To provide, in a simple and cost-effective manner, a planar light-emitting module with reduced thickness as a whole, with its substrate end ensuring shock resistance and low risk of injury, and being excellent in transferring and dissipating heat. A light-emitting module of the present invention includes: a bezel having a leg part having an inner height H; a planar light-emitting tile; and a printed circuit board having a plurality of heat dissipating through holes. A heat dissipating interval is provided between the printed circuit board and the mounted surface. The printed circuit board includes a tile-side main surface being a soaking metal layer including through hole openings.

TECHNICAL FIELD

The present invention relates to a light-emitting module, and particularly to a light-emitting module in which a planar light-emitting tile is provided with a casing.

BACKGROUND ART

In recent years, as an illumination apparatus replacing an incandescent lamp or a fluorescent lamp, an organic EL module has been receiving attention and many studies have been conducted. Here, an organic EL module refers to a thin organic EL tile that emits light in a planar manner and is housed in a housing such as a bezel (a case, a frame). The terms such as an organic EL tile or panel as used herein are defined in International Standard IEC62868.

An organic EL tile is obtained by forming an organic EL element on a substrate such as a glass substrate or a substrate formed by a transparent resin film/metal sheet. The organic EL element is made up of a pair of electrodes one or both of which are light pervious and oppose to each other, and functional layers (light-emitting functional layers) laminated between the pair of electrodes.

In many cases, an organic EL tile is sealed with a sealing glass cap having a recess, or a sealing film such as an inorganic insulating film of Sift or SiN deposited on the organic EL element, or an organic insulating film such as an acrylic insulating film.

When power is applied across the electrodes of an organic EL element, electrically excited electrons and holes are recombined with each other in the organic EL element, allowing the organic EL tile to emit light. That is, an organic EL tile is a device characterized in being thin, lightweight, and emitting light in a planar manner.

A planar light-emitting tile also refers to, in addition to the above-described organic EL tile, an LED tile which is obtained by arranging LEDs in a planar manner or combining an LED and a diffusing plate. That is, a planar light-emitting tile generally refers to a planar light-emitting member, including the organic EL tile.

In order for a planar light-emitting tile represented by an organic EL tile to be used as an illumination device, a power supply circuit and power supply lines for connecting the electrodes of the planar light-emitting tile and any external power supply are necessary. In some cases, a printed circuit board (PCB) such as an FPC (flexible printed circuit) or an RPC (rigid printed circuit) is used as the power supply circuit or the power supply lines.

Further, as described above, an organic EL tile has a substrate such as a glass substrate. Therefore, it is necessary to prevent any break or crack of the substrate, and any injury to the user's finger touching the end part (edge) of the substrate.

Accordingly, in some cases, an organic EL tile and a housing are combined to each other as a module, and introduced in this state to the market as an illumination device.

That is, any housing (casing) is provided to an organic EL tile, and combined with each other as an organic EL module. In this state, the organic EL module is introduced to the market as an illumination device.

Meanwhile, an illumination device structured by a light-emitting module such as the combined organic EL module or the like cannot provide any novel and effective value to the world if it fails to fully exhibit the characteristics of the planar light-emitting tile such as an organic EL tile, that is, being thin, lightweight, emitting light in a planar manner and the like.

Further, in order to improve the light-emitting efficiency, lifetime, and reliability of a combined light-emitting module, heat dissipation or soaking must be promoted. With an LED tile that attains high temperatures in emitting light, the heat problem is significant and heat dissipation or soaking must be achieved.

As method and structure for providing a casing, Patent Document 1 discloses a scheme of holding an organic EL tile with a frame having a flange. The scheme is intended to achieve a reduction in thickness with a simple structure.

Patent Document 2 discloses a scheme of reducing a heat emission amount by providing a second electrode that is in contact with one of electrodes provided on opposite sides of a thin film organic light-emitting layer of an organic EL tile.

Patent Document 3 discloses a structure in which elongated organic EL modules are disposed in parallel in the longitudinal direction.

PRIOR ART DOCUMENTS

Patent Documents

Patent Document 1: JP 2011-3512 A

Patent Document 2: JP 2002-50468 A

Patent Document 3: JP 2007-324063 A

DISCLOSURE OF INVENTION

Technical Problem

Meanwhile, Patent Document 1 does not explicitly show the method of fixing the organic EL tile to the frame. The organic EL tile cannot be retained when the light-emitting surface of the module is oriented to be faced up.

Further, in employing the structure disclosed in Patent Document 2, elaborate works are required for the second electrode being in contact with the electrode, which is costly. Further, the structure disclosed in Patent Document 2 requires accuracy in assembly.

Still further, Patent Document 3 is silent about the structure as to heat dissipation, and is associated with a problem of a reduction in lifetime due to heat.

The present invention is made in view of the problems in the conventional techniques, and an object of the present invention is to provide, in a simple and cost-effective manner, an organic EL module with reduced risk of injury from the edge of the substrate of a planar light-emitting tile, capability of being installed in any orientation, light-weight and thinness, and reliability for a long period.

Solution to Problem

The inventors of the present invention has conducted thorough study in view of the problems described above, and found the following results.

(1) Providing fold-in parts to a bezel (a frame-like metal housing) for protecting the edge of a planar light-emitting tile allows the planar light-emitting tile to be combined smoothly, whereby the light-emitting module can be assembled easily. Further, just a single bezel can surely protect the edge of the planar light-emitting tile and support the same. Thus, with the reduced costs of manufacture and assembly, the light-emitting module can be fabricated cost-effectively.

(2) Power is supplied to the planar light-emitting tile via a printed circuit board, and the printed circuit board is combined with the light-emitting module. The printed circuit board has a non circuit surface and a circuit surface. The non circuit surface of the printed circuit board is a full-metal layer. That is, the printed circuit board having a metal layer on its entire one surface is employed.

That is, the structure of the light-emitting module includes the printed circuit board. The printed circuit board whose tile-side main surface is a non circuit surface composed of the full-metal layer is bonded to the planar light-emitting tile back-to-back with each other. That is, the full-metal layer of the printed circuit board is bonded to the back surface of the planar light-emitting tile.

With this structure having high thermal conductivity of the full-metal layer formed on the printed circuit board, the in-plane heat distribution becomes uniform, and light-emission luminance distribution becomes uniform.

(3) By disposing lots of through holes passing through both the surfaces of the printed circuit board, heat is dissipated through the through holes to the back surface-side main surface which is the circuit surface. Thus, a reduction in lifetime due to heat of the light-emitting element can be alleviated.

(4) Setting the position of the fold-in parts of the bezel, a heat dissipation space can be formed over the mounted surface. Thus, heat dissipation property improves.

The inventors have extensively studied the structures in which the effects described above work synergistically without counteracting each other, and by which a compact light-emitting module is obtained cost-effectively. Thus, the inventors has made the present invention.

A first aspect of the present invention based on the above-described finding provides a light-emitting module that includes: a bezel; a planar light-emitting tile having a predetermined light-emitting region at least on a front surface side thereof; and a printed circuit board, wherein the planar light-emitting tile and the printed circuit board are installed in the bezel with the printed circuit board on a back surface side of the planar light-emitting tile, wherein the printed circuit board includes: a base substrate; a tile-side metal layer on a planar light-emitting tile side of the base substrate; and a plurality of through holes connecting the tile-side metal layer to an other surface side of the base substrate, wherein the bezel includes: a rim part having an opening; and a leg part having a leg part body that supports the rim part in mid-air, wherein the printed circuit board is located in a region surrounded by the leg part body, wherein a height H of the leg part body is greater than a total thickness of the planar light-emitting tile and the printed circuit board, and wherein a space formed over a back surface side of the printed circuit board is at least ¼ of the height H of the leg part body.

Desirably, a height h of the space over the back surface side of the printed circuit board is not less than H/4 and not more than 3H/4, H being the height of the leg part body.

Further, other aspect of the present invention provides a light-emitting module that includes: a bezel that includes a rim part surrounding a radiation opening, the rim part having a thickness T; a printed circuit board including a plurality of through holes; and a planar light-emitting tile having a light-emitting region on a light-emitting main surface thereof, wherein the planar light-emitting tile is interposed between the rim part and the printed circuit board, wherein light of the light-emitting region is radiated from the radiation opening of the rim part, wherein the bezel further including: a predetermined abutting part being in contact with the planar light-emitting tile; and a leg part extending in a direction perpendicular to the planar light-emitting tile, the leg part having a height (T+H) including the thickness T of the rim part and integrated with the rim part, wherein the printed circuit board further including: a tile-side metal layer located on a planar light-emitting tile side of the printed circuit board, the tile-side metal layer covering substantially the light-emitting region completely when seen in a plan view, the tile-side metal layer having tile-side through hole openings that are openings of the plurality of through holes; and back surface-side through hole openings located on a back surface side that is opposite side to the planar light-emitting tile side, the back surface-side through hole openings being openings of the plurality of through holes, and wherein the printed circuit board is supported by part of the bezel at a position H/4 to 3H/4 in a direction from the abutting part to an end of the leg part.

