installed on the wall of the living room. When the display is not emitting light, the design of the wall created by the decorative layer 13 is visible, and when it is emitting light, the entire wall may display a scene of the Hawaiian beach or an image of the conference room of the meeting partner.

For example, as shown in Figure 12, the display device 100 may be installed on the wall of the living room, like a painting or an interior board. In the example in Figure 12, the display device 100 is hung on the wall alongside the painting 111.

<Amusement>
The display device 1 or 100 can be installed, for example, as part of an amusement park, an art installation, or an art installation in a museum. It can be applied to sculptures or other art installations, or to a combination of optical camouflage and art installations. The entire wall surface surrounding an interior space can be made up of the display device 100, creating a sense of realism as if warping from a non-illuminated interior to another world when illuminated.

<Event>
Display device 1 or 100 can be used, for example, for decorating sets for events such as anime events, concerts, or theatrical performances, as well as entrances and booths at exhibitions.

<Interior space>
The display device 1 or 100 can be installed in any area, such as the dashboard, ceiling, doors, pillars, or seat backs of a vehicle like an automobile.

Figure 13 shows an example of the display device 100 being applied to the dashboard of a car.

For example, a display device 100 can be placed on the pillar of a car, and the display device 100 can be configured to display an image of the direction of the driver's line of sight to the pillar. In this case, blind spots can be eliminated without disrupting the design of the car's interior space.

<Home appliances/information equipment>
The display device 1 or 100 can be applied to portable information devices such as smartphones and smartwatches, as well as home appliances such as refrigerators and air conditioners.

The embodiments of this technology are not limited to those described above, and various modifications are possible without departing from the spirit of this technology.

For example, a combination of all or some of the above-described embodiments can be adopted.

Furthermore, the effects described herein are merely illustrative and not limiting; other effects may also occur.

The technology relating to this disclosure can take the following configuration.
(1)
circuit board and
Multiple light-emitting units mounted on the substrate,
The substrate comprises a decorative layer formed on the substrate other than the region on which the light-emitting part is mounted,
The light-emitting part is a display device having a light guide part in which the area of the bottom surface, which is the connection surface with the substrate, is formed to be larger than the area of the upper part, which is the light emission opening.
(2)
The display device according to (1) above, wherein the light guide unit comprises a light distribution control unit at the light output port.
(3)
The light distribution control unit is configured with a predetermined uneven structure, as described in (2) above.
(4)
The light distribution control unit is configured by dispersing fine particles with different refractive indices, as described in (2) above.
(5)
The display device according to any one of (1) to (4) above, wherein the light guide portion comprises a light reflecting portion that reflects light emitted from the light source.
(6)
The display device according to (5) above, wherein the light-reflecting portion is composed of a metal film, a dielectric multilayer film, or a high refractive index film.
(7)
The display device according to any one of (1) to (6) above, wherein the light guide portion comprises a strength-enhancing portion that reinforces the light guide portion.
(8)
The display device according to (7) above, wherein the strength-enhancing portion is composed of an inorganic insulating film, a metal film, or a resin film.
(9)
The display device according to any one of (1) to (4) above, wherein the light guide portion has a coating that serves as both a light reflecting portion for reflecting light emitted from a light source and a strength-enhancing portion for reinforcing the light guide portion.
(10)
The light guide unit is a display device according to any one of (1) to (9) above, having a light-gathering optical system.
(11)
The light-gathering optical system is composed of a high refractive index layer. The display device according to (10) above.
(12)
The light-gathering optical system is composed of a reflector. The display device according to (10) above.
(13)
The display device according to any one of (1) to (10), wherein the decorative layer is provided with a penetration assist portion that assists in the penetration of the light guide portion when bonding with the substrate.
(14)
The display device according to any one of (1) to (10), wherein the decorative layer comprises a protective portion that protects the periphery of the light guide portion.
(15)
The three-dimensional shape of the light guide portion is a protruding shape in which the tip portion is smaller than the bottom portion, as described in any of (1) to (10).
(16)
The light guide portion has a tapered shape in which the side walls widen outward from the top to the bottom. The display device according to any one of (1) to (10).
(17)
A display device according to any one of (1) to (16) above, which is configured by arranging multiple devices in a two-dimensional matrix and displays a single image in cooperation with other display devices arranged in multiples.
(18)
Multiple light-emitting units are mounted on a substrate at a predetermined arrangement pitch.
A method for manufacturing a display device, comprising passing the light guide portion of the light-emitting portion through the decorative layer and bonding the substrate and the decorative layer together.
(19)
A method for manufacturing a display device according to (18), wherein, after mounting the light source of the light-emitting unit on the substrate, a light guide is formed around the light source, thereby mounting the plurality of light-emitting units on the substrate at a predetermined arrangement pitch.
(20)
A method for manufacturing a display device according to (18), wherein the light source of the light-emitting unit, in which the light guide unit is packaged, is mounted on the substrate, thereby mounting the plurality of light-emitting units on the substrate at a predetermined arrangement pitch.

