light-emitting device and method for making the same

专利摘要:
LIGHT-EMITTING DEVICE AND METHOD FOR MANUFACTURING THE SAME. The present invention relates to a light-emitting device provided with: a light-emitting element; a metal member that has a first face on which the light-emitting element is mounted, and a second face which is opposite the first face; and a translucent member that seals part of the metal member and the light-emitting element, the metal member has a positioning portion of the element on which the light-emitting element is placed, and a flat portion arranged around the portion of positioning of the element, a cover member is disposed on the side of the second face of the flat portion, and the top and side faces of the cover member are covered by the translucent member.
公开号:BR112013001195B1
申请号:R112013001195-5
申请日:2011-10-20
公开日:2021-03-02
发明作者:Hiroki Takahashi；Yoshitaka Bando
申请人:Nichia Corporation；
IPC主号:

专利说明:

Technical Field
[0001] The present invention relates to a light-emitting device and a method for manufacturing it. Background of the Technique
[0002] The light-emitting element shown in Figure 11, for example, has been suggested as an example of a light-emitting device in which a light-emitting element mounted on a metal member, and part of the metal member and the element light emitting devices are embedded in a sealing member (Japan Patent Application Open to Public Inspection H11-346008, for example).
[0003] With this light emitting device 40, a pair of cable terminals consists of a metal member 42 in which a light emitting element 41 is placed, and a paired metal member 43. The light emitting element 41 and the metal members 42 and 43 are embedded in a translucent member 44, and the sealing member 44 constitutes a lenticular convex portion 44a above the light-emitting element 41. The cable ends are bent outside the sealing member.
[0004] With such a light-emitting device, when severe temperature changes in the environment in which the light-emitting device is used are considered, the adhesion between the metal members and the sealing member becomes questionable. In addition, the area around the metal members is enveloped by a relatively thick film of the sealing member to ensure the resistance of the sealing member, but there is an involuntary leakage of light from the bottom face and the side faces of the light emitting device, and the efficiency of light extraction to the side of the upper face of the light emitting device tends to decrease.
[0005] At the same time, as shown in Figure 12, to achieve a more uniform emission pattern, a light-emitting device has been suggested in which the side of a metal member 50 on which a light-emitting element 51 is mounted is covered with a translucent resin 53, and the metal member 50 is covered with a black resin 52, except for the portion around the light-emitting element 51, which prevents reflection through the metal member 50, except around the emitting element of light 51, and prevents light from being scattered (Order of the Utility Model Open to Public Inspection in Japan H5-50754). Description of the Invention Problem to be solved
[0006] With modern light-emitting devices, however, there is a need for better light extraction efficiency, an even smaller size, and a thinner profile, and it is necessary to achieve a satisfactory balance in the relationship between ensuring good resistance of the sealing member and adhesion between the metal member and the sealing member, reducing size and thickness, etc., while improving all aspects related to performance, such as better light extraction efficiency.
[0007] The present invention was conceived in light of the above problem, and an objective of the present invention is to provide a light emitting device with which the efficiency of light extraction can be increased and better performance can be ensured. Means to Solve the Problem
[0008] The inventors conducted judicious research to design a light-emitting device, including the shape, design and other characteristics of a metal member and a sealing member that will result in high light extraction efficiency and a smaller light-emitting device and thinner, and to determine the manufacturing effectiveness at which this can be accomplished. As a result, a constitution of the light-emitting device was discovered with which, even if a reduction in the size of the light-emitting device decreases the area of the contact surface between the metal member and the sealing member, the metal member still remains. it will be adequately sealed by the sealing member and the manufacturing efficiency will be improved, and several characteristics, such as thermal dispersion, resistance of the light emitting device, useful life, among others, can also be improved. This led to the completion of the present invention.
[0009] That is, the present invention includes the following inventions.
[00010] (1) a light-emitting device provided with: a light-emitting element; a metal member that has a first face on which the light-emitting element is mounted, and a second face which is opposite the first face; and a translucent member that seals part of the metal member and the light-emitting element, the metal member has a positioning portion of the element on which the light-emitting element is placed, and a flat portion arranged around the portion of positioning of the element, a cover member is disposed on the side of the second face of the flat portion, and the top and side faces of the cover member are covered by the translucent member.