That is, the present aspect provides a light-emitting module that includes: a bezel having a rim part having a thickness of T; a printed circuit board having a plurality of through holes; and a planar light-emitting tile having a light-emitting region at its light-emitting main surface. The planar light-emitting tile is held between the rim part and the printed circuit board. The light-emitting module radiates light of the light-emitting region from the light-emitting surface side. The tile is in contact with an abutting part of the bezel. The bezel surrounds a radiation opening corresponding to the light-emitting region and relating to the radiation. The bezel has the rim part that has the abutting part, and a leg part that has a height T+H and extends perpendicularly to the tile, the leg part being continuous to the rim part and integrally formed. The printed circuit board is supported by the bezel at a position (¼)*H to (¾)*H in a direction from the abutting part to an end of the leg part. The printed circuit board includes a tile-side main surface that is a tile-side main surface on the tile side, includes substantially the entire light-emitting region as seen in a plan view, and includes a metal layer that includes tile-side through hole openings being openings of the plurality of through holes. The printed circuit board further includes a back surface-side main surface on the opposite side of the tile-side main surface, the back surface-side main surface including back surface-side through hole openings being openings of the plurality of through holes.

In the present aspect, the planar light-emitting tile is preferably an organic EL tile. In this manner, the light-emitting module according to the present aspect includes the bezel having the leg part having an inner height H, the planar light-emitting tile, and the printed circuit board having a plurality of heat-dissipating through holes.

The light-emitting module according to the present aspect is a light-emitting module that includes an space for heat dissipation between the printed circuit board and the mounted surface, in which the printed circuit board includes a tile-side main surface which is a soaking metal layer including through hole openings.

The present aspect provides, in a simple and cost-effective manner, the light-emitting module being reduced in thickness as a whole, with its substrate end ensuring shock resistance and low risk of injury, and being excellent in soaking and dissipation characteristics.

In each of the above-described aspects, desirably, the tile-side metal layer of the printed circuit board has an area not less than 70 percent of an area of the light-emitting region of the planar light-emitting tile, the printed circuit board further including a heat dissipation-side metal layer on the back surface side thereof, the heat dissipation-side metal layer being connected to the tile-side metal layer via the through holes, and the heat dissipation-side metal layer has an area not less than 60 percent of the area of the light-emitting region of the planar light-emitting tile.

Further, preferably, the leg part further including a fold-in part partly along an end part thereof, the fold-in part supporting the printed circuit board.

According to the present aspect, the light-emitting module can be manufactured simply and cost-effectively.

Further, preferably, the leg part has a notch part for storage or passage of an external power supply line supplying the printed circuit board with power from an external source, the notch part being recessed from an end of the leg part toward the rim part partly in the leg part.

According to the present aspect, the light-emitting module being excellent in stability in attaching the module and in appearance in the attaching can be manufactured simply and cost-effectively.

Further, preferably, each of the two short side leg parts including the notch part.

That is, preferably, the light-emitting module has an elongated quadrangular outer shape in which a length is greater than a width, wherein the bezel includes: the rim part having a quadrangular outer shape with two long sides and two short sides; two long side leg parts; and two short side leg parts, the two long side leg parts and the two short side leg parts being perpendicular to the rim part.

According to the present aspect, two or more organic EL modules can be connected to each other by their respective short sides. This realizes structuring an elongated light-emitting system as a whole.

According to the present aspect, while the interval between the modules, that is, the non light-emitting region between the modules is kept to be narrow, an elongated light-emitting system can be structured with simple electrical connection. Further, the bezel employed in the present aspect allows the fold-in part and the notch part to be disposed respectively at separate leg parts of the bezel. Thus, the bezel can be manufactured cost-effectively without reducing its strength, and is an excellently productive bezel.

Further, preferably, the module has an elongated quadrangular outer shape in which a length of the module is greater than a width of the module. The bezel includes: the rim part having a quadrangular outer shape with two long sides and two short sides; two long side leg parts; and two short side leg parts, the two long side leg parts and the two short side leg parts being perpendicular to the rim part.

The present aspect provides the light-emitting module being excellent in stability in attaching the module to the bezel and in appearance in the attaching.

Each of the above-described aspects further includes, preferably, a power receiving terminal that is connected to an external power supply line on the back surface side of the printed circuit board. More preferably, the power receiving terminal is a connector. According to the present aspect, two or more light-emitting modules can be connected with ease.

Further, each of the above-described aspects further includes, preferably, a protective circuit and/or a dimming circuit on the back surface side of the printed circuit board.

The present aspect implements the light-emitting module in a compact structure, with added values of module protection and module lighting adjustment.

Further, each of the above-described aspects further includes, preferably, a wiring member that electrically connects the planar light-emitting tile and the printed circuit board, the wiring member including a terminal portion having a terminal connected to the printed circuit board, wherein a receiving terminal is disposed on the back surface side of the printed circuit board, the receiving terminal being connected to the terminal of the wiring member.

Effect of Invention

The light-emitting module of the present invention is a thin and lightweight light-emitting module, has a proper edge protection function, and has a planar light-emitting tile reinforced with a printed circuit board.

Further, the light-emitting module of the present invention can be installed in any orientation. Still further, the light-emitting module of the present invention exhibits uniform in-plane heat distribution, is thermally excellent, and is suitable for production.

BEST MODE FOR CARRYING OUT THE INVENTION

Prior to a detailed description of the constituents, a description will be given of the overview of a light-emitting module100according to an embodiment of the present invention.

As shown inFIG. 7, the light-emitting module100according to the present embodiment is structured by a module body1and a bezel8. Further, as shown inFIG. 15, the module body1is structured by a planar light-emitting tile120, a printed circuit board71, and a wiring member51.

In the following, a description will be given of the bezel8shown inFIG. 5representative of the bezels8,18.

In the present embodiment, the bezel8is formed by bending a thin metal plate or the like. As shown inFIGS. 5 and 8, the bezel8has the frame-like rim part81having a large opening (radiation opening)82, and the leg part84folded perpendicularly to the rim part81.

The shape of the bezel8as seen in a plan view is rectangular, and the opening (radiation opening)82is also rectangular.

A thickness T of the rim part81itself is about 0.3 mm to 1.0 mm.

The leg part84is integrated with the rim part81, and a height H of a leg part body (FIGS. 1 and 26)80is from 2 mm to 10 mm.

As shown inFIG. 5, the leg part84is on the back surface side of the rim part81, and wall-like projecting perpendicularly from the four sides of the rim part81. As described above, the bezel8is rectangular, and has parallel two long sides and parallel two short sides. Accordingly, the leg part84includes leg parts87a,87balong the long sides, and leg parts88a,88balong the short sides.

The leg part body80is a portion attached to the wall, ceiling, floor or the like of a building or any other structure. Whatever the attaching orientation is, the leg part body80keeps the rim part81to be spaced apart from the building or the like. That is, the leg part body80supports the rim part81in the air.

In the present embodiment, the leg parts87a,87balong the long sides are each provided with two fold-in parts85.

As shown inFIG. 26A, the fold-in parts85are formed as follows. Two slits90are provided from the free end of each of the leg parts87a,87btoward the rim part81to form a tongue part91. As shown inFIG. 26B, the tongue parts91are folded inward relative to the leg parts87a,87b, to form the fold-in parts85.

The height of the free end of each tongue part91before being folded is higher than that of the leg parts87a,87b. A neck part92having a narrow width is provided on the basal end side of each tongue part91.

Further, a notch part86is provided to each of the leg parts88a,88balong the short sides of the leg part84(FIG. 5).

In the present embodiment, while the leg part84projects perpendicularly from the four sides of the rim part81, the projecting direction is not necessarily perpendicular to the rim part81. The projecting direction having a perpendicular component will suffice.

In the present embodiment, the planar light-emitting tile120is an organic EL tile.

As shown inFIG. 15, the planar light-emitting tile120is formed as follows. An organic EL element10is laminated on a glass substrate11. Further, a sealing layer6is layered on the organic EL element10.

The module body1is formed of the planar light-emitting tile120to which the printed circuit board71and the wiring member51are attached. The module body1is a member that includes the planar light-emitting tile120on which electrical components are mounted. In other words, the module body1is an assembly capable of causing the planar light-emitting tile120to emit light when connected to an external power supply.

The light-emitting module100is a member formed of the module body1installed in the bezel8, and capable of being attached to the wall or the ceiling. It can be said that the light-emitting module100is a member having a function of an illumination device.

The module body1is mounted on the back surface of the bezel8. That is, the module body1is disposed in the space surrounded by the rim part81of the bezel8, the leg parts87a,87balong the long sides, and the leg parts88a,88balong the short sides.

Note that, in the present embodiment, the leg part body80is wall-like, and the module body1is fully encased in the space surrounded by the wall. However, the leg part84is not limited to be wall-like. For example, like legs of a table, a portion connected to the rim part81may be greater in area than the portion connected to the rim part81.

In this case also, assuming that virtual walls connect the leg part bodies80, the module body1is set in the region surrounded by the leg part bodies80.

The area around the outer circumference of the front surface (light-emitting side) of the light-emitting module100is in contact with the back surface (an abutting part83) of the rim part81. Further, the side surface of the light-emitting module100is surrounded by the boundary between the rim part81and the leg part body.