1: Display device, 11: Substrate, 12: Light-emitting part, 13: Decorative layer, 21: Light source, 22: Light guide part, 31: Area, 32: Area, 41: Light distribution control unit, 42: Light reflecting part, 43: Strengthening part, 45: High refractive index layer, 46: Reflector, 51: Roller, 52: Dryer, 53N: Magnet, 53S: Magnet, 54: Jig, 100: Display device, P1: Arrangement pitch, P2: Arrangement pitch, S1: Bottom, S2: Top

Claims (19)

circuit board and
Multiple light-emitting units mounted on the substrate,
The substrate comprises a decorative layer formed on the substrate other than the region on which the light-emitting part is mounted,
The light-emitting section has a light guide section in which the area of the bottom surface, which is the connection surface with the substrate, is formed to be larger than the area of the upper part, which is the light-emitting opening.
The light guide portion has a tapered shape in which the side walls widen outward from the top to the bottom.
Display device. The display device according to claim 1, wherein the light guide unit is provided with a light distribution control unit at the light output port. The display device according to claim 2, wherein the light distribution control unit is configured with a predetermined uneven structure. The display device according to claim 2, wherein the light distribution control unit is configured by dispersing fine particles with different refractive indices. The display device according to claim 1, wherein the light guide portion comprises a light reflecting portion that reflects light emitted from a light source. The display device according to claim 5, wherein the light-reflecting portion is composed of a metal film, a dielectric multilayer film, or a high refractive index film. The display device according to claim 1, wherein the light guide portion comprises a strength-reinforcing portion that reinforces the light guide portion. The display device according to claim 7, wherein the strength-enhancing portion is composed of an inorganic insulating film, a metal film, or a resin film. The display device according to claim 1, wherein the light guide portion has a coating that serves as both a light reflecting portion for reflecting light emitted from a light source and a strength-enhancing portion for reinforcing the light guide portion. The display device according to claim 1, wherein the light guide unit has a light-gathering optical system. The display device according to claim 10, wherein the light-gathering optical system is composed of a high refractive index layer. The display device according to claim 10, wherein the light-gathering optical system is composed of a reflector. The display device according to claim 1, wherein the decorative layer is provided with a penetration assist portion that assists in the penetration of the light guide portion when bonding it to the substrate. The display device according to claim 1, wherein the decorative layer comprises a protective portion that protects the area around the light guide portion. The display device according to claim 1, wherein the three-dimensional shape of the light guide portion is a protruding shape in which the tip portion is smaller than the bottom portion. The display device according to claim 1, which is configured by arranging multiple devices in a two-dimensional matrix and displays a single image in cooperation with other display devices arranged in multiples. Multiple light-emitting units are mounted on a substrate at a predetermined arrangement pitch.
The light guide portion of the light-emitting portion is passed through the decorative layer, and the substrate and the decorative layer are bonded together .
The light-emitting section has a light guide section in which the area of the bottom surface, which is the connection surface with the substrate, is formed to be larger than the area of the upper part, which is the light-emitting opening.
The light guide portion has a tapered shape in which the side walls widen outward from the top to the bottom.
A method for manufacturing a display device. A method for manufacturing a display device according to claim 17 , wherein after mounting the light source of the light-emitting unit on the substrate, a light guide is formed around the light source, thereby mounting the plurality of light-emitting units on the substrate at a predetermined arrangement pitch. The method for manufacturing a display device according to claim 17 , wherein the light source of the light-emitting unit, in which the light guide unit is packaged, is mounted on the substrate, thereby mounting the plurality of light-emitting units on the substrate at a predetermined arrangement pitch.