[00011] (2) The light-emitting device according to item (1) above, in which the translucent member is more malleable than the covering member.
[00012] (3) The light emitting device according to items (1) or (2) above, in which the covering member exposes the first face of the flat portion.
[00013] (4) The light emitting device according to any of the items (1) to (3) above, in which the covering member covers the second face of the flat portion and an outer periphery of the flat portion, the face top of the covering member substantially coincides with the first face of the flat portion, and the upper face of the covering member and the upper face of the flat portion are covered by the translucent member.
[00014] (5) The light emitting device according to any of the items (1) to (4) above, in which the translucent member has a convex portion and a flange disposed around the convex portion, and the flange is arranged outside the illumination range of the light emitted by the light emitting element.
[00015] (6) The light emitting device according to item (5) above, in which part of the flat portion of the metal member is disposed within the flange.
[00016] (7) The light emitting device according to any of the items (1) to (6) above, in which the metal member has a first curved portion that curves continuously from the flat portion to the side of the bottom face of the light emitting device, and a second curved portion that curves further to the side of the side face of the light emitting device, and is covered by the cover member from the first curved portion to the second curved portion.
[00017] (8) The light emitting device according to any of the items (5) to (7) above, in which the thickness of the flange on the upper face of the covering member and the flat portion is less than the thickness of the translucent member on the lateral face of the covering member.
[00018] (9) The light emitting device according to any of the items (1) to (8) above, in which the thickness of the translucent member on the upper face of the covering member and on the flat portion is 50 to 100 μm .
[00019] (10) The light emitting device according to any of the items (1) to (3) and (5) to (9) above, in which the covering member still covers the outer periphery of the flat portion.
[00020] (11) The light emitting device according to any of the items (1) to (10) above, in which the covering member exposes the bottom face of the positioning portion of the element of the metal member, and it is disposed on the outer periphery of the positioning portion of the element.
[00021] (12) The light-emitting device according to any of the items (1) to (11) above, wherein the positioning portion of the element of the metal member is formed as a concave portion that is bent to the side of the bottom face of the light-emitting device in relation to the flat portion.
[00022] (13) The light-emitting device according to (12) above, in which the covering member is wrapped so as to surround the concave portion, and the height of the lower face of the covering member substantially coincides with the height of the lower face of the concave portion.
[00023] (14) A method for manufacturing a light-emitting device comprising the steps of: (a) arranging, in molds, a metal member that has a positioning portion of the element on a first face on which is placed a light-emitting element, and a flat portion arranged around the positioning portion of the element, and forming a cover member that covers at least a second face, which is opposite the first face, from the flat portion of the metal member; (b) installing a light-emitting element on the element positioning portion of the metal member; and (c) arranging the metal member covered by the cover member in the second molds, securing the upper face and the bottom face of the covering member with the second molds, and forming a translucent member covering part of the metal member and the face top and side faces of the cover member.
[00024] (15) The method for manufacturing a light-emitting device according to (14) above, in which, in step (a), a first face of the flat portion is exposed to form the covering member, and in step (c), the first face of the flat portion and the top face of the cover member, and the bottom face of the cover member are held by the second molds.
[00025] (16) The method for making a light emitting device according to (14) or (15) above, in which, in step (a), the bottom face of the positioning portion of the element is exposed to form the covering member, and in step (c), the translucent member is formed which exposes the bottom face of the positioning portion of the element.
[00026] (17) The method for manufacturing a light-emitting device according to (14) to (16) above, in which the viscosity of the material of the covering member, at the time of forming the covering member, is highest than the viscosity of the material of the translucent member, at the time of the formation of the translucent member. Effect of the Invention
[00027] With the light emitting device of the present invention, it is possible to obtain a light emitting device with which the light extraction efficiency is improved and a better performance can be ensured.