The back surface of the light-emitting module100is supported by the fold-in parts85of the bezel8.

That is, the light-emitting module100has its edge on the front surface side supported by the abutting part83formed of the back surface of the rim part81, and has a back surface side supported by the fold-in parts85of the bezel8.

That is, the light-emitting module100is clamped between the abutting part83of the rim part81and the fold-in parts85of the leg part, and fixed in the front-back surface direction.

Further, the circumferential surface of the light-emitting module100is surrounded by the boundary between the rim part81and the leg part body80, and thus the light-emitting module100is restricted from shifting also in the lateral direction.

The light-emitting module100is positioned toward the rim part81side in the bezel8. Further, the thickness of the light-emitting module100is smaller than the total height “T+H” of the bezel8.

Therefore, the light-emitting module100is spaced apart from a building or the like and held in the air by the leg part body80.

Accordingly, there exists a space110having a height h, on the back surface side of the light-emitting module100.

As will be described later, the printed circuit board71is positioned on the most back surface side of the light-emitting module100, and the printed circuit board71is supported by the fold-in parts85of the leg part84.

The position on the most back surface side of the printed circuit board71is ¼ to ¾ as great as the height H of the leg part body80. Therefore, on the back surface side of the printed circuit board71, there exists the space110having a height (height h) ¼ to ¾ as great as the height H of the leg part body80.

As to the dimensional relationship of the constituents, the total height “T+H” of the bezel8is from 2 mm to 20 mm, preferably from 2 mm to 10 mm. Most preferably, the total height “T+H” is from 2 mm to 5 mm.

The thickness of the light-emitting module100is from 1 mm to 5 mm, preferably from 1 mm to 3 mm, and more preferably less than 3 mm.

The height h of the space110formed on the back surface side of the printed circuit board71is from 0.5 mm to 18 mm. Note that, the height h of the space110is preferably from 1.0 mm to 5 mm, and most preferably from 1.0 mm to 3 mm. Note that, the height h of the space110is the height from the free end of the leg part body80to the base portion of the printed circuit board71, without taking into consideration of any terminals, connectors, ICs and the like mounted on the printed circuit board71.

In the case where the height H of the leg part body80is great, the height h of the space110becomes great. Further, in the case where the height H of the leg part body80is small, the height h of the space110becomes small.

In the case where the height H of the leg part body80is small and the height h of the space110is excessively small, the heat dissipation space becomes narrow, containing heat inside and reducing the heat dissipation effect. Further, in the case where the height H of the leg part body80is high and the height h of the space110is excessively high, the characteristic of the organic EL panel, which is small in thickness, cannot be fully exhibited.

The light-emitting module100according to the present embodiment includes a metal layer on each of the front and back surfaces of the printed circuit board71. More specifically, as shown inFIG. 24, a tile-side metal layer202is provided on the front surface, and a heat dissipation-side metal layer205is provided on the back surface. The tile-side metal layer202and the heat dissipation-side metal layer205are connected to each other via through holes201, whereby heat is transferred between the tile-side metal layer202and the heat dissipation-side metal layer205.

In the light-emitting module100according to the present embodiment, the tile-side metal layer202of the printed circuit board71is in contact with the back surface of the planar light-emitting tile120, and the tile-side metal layer202absorbs heat of the planar light-emitting tile120. Then, the heat is transferred to the heat dissipation-side metal layer205on the back surface side of the printed circuit board71.

By virtue of the great area of the heat dissipation-side metal layer205and presence of the space110formed on the back surface side of the printed circuit board71, heat of the heat dissipation-side metal layer205is dissipated into the space110, whereby heat of the planar light-emitting tile120is released to the outside.

Next, a description will be sequentially given about the overview of the members of the light-emitting module100.

Firstly, a description will be given about the planar light-emitting tile120. As shown inFIG. 17, the planar light-emitting tile120has a greater total length La relative to a width Wa, and is elongated.

As shown inFIG. 17, a light-emitting region2of the planar light-emitting tile120is planar and rectangular. The light-emitting region2has a greater total length Lb relative to a width Wb, and is elongated.

The width Wb of the light-emitting region2is not more than ⅓ of the total length Lb of the light-emitting region2. More desirably, the width Wb is not more than ⅕ of the total length Lb, and further desirably ⅛ as great as or smaller than the total length Lb.

Further, the width Wb of the light-emitting region2is narrow and not longer than 5 cm. More desirably, the width Wb of the light-emitting region2is not longer than 3 cm. More preferably, the width Wb of the light-emitting region2is not loner than 2 cm.

The total length Lb of the light-emitting region2is not smaller than 5 cm, and more desirably not smaller than 10 cm.

As described above, the light-emitting region2of the planar light-emitting tile120is rectangular, and surrounded by the parallel long sides3,4and the parallel short sides15,16.

In the present embodiment, as shown inFIG. 17, the power supply part17for the light-emitting region2is centrally positioned on one long side3of the light-emitting region2.

The planar light-emitting tile120is an organic EL panel of the bottom emission type, in which the organic EL element10is laminated on the glass substrate11as shown inFIGS. 15 and 16. Further, in the present embodiment, the organic EL element10is sealed by the sealing layer6.

As described above, in the module body1according to the present embodiment, the printed circuit board71is attached to the sealing layer6of the planar light-emitting tile120, and further the wiring member51connects the printed circuit board71and the organic EL element10. In the present embodiment, the wiring member51is a flexible printed wiring.

As described above, the planar light-emitting tile120is formed by the glass substrate11on which the organic EL element10is laminated.

As shown inFIGS. 15 and 16, the organic EL element10has a transparent conductive anode layer21, which is a transparent electrode layer, and the metal cathode layer41, which is a metal layer, and a functional layer (light-emitting functional layer)31is interposed between them.

As shown inFIGS. 15 and 16, in the present embodiment, the transparent conductive anode layer21is substantially rectangular as seen in a plan view, and has recesses and projections along one long side of the rectangle. Specifically, as shown inFIGS. 15 and 16, the transparent conductive anode layer21has notch parts25a,25bat two portions along one long side. In other words, the transparent conductive anode layer21has projecting parts26a,26b,26cat three portions along one long side.

The transparent conductive anode layer21is functionally separated into an anode layer body region27that functions as an electrode, and the other area, a pad region28.

The anode layer body region27is a rectangular region other than the notch parts25a,25band the projecting parts26a,26b,26c.

The pad region28is a region where the projecting parts26a,26b,26care formed.

The above-described projecting parts26a,26b,26care transparent electrode-side power supply pad parts, and function as anode-side power supply pad parts22a,22b,22cin the present embodiment.

Since the projecting parts26a,26b,26care connected to the transparent conductive anode layer21, they can be referred as transparent electrode-side power supply pad parts. Viewing polarity of the electrode, the projecting parts26a,26b,26cfunction as anode-side power supply pad parts. In the present embodiment, while the names of anode-side power supply pad parts22a,22b,22care mainly used, the anode-side power supply pad parts22a,22b,22care also transparent electrode-side power supply pad parts.

The anode-side power supply pad parts22a,22b,22care part of the transparent conductive anode layer21. The anode-side power supply pad parts22a,22b,22care extending parts of the transparent conductive anode layer21, and function as terminals for energizing the functional layer (light-emitting functional layer)31.

The shape of the projecting parts26a,26b,26cis rectangular. That is, the projecting parts26a,26b,26care each elongated and rectangular along the long side3of the light-emitting region2.

The three projecting parts26a,26b,26care arranged in this order from the left side of the drawing. The notch part25ais present between the projecting parts26a,26b, and the notch part25bis present between the projecting parts26b,26c.

The ends in the longitudinal direction of the opposite projecting parts26a,26care aligned with the end of the anode layer body region27.

Lengths L26a, L26b, L26cin the longitudinal direction of three projecting parts26a,26b,26cof the planar light-emitting tile120are each greater than lengths L25a, L25bof the notch parts25a,25b.

The lengths L26a, L26b, L26cof the projecting parts26a,26b,26cin total are not less than 60 percent, more desirably 70 percent, and further more preferably 80 percent the length of the anode layer body region27.

Since the shape of each projecting parts26a,26b,26cis rectangular, the length of the portions connecting the projecting parts26a,26b,26cwith the anode layer body region27is equal to the lengths L26a, L26b, L26cof the projecting parts26a,26b,26c.

Accordingly, the length of the portions connecting the projecting parts26a,26b,26cwith the anode layer body region27is not less than 60 percent, more desirably 70 percent, and further preferably 80 percent of the length of the anode layer body region27.

In the present embodiment, while the three projecting parts26a,26b,26care provided along one long side of the anode layer body region27, they are not identical to one another in length. In the present embodiment, while the opposite projecting parts26a,26care identical to each other in length, the central projecting part26bis longer than the other two. Specifically, the central projecting part (central anode-side power supply pad part)26bis about twice as great as the other two in length.

In the present embodiment, cathode-side power supply pad parts23a,23bare formed at the positions of the notch parts25a,25b. The cathode-side power supply pad parts23a,23bare formed simultaneously with the formation of the transparent conductive anode layer21, and are identical to the transparent conductive anode layer21in material and thickness.

The cathode-side power supply pad parts23a,23bare named in terms of the polarity of the electrode. In terms of their connection to the metal cathode layer41, they are metal electrode-side power supply pad parts. In the present embodiment, while the names of cathode-side power supply pad parts23a,23bare mainly used, the cathode-side power supply pad parts23a,23bare also metal electrode-side power supply pad parts.

The cathode-side power supply pad parts23a,23bare island parts that are independent of the transparent conductive anode layer21. That is, the transparent conductive anode layer21is formed island-like, and the cathode-side power supply pad parts23a,23band the transparent conductive anode layer21are electrically disconnected from each other.

As shown inFIG. 15, the functional layer (light-emitting functional layer)31is laminated on the anode layer body region27of the transparent conductive anode layer21. More specifically, as shown inFIGS. 15 and 16, the functional layer31is formed to fully fall within the range of the anode layer body region27of the transparent conductive anode layer21.

The metal cathode layer41is further laminated on the functional layer (light-emitting functional layer)31. As shown inFIGS. 15 and 16, the metal cathode layer41is also substantially rectangular as seen in a plan view. The metal cathode layer41also has recesses and projections along one long side. However, the positional relationship of the recesses and projections of the metal cathode layer41is converse to that of the transparent conductive anode layer21. In the metal cathode layer41, projecting extending parts42a,42bare provided at portions corresponding to the notch parts25a,25bof the transparent conductive anode layer21.

The metal cathode layer41is also functionally separated into a metal cathode layer body region43that functions as an electrode, and the other region, a pad region45.

In the present embodiment, the pad region45is a region where the extending parts42a,42bare formed. The other region is the metal cathode layer body region43.

The metal cathode layer body region43of the metal cathode layer41is overlaid on the functional layer31, and does not protrude from the functional layer31.

On the other hand, the extending parts42a,42bof the pad region45protrude from the functional layer31. The positions of the extending parts42a,42bcorrespond to those of the notch parts25a,25bof the transparent conductive anode layer21. Accordingly, the extending parts42a,42bof the metal cathode layer41are overlaid on the cathode-side power supply pad parts23a,23bprovided to the notch parts25a,25bof the transparent conductive anode layer21.

In the present embodiment, the projecting portions of the extending parts42a,42bof the metal cathode layer41reach the ends of the cathode-side power supply pad parts23a,23b, and the extending parts42a,42bof the metal cathode layer41partially are overlaid on the cathode-side power supply pad parts23a,23b.

Note that, the extending parts42a,42bof the metal cathode layer41may entirely cover the cathode-side power supply pad parts23a,23b.

Next, a description will be given about the wiring member51.

In the present embodiment, two wiring members51are connected to the organic EL element10of the planar light-emitting tile120. The transparent conductive anode layer21and the metal cathode layer41are energized via the two wiring members51.

The wiring member51shown inFIG. 18Ais what is called a flexible printed wiring, in which a resin-made substrate layer52, a metal conductive layer53, and a cover layer55are layered.

In the wiring member51, the metal conductive layer53is largely covered with the cover layer55, and part of the metal conductive layer53is exposed outside as an electrode.

In the present embodiment, the wiring member51is T-shaped, having a horizontally elongated part56and a vertically elongated part57. The vertically elongated part57extends in the direction perpendicular to the horizontally elongated part56, and connected to the center in the longitudinal direction of the horizontally elongated part56.

The metal conductive layer53is separated into three lines. That is, on the substrate layer52, a left-line metal conductive layer53a, a middle-line metal conductive layer53b, and a right-line metal conductive layer53care layered.

In the present embodiment, the tip on the free end side of the vertically elongated part57functions as a terminal part58, and the three lines of the metal conductive layer53are exposed at the tip on the free end side of the vertically elongated part57.

In the present embodiment, the three lines of the metal conductive layer53are exposed at the terminal part58, to form an A-side left terminal72a, a B-side terminal73, and an A-side right terminal72b.

Further, in the present embodiment, the horizontally elongated part56functions as a pad part, and the three lines of the metal conductive layer53are exposed at any portion of the horizontally elongated part56.

That is, the horizontally elongated part56includes an A-side left pad60a, a B-side pad60b, and an A-side right pad60c.

The above-described A-side left terminal72ais connected to the A-side left pad60a. The B-side terminal73is connected to the B-side pad60b. The A-side right terminal72bis connected to the A-side right pad60c.

Note that, the A-side left pad60aand the A-side right pad60care connected to the anode-side power supply pad parts (transparent electrode-side power supply pad parts)22a,22b,22c. Further, the B-side pad60bis connected to the cathode-side power supply pad parts (metal electrode-side power supply pad parts)23a,23b.

Among the three lines of the metal conductive layer53, the central middle-line metal conductive layer53bpasses through the center of the vertically elongated part57, to reach the horizontally elongated part56. The middle-line metal conductive layer53bis exposed at the center of the horizontally elongated part56, to form the B-side pad60b. The exposed portion (the B-side pad60b) of the middle-line metal conductive layer53bis dot-like.

On the other hand, the left-line metal conductive layer53aextends along the vertically elongated part57to reach the horizontally elongated part56, and further extends along the horizontally elongated part56leftward in the drawing. The left-line metal conductive layer53ais exposed in a region half as great as the width of the horizontally elongated part56, to form the A-side left pad60a. The exposed portion (the A-side left pad60a) of the left-line metal conductive layer53ais linear and elongated.

The right-line metal conductive layer53cis symmetric to the left-line metal conductive layer53a. Similar to the left-line metal conductive layer53a, the right-line metal conductive layer53cis linear and elongated.

In the present embodiment, the horizontally elongated part56of the wiring member51abuts on the pad regions28,45of the transparent conductive anode layer21and the metal cathode layer41.

For the sake of convenience, the projecting parts26a,26b,26care referred to as a first projecting part26a, a second projecting part26b, and a third projecting part26c, respectively. Further, the two wiring members51are separately recognized as a first wiring member51a, and a second wiring member51b.

Further, the horizontally elongated part56of the wiring member51is separately recognized as the left wing side and the right wing side.

As shown inFIG. 15, in the present embodiment, a left wing side61of the first wiring member51ais on the projecting part26aof the transparent conductive anode layer21(the anode-side power supply pad part22a, the transparent electrode-side power supply pad part), and the exposed portion (the A-side left pad60a) of the left-line metal conductive layer53ais in contact with the anode-side power supply pad part22awhich is the extending part of the transparent conductive anode layer21.

With reference toFIG. 19B, as shown in the cross-sectional view taken along line B-B, the A-side left pad60aof the wiring member51is overlaid on the projecting part26a(the anode-side power supply pad part22a) of the transparent conductive anode layer21.

Further, the central portion of the first wiring member51ais on the notch part25aof the transparent conductive anode layer21, and the exposed portion (the B-side pad60b) of the middle-line metal conductive layer53bis in contact with the cathode-side power supply pad part23a.

With reference toFIG. 19A, as shown in the cross-sectional view taken along line A-A, the extending part42aof the metal cathode layer41is in contact with the island part (the cathode-side power supply pad part23a) which is independent of the transparent conductive anode layer21, and the B-side pad60bof the wiring member51is overlaid on the island part (the cathode-side power supply pad part23a).

Further, the right wing side62of the first wiring member51ais on the projecting part26b(the anode-side power supply pad part22b) of the transparent conductive anode layer21.

Here, the central projecting part26bof the transparent conductive anode layer21is longer than the opposite projecting parts26a,26c. Accordingly, the right wing side62of the first wiring member51acovers substantially half the central projecting part26bof the transparent conductive anode layer21.

The exposed portion (the A-side right pad60c) of the right-line metal conductive layer53cis in contact with substantially half the anode-side power supply pad part22bextending from the transparent conductive anode layer21.

Similarly, the left wing side63of the second wiring member51bcovers substantially half the central projecting part26bof the transparent conductive anode layer21.

The exposed portion (the A-side left pad60a) of the left-line metal conductive layer53ais in contact with substantially half the anode-side power supply pad part (transparent electrode-side power supply pad part)22bextending from the transparent conductive anode layer21.

Further, the central portion of the second wiring member51bis on the notch part25bof the transparent conductive anode layer21, and the exposed portion (the B-side pad60b) of the middle-line metal conductive layer53bis in contact with the cathode-side power supply pad part23b.

Further, the right wing side65of the second wiring member51bis on the projecting part26c(the anode-side power supply pad part22c) of the transparent conductive anode layer21, and the exposed portion (the A-side right pad60c) of the right-line metal conductive layer53cis in contact with the anode-side power supply pad part22cthat is the extending part of the transparent conductive anode layer21.

In the present embodiment, the sealing layer6that covers the organic EL element10is provided. Further, the printed circuit board71is overlaid on the sealing layer6. Note that, the sealing layer6seals at least a region corresponding to the light-emitting region2. In the present embodiment, the sealing layer6is not provided at the power supply part17.

Next, a description will be given about the printed circuit board71.

As shown inFIG. 23, the printed circuit board71has a base substrate200made of resin or the like. On the front and back surfaces (the upper side in the drawing) of the base substrate200, circuitry and the like are formed.