[00028] Using the method of manufacturing a light-emitting device of the present invention, a light-emitting device with good emission efficiency and improved characteristics can be manufactured efficiently. Brief Description of Drawings
[00029] Figure 1A is an oblique view of an embodiment of the light emitting device of the present invention, and particularly the external shape of a translucent member 14; Figure 1B is an oblique view of the moment when the translucent member is removed from the light emitting device in Figure 1A; Figure 1C is a plan view of the light emitting device in Figure 1B (with the translucent member 14); Figure 1D is a cross section along line E-E 'of the light-emitting device in Figure 1C; Figure 2 is a cross section along line F-F 'that illustrates the shape of the translucent member in the light-emitting device in Figure 1C; Figure 3 is a plan view of a metal member 12 in the light emitting device in Figure 1A; Figure 4A is a cross section of the simplified manufacturing step that illustrates the formation of a cover member 15 in the light emitting device of the present invention (corresponds to the cross section of line A-A 'in Figure 4B); Figure 4B is a cross section of the simplified manufacturing step that illustrates the formation of the cover member 15 in the light emitting device of the present invention; Figure 5A is a cross section of the simplified manufacturing step that illustrates the formation of the translucent member 14 in the light emitting device of the present invention (corresponds to the cross section of line A-A 'in Figure 5B); Figure 5B is a cross section of the simplified manufacturing step that illustrates the formation of the translucent member 14 in the light emitting device of the present invention; Figure 6 is another cross section of the simplified manufacturing step that illustrates the formation of the translucent member 14 in the light emitting device of the present invention (corresponds to the cross section of line A-A 'in Figure 5B); Figure 7 is a simplified cross section of the main portions in another embodiment of the light emitting device of the present invention (corresponds to the cross section of the line E-E 'in Figure 1C); Figure 8A is an oblique view of the external shape of another translucent member 24 in the light emitting device of the present invention; Figure 8B is an oblique view of the moment when the translucent member is removed from the light-emitting device in Figure 8A; Figure 8C is a plan view of the simplified manufacturing step illustrating the formation of another cover member 25 in the light emitting device of the present invention; Figure 9 is a plan view of other metal members 12 and 13 in a light-emitting device; Figure 10 is a simplified cross section of the main portions in another embodiment of the light emitting device of the present invention (corresponds to the cross section of the line E-E 'in Figure 1C); Figure 11 is a simplified cross section of a conventional light-emitting device; and Figure 12 is a simplified cross section of another conventional light-emitting device. Detailed Description of Preferred Arrangements
[00030] The light-emitting device of the present invention is basically formed by a light-emitting element, a metal member, a translucent member, and a cover member. The translucent member and the covering member constitute what is known as an envelope, and both collectively can be simply called "sealing member." The term "sealing" in this document means sealing by direct contact or without contact.
[00031] In the present application, the terms "top face" and "first face (one face)" refer to a face on the light-extracting side of the light-emitting device, and "first face", in particular, refers to to one face of the metal member, while "bottom face" and "second face (other face)" refer to faces opposite the upper face and to one face (first face), and "second face" in particular , concerns a face of the metal member. The term "bottom face of the light-emitting device" refers to the bottom face of the sealing member that constitutes the light-emitting device.
[00032] Translucent means a property in which at least about 70%, and preferably at least about 80%, at least about 90%, and at least about 95%, of the light emitted by the light-emitting element is transmitted . Light Emitting Element
[00033] The light-emitting element is a semiconductor light-emitting element, and can be any element that is known as a light-emitting diode. For example, a laminated structure that includes a light-emitting layer can be formed by several semiconductors, such as InN, AlN, GaN, InGaN, AlGaN, InGaAlN, or any other nitrite semiconductor of this nature, a group III- compound semiconductor V, a semiconductor of the group II-VI compound, or others of its kind, as a substrate.
[00034] Examples of substrates include insulating substrates such as sapphire or spinel (MgAl2O4) whose main plane is plane C, plane A, or plane R, silicon carbide (6H, 4H, 3C), silicon, ZnS, ZnO, GaAs, diamond, an oxide substrate such as lithium niobate or neodymium gallate, and nitride semiconductors, such as GaN and AlN.
[00035] Examples of the semiconductor structure include a MIS bond, a PIN bond, a PN bond, or any other homostructure of this type, a hetero bond, and a hetero double bond.