In the present embodiment, circuitry is formed just on one surface of the base substrate200, and the other surface is substantially entirely a metal layer.

Further, numerous through holes201are formed at the base substrate200. Accordingly, on the front and back surfaces of the printed circuit board71, through hole openings208,212that are the openings of the through holes201are opened.

In the present embodiment, the printed circuit board71is attached on the back surface side of the planar light-emitting tile120.

In the printed circuit board71employed in the present embodiment, the surface of the base substrate200, which is in contact with the planar light-emitting tile120, is substantially covered with a metal layer (hereinafter referred to as a tile-side metal layer202) entirely.

On the other hand, circuitry is formed on the back surface of the printed circuit board71, and anode receiving terminals103a,103c, a cathode receiving terminal103b, a power receiving terminal101and the like are mounted. Further, on the back surface of the printed circuit board71, besides connecting lines220,221connecting the above-described elements, a heat dissipation-side metal layer205is provided.

In the following, a description will be given of such elements.

As described above, on the planar light-emitting tile120side of the surface of the printed circuit board71, the tile-side metal layer202is formed. The tile-side metal layer202is provided on the area shaded inFIG. 21A.

That is, as described above, the tile-side metal layer202is provided on a substantially entire area of one main surface of the printed circuit board71.

Here, an area A of the tile-side metal layer202of the printed circuit board71corresponds to the area of the planar light-emitting tile120. On the other hand, the above-described light-emitting region2is part of the planar light-emitting tile120. Accordingly, the tile-side metal layer202is greater in area than the light-emitting region2, and covers the entire region of the light-emitting region2.

As in the present embodiment, the area A of the tile-side metal layer202is desirably greater than an area a of the light-emitting region2, and the area A of the tile-side metal layer202is not less than most recommendably 120 percent of the area a of the light-emitting region2.

It goes without saying that the area A of the tile-side metal layer202may be smaller than the light-emitting region2. Further, the light-emitting region2may be partially not covered with the tile-side metal layer202.

The area A of the printed circuit board71is desirably 70 percent, and recommendably 100 percent, as great as or greater than the area a of the light-emitting region of the planar light-emitting tile120. Further, as described above, the area A of the tile-side metal layer202is most recommendably not less than 120 percent of the area a of the light-emitting region2.

Depending on the circuit structure on the back surface, the tile-side metal layer202may not be able to entirely cover the light-emitting region2.

The uncovered area of the light-emitting region2is not less than desirably 20 percent, more recommendably 5 percent, of the area a of the light-emitting region2.

While the tile-side metal layer202desirably is metal exposed at one main surface of the printed circuit board71, it may has its front surface covered with a thin insulating film.

As described above, the back surface side of the printed circuit board71(the side not being in contact with the planar light-emitting tile120) is a circuit surface, where the anode receiving terminals103a,103c, the cathode receiving terminal103b, the power receiving terminal101and the like are mounted. Further, the connecting lines220,221connecting the above-described elements are provided.

The connecting lines include an anode connecting line220connecting the anode receiving terminals103a,103cand the power receiving terminal101shown inFIGS. 20 and 21, and a cathode connecting line221connecting the cathode receiving terminal103band the power receiving terminal101shown inFIGS. 20 and 22.

Further, as described above, on the back surface side of the printed circuit board71, the heat dissipation-side metal layer205is formed.

The heat dissipation-side metal layer205is formed on a wide area excluding the above-described anode connecting line220and cathode connecting line221.

In the present embodiment, the heat dissipation-side metal layer205is largely divided into three areas.

That is, in the present embodiment, the heat dissipation-side metal layer205is divided into a power supply-side heat dissipation-side metal layer205acovering the power supply-side area, a central heat dissipation-side metal layer (large side)205band a central heat dissipation-side metal layer (small side)205ccovering the central area, and an other-side heat dissipation-side metal layer205dcovering the other side.

The power supply-side heat dissipation-side metal layer205a, the central heat dissipation-side metal layers205b,205c, and the other-side heat dissipation-side metal layer205dare each island-like, and electrically insulated from one another. Further, the power supply-side heat dissipation-side metal layer205a, the central heat dissipation-side metal layers205b,205c, and the other-side heat dissipation-side metal layer205dare insulated from the anode connecting line220and the cathode connecting line221.

The heat dissipation-side metal layer205occupies most of the area of the printed circuit board71on the back surface side. A total area B of the heat dissipation-side metal layer205is not less than desirably 60 percent, recommendably 100 percent, of the area a of the light-emitting region of the planar light-emitting tile120. Further, when possible, the total area B is not less than desirably 120 percent of the area a of the light-emitting region of the planar light-emitting tile120.

The front surface of the heat dissipation-side metal layer205is covered with a thin insulating film.

As described above, numerous through holes201are formed at the printed circuit board71. However, the through holes201are present at only the portions where the heat dissipation-side metal layer205exists.

As described above, the tile-side metal layer202is on the side of the base substrate200where the base substrate200is in contact with the planar light-emitting tile120. The tile-side metal layer202solidly covers substantially the entire surface of the printed circuit board71. Therefore, the through holes201penetrate through the printed circuit board71from the tile-side metal layer202to the heat dissipation-side metal layer205. Further, the inner surface of the through holes201is coated with a metal layer206of silver or copper in any known manner.

Accordingly, the tile-side metal layer202on the planar light-emitting tile120side and the heat dissipation-side metal layer205on the back surface side are connected to each other by the highly thermally conductive metal layer206.

The above-described printed circuit board71includes one base substrate200, one surface of which is the circuit surface and the other surface of which is the tile-side metal layer202. On the other hand, the printed circuit board may have a structure including greater number of layers. For example, like the printed circuit board shown inFIG. 25, two base substrates200may be provided, and the tile-side metal layer202may be provided on one surface of the entire structure, and the circuitry may be provided at each of the back surface and the intermediate layer.

Next, a description will be given of the positional relationship between the printed circuit board71and the planar light-emitting tile120.

As shown inFIG. 24, the printed circuit board71is attached to the back surface side of the planar light-emitting tile120. That is, as shown inFIG. 24, the printed circuit board71is provided by being overlaid on the sealing layer6of the planar light-emitting tile120. The printed circuit board71is oriented such that the tile-side metal layer202becomes in contact with the back surface of the planar light-emitting tile120.

As described above, the sealing layer6is provided at the back surface of the planar light-emitting tile120. The sealing layer6is flat. On the other hand, the tile-side metal layer202being the front surface side of the printed circuit board71is also flat. In the present embodiment, the tile-side metal layer202of the printed circuit board71is in close contact with the back surface of the planar light-emitting tile120.

As described above, the tile-side metal layer202is provided over substantially the entire surface of the printed circuit board71. The tile-side metal layer202is overlaid on the functional layer31with the sealing layer6and the metal cathode layer41being interposed between them.

That is, the tile-side metal layer202covers the light-emitting region2.

Further, the tile-side metal layer202is greater in area than the light-emitting region2. Therefore, it can be said that the tile-side metal layer202covers the tile-side metal layer202with a margin.

As shown inFIGS. 10 and 20, the printed circuit board71is provided with the anode receivers103a,103band the cathode receiver103c. The anode receivers103a,103band the cathode receiver103care provided on the main surface which is opposite to the glass substrate11.

Terminal parts58of the two wiring members51a,51bare connected to the printed circuit board71. More specifically, the A-side left terminal72aof the terminal part58is connected to the anode receiver103a. The B-side terminal73is connected to the cathode receiver103b. The A-side right terminal72bis connected to the anode receiver103c.

The organic EL element10is energized via the printed circuit board71. That is, voltage is applied across the anode layer body region27of the transparent conductive anode layer21and the metal cathode layer body region43of the metal cathode layer41, and current flows through the functional layer31of the organic EL element10.

Here, in the present embodiment, a power supply portion (anode-side power supply pad parts22a,22b,22c) extends in an elongated manner along one side of the anode layer body region27. In addition, the anode layer body region27is small in width.

Accordingly, the resistance value across the power supply portion and each part of the anode layer body region27is substantially uniform.

That is, though the transparent electrode that forms the anode layer body region27is high in resistance, the anode layer body region27is supplied from the wide range and the width of the region is small. Therefore, the resistance value across the power supply portion and each part of the anode layer body region27less varies.

On the other hand, the metal cathode layer41is primarily low in resistance. Therefore, the resistance value of the metal cathode layer body region43is uniform.

As to the flow of current, the current supplied from the printed circuit board71flows from the terminal part58of the wiring member51a,51bto the left-line metal conductive layer53aand the right-line metal conductive layer53c. Then, through the A-side pads60a,60c, the current is supplied to the anode-side power supply pad parts (transparent electrode-side power supply pad parts)22a,22b,22c. The current further flows from the anode-side power supply pad parts22a,22b,22cto the anode layer body region27, and to the functional layer (light-emitting functional layer)31. The current further flows to the metal cathode layer41on the back surface side, and arrives at the printed circuit board71via the cathode-side power supply pad part (metal electrode-side power supply pad part)23aand the middle-line metal conductive layer53b.

In the present embodiment, what functions as the electrode on the anode side of the organic EL element10is the transparent conductive anode layer21, which is high in electrical resistance. Therefore, when the energizing path is long, voltage drops at the end side, which invites planar variations in the amount of current passing through the functional layer31.

On the other hand, the module body1of the present embodiment has the elongated light-emitting region, and the transparent conductive anode layer21is supplied with power from the long side. In addition, the energizing path to the anode layer body region27that functions as an anode is rectangular and great in width. Further, since the light-emitting region is elongated and small in width, the energizing path of the transparent conductive anode layer21itself is short. Accordingly, voltage does not easily drop at the end side of the transparent conductive anode layer21, whereby planar variations in the amount of current passing through the functional layer31are small.

Specifically, since the metal conductive layer53of the wiring members51a,51bis made of metal with small electrical resistance, such as copper, the resistance value is still low despite a change in the energizing distance to some extent, and voltage drop is negligible.

In the present embodiment, in the wiring members51a,51bleading to the transparent conductive anode layer21, the exposed portion of the metal conductive layer53is long along the light-emitting region of the module body1. However, as described above, the metal conductive layer53is metal with low electrical resistance, and voltage drop is negligible for a change in the energizing distance to some extent. Accordingly, voltage applied to the anode-side power supply pad parts22a,22b,22cover the entire region of the horizontally elongated part56of the wiring member51is uniform.

Further, the anode-side power supply pad parts22a,22b,22care extending parts that project from the anode layer body region27, and the length of the cross section of the portion connected to the anode layer body region27is great. Therefore, there is no resistance component when current flows from the anode-side power supply pad parts22a,22b,22cto the anode layer body region27.

Further, since the anode layer body region27itself is narrow, voltage drop in the anode layer body region27is small.

That is, in the anode layer body region27, while current flows from the one long side3to the other long side4, the distance between the supplying long side3and the consuming long side4is small. Therefore, the potential of the other long side4of the anode layer body region27does not largely differ from that around the supplying long side3.

Therefore, the potential on the surface of the anode layer body region27is uniform.

Further, the metal conductive layer53opposing to the anode layer body region27is primarily low in electrical resistance due to its being made of metal, and therefore the potential of the metal cathode layer body region43is uniform.

Accordingly, the voltage distribution among each part of the anode layer body region27and each part of the metal cathode layer body region43is uniform, and current uniformly flows through the functional layer31. Therefore, current evenly flows from the entire surface of the anode layer body region27to the entire surface of the metal cathode layer body region43.

Further, while energizing the planar light-emitting tile120causes the functional layer (light-emitting functional layer)31to generate heat, in the present embodiment, the tile-side metal layer202provided at the printed circuit board71and the heat dissipation-side metal layer205diffuse the heat, and thus the heat is smoothly dissipated.

That is, while energizing the planar light-emitting tile120causes the functional layer31to generate heat, the entire surface of the functional layer31is covered with the tile-side metal layer202via the metal cathode layer41and the sealing layer6. Further, as shown inFIG. 24, the tile-side metal layer202is in planar-contact with the sealing layer6of the planar light-emitting tile120. Accordingly, the heat generated at the functional layer31is transferred to the tile-side metal layer202.

Further, the tile-side metal layer202is in contact with the heat dissipation-side metal layer205via the metal layer206of the through holes201.

Therefore, the heat transferred to the tile-side metal layer202is transferred to the heat dissipation-side metal layer205via the metal layer206of the through holes201.

Here, in the present embodiment, while a thin insulating film exists on the heat dissipation-side metal layer205, on the outer side of the heat dissipation-side metal layer205, there exists a space that is surrounded by the leg parts87a,87balong the long sides and the leg parts88a,88balong the short sides and has a height not less than ¼ of the height H of the leg part body80.

Therefore, the heat dissipation-side metal layer205is exposed to the space and thus cooled.

Accordingly, the heat generated at the functional layer31is absorbed by the tile-side metal layer202and transferred to the heat dissipation-side metal layer205via the metal layer206of the through holes201, and dissipated to the atmosphere from the heat dissipation-side metal layer205.

Thus, the heat does not stay in the planar light-emitting tile120.

In this manner, in the light-emitting module100according to the present embodiment, the voltage distribution among each part of the anode layer body region27and each part of the metal cathode layer body region43is uniform, and current uniformly flows through the functional layer31. Further, heat generated at the functional layer31is smoothly dissipated. Thus, the planar light-emitting region2uniformly emits light.

In the foregoing, the description has been given of the overall structure of the module body1. In the following, with reference to the drawings, a description will be given of the constituents including the detailed structure and the manufacturing method.

FIG. 1is a cross-sectional view showing the light-emitting module100of the present invention.

As shown inFIG. 1, the light-emitting module100of the present invention includes the bezel8, the planar light-emitting tile120, and the printed circuit board71. Further, the light-emitting module100preferably further includes the wiring member51. The planar light-emitting tile120having the light-emitting region2at its light-emitting main surface is held between the bezel8and the printed circuit board71.

A preferable planar light-emitting tile120is an organic EL planar light-emitting tile. A preferable bezel is the metal bezel8.

For example, the light-emitting module100may be manufactured by: employing the planar light-emitting tile (organic EL planar light-emitting tile)120, the wiring member51, the printed circuit board71, and the metallic bezel8as the basic constituent members, bonding the wiring member51and the printed circuit board71to the planar light-emitting tile120, and installing the same in the metal-made bezel8.

The light-emitting module100of the present invention is an illumination device that causes the light-emitting region2to emit light from its light emitting surface side. The light-emitting module100specifically is an illumination device that radiates light generated by the light-emitting element (the organic EL element10) in the planar light-emitting tile120, from the radiation opening82provided at the rim part81of the bezel8.

That is, as shown inFIG. 1, the bezel8has the rim part81that has a portion (the abutting part83) being in contact with the planar light-emitting tile120, and the radiation opening82is provided at the rim part81. The light-emitting module100is an illumination device that emits light generated by the light-emitting element in the planar light-emitting tile120from the radiation opening82that corresponds to the light-emitting region2of the planar light-emitting tile120.

Here, in consideration of effective use of light generated in the planar light-emitting tile120, as seen in a plan view, the light-emitting region2is preferably included in the radiation opening82. In other words, the non light-emitting region on the light-emitting main surface (the front surface) of the planar light-emitting tile120preferably abuts on the abutting part83.

As to the outer shape of the light-emitting module100of the present invention, in order to implement a compact illumination device relative to its light-emitting region2, the outer shape of the radiation opening82is preferably identical or similar to that of the light-emitting region2. The outer shape of the light-emitting module100, that is, the outer shape of the rim part81is preferably similar to the radiation opening82. It is preferable to implement an elongated quadrangular module (an elongated module) that has the elongated quadrangular light-emitting region2having a great length relative to its width, and the outer shape of the similarly elongated shape. Suitably, the light-emitting module100has a width equal to or smaller than 30 mm, and a length equal to or greater than 100 mm.

It goes without saying that the outer shape of the light-emitting module100may be a triangle, a quadrangle including a square, other polygons, or an ellipse including a perfect circle. However, in order to fully use the advantage of the reduced area of the rim part81which is one of the characteristics of the present invention, and apply the light-emitting module100to a system capable of evenly illuminating an elongated illumination target, the outer shape of the light-emitting module100is desirably rectangular.

FIG. 2is a perspective view showing the planar light-emitting tile according to one embodiment of the present invention.

The planar light-emitting tile120of the present invention is a plate-like member having opposite main surfaces, namely, the light-emitting main surface (the lower side inFIG. 1) having the light-emitting region2and the non light-emitting main surface (the upper side in FIG.1). The planar light-emitting tile120includes therein the light-emitting element (the organic EL element10or the like). In the present specification, the planar light-emitting tile120is referred to as the organic EL tile when the light-emitting element includes the organic EL element10, and the planar light-emitting tile120is referred to as the LED tile when it includes just an LED element.

The non light-emitting main surface preferably includes an electrode-side power supply pad region (the power supply part17) that is not sealed, which will be described later, in order to facilitate establishing electrical connection for supplying power to the light-emitting element. Further, in order to prevent entry of moisture or the like to the light-emitting element to thereby reliably attain long lifetime and high reliability, when seen in a plan view, a sealed region7which is continuously sealed over the region including the light-emitting region2is preferably provided. The sealed region7will be described later.

Here, as described above, when the planar light-emitting module100is an elongated module, which is the preferred embodiment, preferably the electrode-side power supply pad regions (the pad regions28,45) are provided just along one long side3which is one of the opposite long sides of the planar light-emitting module100. In this manner, as described above, the sealed region7including the light-emitting region2when seen in a plan view is provided unevenly, that is, just along the other long side which is the other one of the opposite long sides. However, by virtue of the light-emitting region2being elongated, a light-emitting module being compact and exhibiting high area efficiency while maintaining the power supply which does not cause luminance distribution is implemented.

Among various types of planar light-emitting tiles, with an organic EL planar light-emitting tile (an organic EL tile), the most cost-effective internal wiring can be employed, and soft planar light-emission can be realized with a single light-emitting element. Therefore, an organic EL planar light-emitting tile (an organic EL tile) is a suitable embodiment of the planar light-emitting tile120. In the following, a detailed description is given about the organic EL planar light-emitting tile (the organic EL tile).