[00036] The semiconductor layers that make up the light-emitting element can be doped with silicon, germanium, or other donor impurity of that nature and / or zinc, magnesium, or any acceptor impurity of that nature.
[00037] The light-emitting layer can be a single quantum well structure or a multiple quantum well structure formed as a thin film that produces a quantum effect.
[00038] The emission wavelength of the light-emitting element can be varied from the ultraviolet to the red band, varying the material of the semiconductor, the mixed crystal ratio, the content of InGaN in the light-emitting layer, or the type of impurity with which the light-emitting layer is doped. Metal Member
[00039] The metal member is normally electrically connected to the light-emitting element and, optionally, a protective or similar element (hereinafter may be called "light-emitting or similar element"), and in general acts as an electrode cable and for mounting the light-emitting element or similar. The metal member is partially embedded in the sealing member (discussed below) together with the light-emitting element or the like. Accordingly, the metal member comprises a portion (such as an internal terminal) that acts as a mounting seat for the light-emitting element or the like on the sealing member, and a portion (such as an external terminal) that extends externally. to the sealing member and acts for electrical connection with the outside.
[00040] Therefore, there are no specific restrictions on the material of the metal member, as long as these functions can be fulfilled, but it is preferable to form it from a material that has a relatively high thermal conductivity. The formation of the metal member with this material allows the heat generated by the light-emitting element to be efficiently eliminated. For example, it can be a material that has a thermal conductivity of at least about 200W / (m ^ K), or a material with a relatively high mechanical strength, or a material that can be easily drilled, etched, or otherwise machined. form. Examples include copper, aluminum, gold, silver, tungsten, iron, nickel, or any other metal, an alloy of iron-nickel, phosphor-bronze, or another type of alloy, and those metals or alloys whose surface has been plated with silver, aluminum, copper, gold, or other such metal. It is particularly favorable for the metal member to be formed of a conductive material that provides a good electrical connection (such as gold or gold plating). It is also favorable for the surface of the metal member to be smooth to increase reflectivity. In particular, it is preferable that the positioning portion of the element (or the positioning portion of the element and the surrounding portion) is formed of a material with high reflectivity (such as gold or gold plated). The metal member is normally formed with a uniform film thickness, but it can be partially thicker or thinner.
[00041] For the above reasons, it is preferable that the entire metal member is formed in gold or a material whose surface is plated with gold, and that the positioning portion of the element is formed in silver or a material whose surface is plated in silver . If a concave portion is formed as the positioning portion of the element, the silver or silver plating can extend not only to the concave portion, but also to the flat portion, and preferably extends to the flat portion located in the outer environment of the concave portion. When the outer periphery of the concave portion is formed by a silver plated material, if that part width is too narrow, and misalignment occurs at the point of the silver plating, part of the interior of the concave portion may not be covered by the silver plated material , but if the width of this outer peripheral part is too wide, it will be far from the region where the wire joins, and this can lead to wire fatigue, wire breakage, widening of the light emitting device, etc. Thus, the width of the outer periphery is favorably equal to or less than about 0.3 mm, being even better that it is equal to or less than about 0.2 mm. As a result, silver will enhance adhesion between the portions when the first face of the metal member is covered by the sealing member, and this will increase long-term reliability.
[00042] The metal member has a first face on which the light-emitting element is placed, and a second face that is opposite the first face. It also has a positioning portion of the element on which the light-emitting element is placed, and a flat portion arranged around this positioning portion of the element.
[00043] There are no specific restrictions as to the shape of the metal member, which can be conveniently decided taking into account the shape of the light emitting device, the number of light emitting elements, its design, the installation space, and others factors.
[00044] The positioning portion of the element is a portion whose function is to position the light-emitting element, and is preferably flat so that the light from the light-emitting element is efficiently emitted on its upper face. As shown in Figure 3, the flat portion of the metal member 12 has a concave portion formed in a concave shape that is folded up to the side of the bottom face of the light emitting device, and a first face (the top face) of the part from the bottom of this concave portion it can function as a positioning portion of the element 12a. Forming a concave portion ensures that the light-emitting element is disposed in the appropriate location, and ensures the sealing stability of the sealing member. In addition, if the light is reflected on the side faces of the concave portion, the light emitted laterally by the light emitting element can be directed next to the upper face of the light emitting device, which increases the efficiency of light extraction to the upper face of the light-emitting device.