Firstly, the organic EL planar light-emitting tile (the planar light-emitting tile120) according to the present invention preferably has the organic EL element10that includes just a light-emitting element whose equipotential electrodes directly supplied with power from the outside of the organic EL tile are just a single positive and negative opposing pair of electrodes, in order to improve the area efficiency and the like.

That is, the organic EL planar light-emitting tile desirably has one transparent conductive anode layer21and one metal cathode layer41, between which one functional layer (light-emitting functional layer)31is interposed.

Such an organic EL element10is structured as follows, for example. On the glass substrate11, the light-pervious conductive anode layer21, the functional layer31, and the metal cathode layer41each in a predetermined shape are formed.

The glass substrate11is a preferable substrate in view of transparency and sealability. The glass substrate11is positioned on the light-emitting main surface of the light-emitting element.

The functional layer31is made up of a plurality of laminated thin films including a light-emitting layer containing an organic compound.

Preferably, the organic EL element10formed in this manner is sealed.

Further, in order to improve luminance, color, and angle-dependent optical characteristics, the organic EL planar light-emitting tile (the planar light-emitting tile120) is preferably provided with an optical functional body on the light emission side of the glass substrate11.

That is, the optical functional body is preferably provided on the outermost surface of the region including the light-emitting region2on the light-emitting main surface side.

The optical functional body may be formed by nanoimprinting by applying resin such as acrylic resin on the glass front surface, or spray coating or slit coating of resin containing glass beads. Further, the optical functional body is preferably formed by bonding a resin film (an optical film) having a fine irregular structure on one surface and having adhesive on another surface to a glass surface, so that the one surface becomes the above-described outermost surface. This optical film preferably has the light scattering characteristic. Further, since the surface of the film is susceptible to scratches, depending on the circumstances, the bonding of the optical film may be performed after assembling the organic EL planar light-emitting tile (the planar light-emitting tile120), and before or after attaching the wiring member51. Alternatively, the bonding of the optical film may be performed after attaching the planar light-emitting tile120to the bezel8of the present invention.

FIG. 3is a perspective view showing an exemplary planar light-emitting tile120of the present invention having the wiring member51of the present invention.FIGS. 9A and 9Bare external views of a wiring member51according to Example being an exemplary wiring member51of the present invention.

As shown inFIG. 3, to the planar light-emitting tile120of the present invention, the wiring member51is preferably attached for being supplied with power from an external source. This wiring member51includes the pad portion (the horizontally elongated part56). In order to reduce the thickness of the planar light-emitting tile120, as shown inFIGS. 9A and 9B, the wiring member51is a flat plate-like member whose opposite main surfaces are the wiring surface and the wiring member back surface, respectively. Further, the wiring member back surface is more preferably an insulating surface. Preferably, the anode pad included in the pad portion is connected to the anode-side power supply pad part22of the electrode-side power supply pad region (the pad region28), and the cathode pad included in the pad portion is connected to the cathode-side power supply pad part23of the electrode-side power supply pad region (the pad region45).

Further, the wiring member51preferably includes the terminal portion58as the conduction path between the pad portion and the external power supply. The terminal portion58includes an anode terminal electrically connected to the anode pad and a cathode terminal connected to the cathode pad. Further, preferably, the planar light-emitting tile120including the printed circuit board71and the wiring member51serves as the module body1, in which the wiring member51includes a terminal portion exposed to the back surface side of the module body1.

Here, the terminal portion is preferably a flat plate-like member whose opposite main surfaces are the terminal surface and the terminal portion back surface, respectively. The terminal portion back surface is more preferably an insulating surface. As described above, when the wiring member51is a flat plate-like member whose opposite main surfaces are respectively the wiring surface and the wiring member back surface, more preferably, the terminal surface is included in the wiring surface, and the terminal portion back surface is included in the wiring member back surface. In this manner, the terminal surface where the terminals are disposed becomes the surface that opposes to the non light-emitting main surface of the planar light-emitting tile120of the planar light-emitting tile120, and a so-called single-surface wired wiring member is obtained. Thus, since electric shock hazards are avoided by virtue of the energized portion not being exposed on the back surface side of the module body1, excellent safety is achieved. Further, the terminals preferably exist in the light-emitting region2when seen in a plan view. Thus, the size of the planar light-emitting tile120can be reduced for the size of its light-emitting region2.

While the wiring member51of the present invention may be made of a lead wire, copper foil, aluminum foil or the like, the wiring member51is desirably a printed circuit board. More preferably, the wiring member51is a flexible printed circuit (FPC). The flexible printed circuit (FPC) is an organic film of polyimide or the like, on which wiring made of copper foil or aluminum foil is patterned. The small thickness of the flexible printed circuit (FPC) allows a reduction in thickness of the panel (the module body1) including the flexible printed circuit (FPC), and allows the panel to be freely bent.

While the pad portion of the wiring member51may be connected to the power supply pad parts22,23using conductive adhesive, in order to improve connection reliability by improving bonding strength, desirably the pad portion is thermocompression-bonded using an anisotropic conductive film (ACF).

The wiring member51of the present invention may be a member that extends from the portion connected to the planar light-emitting tile120just to the portions where supply of power from an external source reaches. Further, the wiring member51covering the entire back surface of the planar light-emitting tile120can additionally acquire the function as a soaking plate. In this manner, the wiring member51that additionally acquires the function as a soaking plate makes it possible to use adhesive in bonding the wiring member51to the planar light-emitting tile120, in addition to establishing electrical connection. Also, it also makes it possible to use an adhesive film such as a double-sided tape for reducing the work man-hours.

FIG. 4is an external view showing an exemplary printed circuit board71of the present invention.FIGS. 10A and 10Bare external views of a printed circuit board71according to Example, an exemplary printed circuit board71of the present invention.FIGS. 14A and 14Bare a detailed external view of the printed circuit board71according to Example, which is an exemplary printed circuit board71of the present invention.

Further,FIG. 6is a back surface-side external view showing an exemplary planar light-emitting tile120(the module body1) that includes the printed circuit board71and the wiring member51of the present invention. InFIG. 6, a shielded portion of the wiring member51that does not appear by being shielded by the printed circuit board71is represented by broken lines. The upper portion of the wiring member51inFIG. 6corresponds to the above-described terminal portion exposed on the back surface side of the module body1.

Further, the cross-sectional view of theFIG. 1corresponds to a cross-sectional view which is obtained by combining a cross-sectional view taken along alternate long and short dashed lines a-a′ inFIG. 6and a cross-sectional view of the bezel8which is mounted afterward.

The printed circuit board71has the function of supplying power from an external source to the planar light-emitting tile120, preferably via the wiring member51.

The printed circuit board71is supported by the bezel8by being held between the fold-in parts85of the leg part84of the bezel8, which will be described later, and the planar light-emitting tile120. More preferably, the printed circuit board71is supported at the position H/4 to 3H/4 in the direction from the abutting part83of the bezel8toward the end of the leg part84. That is, the printed circuit board71is supported such that its entire thickness falls within a range from H/4 to 3H/4 in the direction from the abutting part83of the bezel8toward the end of the leg part84. Further, preferably, the printed circuit board71is held between the above-described terminal portion of the wiring member51and the planar light-emitting tile120.

As shown inFIGS. 10A and 10B, the printed circuit board71is a flat plate-like member whose opposite main surfaces are respectively the tile-side main surface disposed so as to oppose to the back surface side of the planar light-emitting tile120, and the back surface-side main surface opposite to the tile-side main surface.

The printed circuit board71has the circuit surface where the anode receiving terminals103a,103cconnected to the anode terminals72a,72bof the wiring member51, and the cathode receiving terminal103bconnected to the cathode terminal73are disposed.

The printed circuit board71is positioned so that the anode terminals72a,72band the cathode terminal73of the wiring member51are connected to the anode receiving terminals103a,103cand the cathode receiving terminal103b, respectively. Since the receiving terminal portion of the printed circuit board71including the anode receiving terminals103a,103cand the cathode receiving terminal103bis shielded and protected by the wiring member51of the present invention, electric shock hazards are avoided and therefore safety improves.

As shown inFIGS. 1, 14A, 14B, and 20, the printed circuit board71has a plurality of through holes201, and the tile-side main surface includes tile-side through hole openings212where the plurality of through holes201open. Further, one of the characteristics of the present invention is that the metal layer (tile-side metal layer)202including the entire light-emitting region2as seen in a plan view is formed on the tile-side main surface. Further, the back surface-side main surface includes back surface-side through hole openings208, which are the openings of the plurality of through holes corresponding to the tile-side through hole openings212as openings of the same through holes on the opposite side.

In addition, the printed circuit board71preferably has the power receiving terminal101for receiving power from an external source. The power receiving terminal101is more preferably disposed on the circuit surface. The power receiving terminal101is further preferably a connector. As a result, the power supply line from the external source to the printed circuit board (PCB)71can be easily removed. Further, the circuit wiring that distributes power from the power receiving terminal101to the receiving terminal103is also preferably disposed on the circuit surface, and more preferably the exposed surface of the circuit wiring is electrically insulated. As a result, electric shock hazards at the printed circuit board71are avoided and safety improves.

In addition, when a protective circuit, for example an overvoltage short-circuiting protective circuit, is provided on the circuit surface of the printed circuit board (PCB)71, excessive generation of heat can be prevented even though the resistance of the constituent members increases due to use for long hours. Further, when the printed circuit board71is provided with a reverse-current preventing circuit, sudden reverse current to the planar light-emitting tile120can be avoided. Thus, despite the multi-function of the light-emitting module100, the light-emitting module100which is less prone to fail is desirably obtained.

Further, when a dimming circuit that dims light of the light-emitting element (the organic EL element10) is provided on the circuit surface of the printed circuit board (PCB)71, the multi-functional light-emitting module100is desirably obtained.

In attaching the printed circuit board71to the planar light-emitting tile120, adhesive may be used. Preferably, in order to reduce the number of work man-hours, a double-sided tape may be used. As has been described above, the printed circuit board71is preferably provided with the receiving terminal connected to the wiring member51. This connection may be achieved by soldering, using a conductive paste, ACF connection, or mounting a connector.

As shown inFIG. 7, to the module body1, which is the planar light-emitting tile120including the printed circuit board71and preferably the wiring member51, the bezel8according to the present invention is attached. That is,FIG. 7is an exploded perspective view of the light-emitting module100of the present invention.

The bezel8of the present invention includes the rim part81, and the leg part84that is perpendicular to the planar light-emitting tile120, is continuous to the rim part81, and is integrally formed.

As shown inFIG. 1, the rim part81has the thickness T, and surrounds the radiation opening82corresponding to the light-emitting region2of the present invention and relating to radiation of the present invention. The rim part81has the abutting part83on the surface in a certain direction of the leg part84, which will be described later.

Further, the leg part84preferably has the fold-in parts85which are partially folded in toward the planar light-emitting tile120. The printed circuit board71can be held between the fold-in parts85and the planar light-emitting tile120.

Further, as shown inFIG. 5, the leg part84preferably has notch parts86formed by the leg part84being partially cut out from the end thereof toward the rim part81. Provision of the notch parts86makes it possible to house an external power supply line for externally supplying power to the planar light-emitting tile120, and preferably to the printed circuit board71.

FIG. 5is a perspective view showing an exemplary bezel8. Note that, inFIG. 8, the fold-in part85before being folded for supporting is marked as (85).

When the light-emitting module100of the present invention is an elongated module as described above, the rim part81of the bezel8has a quadrangular outer shape including two long sides and two short sides. The leg part84of the bezel8includes two long sides leg part and two short side leg parts that are perpendicular to the rim part81. Here, the fold-in parts85are preferably provided at the opposite two long sides of the leg part, and the notch parts86are preferably provided at the opposite two short sides of the leg part.

The bezel8of the present invention is preferably made of metal. The bezel8may be formed by a steel plate having its surface electroplated, or may be preferably a stainless steel plate which is rust-resistant. Further, the bezel8may be painted.

EXAMPLE

In the following, a description will be given of specific Example of the present invention.

Example

Employing a glass substrate on which a transparent conductive metal oxide film ITO is deposited and which has a thickness of 0.7 mm, the elongated organic EL planar light-emitting tile120was fabricated as the planar light-emitting tile120of the present invention. Attaching the wiring member51and the printed circuit board71to the elongated organic EL planar light-emitting tile120, the module body1was fabricated. Attaching the bezel18to the module body1, the elongated organic EL module100was fabricated as the light-emitting module100of the present invention. In the elongated organic EL planar light-emitting tile120, the outer shape of the glass being identical to the outer shape of the elongated organic EL planar light-emitting tile120measures 142 mm×23 mm, and the light-emitting region2measures 137.5 mm×15.1 mm.

Firstly, on the glass substrate11, the following transparent conductive anode layer (transparent conductive layer)21and cathode-side power supply pad part (metal electrode-side power supply pad part)23are formed by subjecting the ITO film to wet etching patterning, and thus the organic EL element formation-purpose substrate was provided. That is, in the region to be one long side3of the present invention, patterning was performed so that, in order from the short side, the following were formed: the anode-side power supply pad part (the transparent electrode-side power supply pad part)22having a length of 27 mm; an insulating region having a length of 5 mm; the cathode-side power supply pad part23(the transparent conductive island, metal electrode-side power supply pad part) having a length of 6.6 mm and a width of 4.54 mm; an insulating region having a length of 5 mm; the anode-side power supply pad part22having a length of 55.6 mm; the insulating region having a length of 5 mm; the cathode-side power supply pad part23having a length of 6.6 mm and a width of 4.54 mm; the insulating region having a length of 5 mm; and the anode-side power supply pad part22having a length of 27 mm.

Next, on the organic EL element formation-purpose substrate, as the functional layer31, the following layers were deposited in order by vacuum deposition using a predetermined mask: the electron injection layer; the electron transport layer; the light-emitting layer; the hole transport layer; and the hole injection layer. Further thereon, the metal cathode layer41made of aluminum was deposited by vacuum deposition using a predetermined mask. Thus, the organic EL element10was formed.

Next, on the organic EL element10, a silicon nitride film was formed by CVD using a predetermined mask. Subsequently, polysilazane was applied by splaying and baked, to form a sealing layer thereby sealing the organic EL element10.

Next, on the sealed organic EL element10, a protective film made of PET having adhesive is bonded. Thus, the organic EL tile120was fabricated.

Next, provided were two identical wiring members51each formed by a flexible printed circuit (FPC) and having a wiring layer formed on just one surface shown inFIGS. 9A and 9Bto be the wiring surface, and the back surface of the wiring surface being the insulating wiring member back surface. The wiring members51were placed on the anode-side power supply pad part22and the cathode-side power supply pad part23of the organic EL tile120via the anisotropic conductive film (ACF), and further locally heated. Thus, the terminal portions of the wiring member boards (flexible printed circuits)51were thermocompression-bonded to the power supply pad parts. The temperature in thermocompression-bonding was 180° C. and the time taken for thermocompression-bonding was 15 seconds.

Separately, the printed circuit board (PCB)71having a wiring layer on each of its surfaces and having a thickness of 0.4 mm was provided. As shown inFIGS. 10A and 10B, the printed circuit board71had a connector component101, on the circuit surface side of the printed circuit board71, as a power receiving terminal for receiving power from an external source. Further, the printed circuit board71had a Zener diode component102wired thereto. The Zener diode component102operates as a protective circuit when voltage of 12V or greater is applied across the opposite electrode layers of the organic EL element10. Further, the printed circuit board71had the surface of the circuit wiring insulated by being covered with resist, except for the receiving terminal103to which the wiring member (flexible printed circuit)51was connected.

Next, the printed circuit board71and the elongated organic EL planar light-emitting tile (the planar light-emitting tile120) to which the wiring member (flexible printed circuit)51was bonded were combined, to fabricate the elongated organic EL panel (the module body1) of the present invention shown inFIG. 11.

That is, the printed circuit board71was disposed so as to be interposed between the terminal portion of the wiring member (flexible printed circuit)51and the organic EL tile (the planar light-emitting tile120). Then, using a double-sided tape having a thickness of 50 um, the printed circuit board71was bonded to the non light-emitting surface side of the organic EL tile (the planar light-emitting tile120), so that the circuit surface of the printed circuit board71was positioned on the wiring member (FPC)51side. Thereafter, the terminal portion of the wiring member (FPC)51was connected to the receiving terminal103of the printed circuit board71with solder.

Separately, the bezel18was formed by subjecting a stainless steel plate having a thickness of 0.4 mm shown inFIG. 12to press work.

Finally, the module body1was installed in the bezel18. Note that, on the printed circuit board71, a resin-made insulating cover was placed on the module body1, so as to cover the entire surface including the Zener diode component102and particularly the soldered portion, and so as to exclude the connector component101. In this state, four claw bent parts which were the fold-in parts85were bent so as to clamp the module body1and the cover with the abutting part83and the claw bent parts. Thus, they were fixed to the bezel18. In this manner, the elongated organic EL module (the light-emitting module100) shown inFIG. 13were completed.

When the elongated organic EL module100was turned on, the in-plane luminance distribution of 95% or greater was attained, which was calculated by: (maximum luminance−minimum luminance)÷(maximum luminance+minimum luminance). Hence, the organic EL illumination of extremely uniform luminance distribution was obtained. Further, when the elongated organic EL modules100were arranged in the longitudinal direction and turned on, the non light-emitting region between the panels was 7.5 mm. Hence, the organic EL illumination panels with the extremely narrow non light-emitting region were obtained. In addition, on the back surface of the module, no energized portion was exposed. Further, by virtue of the protective element, in the event of sudden great voltage application, the protective circuit actuates so as to cause the current to bypass. Hence, safe organic EL illumination was obtained. Further, by virtue of the power receiving connector being implemented, ease in wiring and use is achieved with the organic EL illumination.

Further, the elongated organic EL module (the light-emitting module100) has an extremely small finished total thickness of 4 mm. Thus, the organic EL illumination capable of being installed in any orientation is obtained.

LIST OF REFERENCE CHARACTERS