[00045] The positioning portion of the element and the concave portion must have an area of the bottom face that is sufficiently large for the positioning of the light-emitting element, and can be circular, elliptical, polyhedral, optionally with corners rounded, or a modified version of one of these forms.
[00046] The size and depth of the concave portion are preferably such that, when the light-emitting element is disposed in the appropriate location within the concave portion, the light emitted by the light-emitting element, the reflected light or any other light emitted does not. will be blocked. In particular, it is preferable that neither the light emitted by the light-emitting element nor the reflected light are blocked by the upper edges, side faces, etc., of the concave portion. For example, the size of the bottom face of the concave portion favorably is larger than the surface area occupied by the light-emitting element, and is preferably at least about 1.2 times the area of the occupied surface. The depth can be at least equal to the height of the light-emitting element, and preferably it is at least about 0.1 mm, and more preferably it is at least about 0.5 mm.
[00047] The lateral faces of the concave portion can be vertical, but preferably they are inclined, narrowing down to the bottom face. For example, they are preferably inclined by about 0 to 45 °, and more preferably by about 20 to 40 °, in the parabolic direction with respect to the bottom face. This allows you to effectively guide the light from the light-emitting element to the top face. In addition, it is preferable that the surface of the concave portion is rounded from its lateral faces to the flat portion (discussed below) on the outer periphery of the concave portion. This rounding helps to prevent cracking of the sealing member (discussed below) at the edge of the opening to the concave portion, and prevents the sealing member from flaking.
[00048] As shown in Figure 3, a flat portion 12d is arranged to surround the exterior of the positioning portion of element 12a (as a concave portion), and usually refers to the portion covered by the sealing member. In addition, a cover member is disposed on the side of the second face of the flat portion.
[00049] The flat portion may be present in the same plane as the positioning portion of the element, but as discussed above, when the positioning portion of the element has a concave shape, the flat portion is arranged at a height different from the height of the face bottom of the concave portion.
[00050] There are no specific restrictions on the flat shape of the flat portion surrounding the concave portion, but as discussed above, for example, a continuous portion from the preferred concave portion and substantially adapts to the shape of the adjacent concave portion (ie , a shape that is the same or substantially the same as the shape of the concave portion, or a corresponding shape) (see the one in Figure 3). For example, it can be circular, elliptical, polyhedral, optionally with rounded corners, or a modified version of one of these shapes. This allows the sealing member that seals the light-emitting element to have a stable formation that adapts to the outer periphery of the concave portion. As Figure 3 shows, the flat portion formed to substantially conform to the shape of the adjacent concave portion is preferably opposed to a second metal member 13 (discussed below).
[00051] The profile of the flat portion on the part other than the part discussed above (see b in Figure 3) may be similar to the flat shape of the sealing member (i.e., a shape that is the same or substantially the same, or a corresponding shape ), and can usually have a rounded polyhedral shape or a modified version of one of these shapes. This increases the strength of the sealing member, and the flange (discussed below) in particular.
[00052] The other part of the flat portion (see c in Figure 3, for example) is a region that functions as the so-called internal terminal and / or external terminal. Therefore, the concave portion already mentioned favorably is a shape that extends to the opposite side from the concave portion. The width of the region that functions as the extended terminal (the width n in Figure 3) can be conveniently adjusted according to the desired performance of the light emitting device and other factors. For example, it is preferably equal to or slightly larger than the diameter of the concave portion.
[00053] The flat portion can also be the region in which the protective element mentioned above, etc., is placed. In addition, the flat portion can be easily sandwiched (retained, tightened, etc.) between the upper and lower molds with a simple shape in the sealing of the metal member with the translucent member and / or cover member discussed below.
[00054] A second metal member, acting as a positive and negative electrode pair in relation to the positioning portion of the element, is located opposite the metal member that includes the positioning portion of the element.
[00055] The second metal member has a flat portion, and this flat portion preferably corresponds to the flat portion of the aforementioned metal member. The light-emitting element and the flat portion of the second metal member are connected by the wire. This reduces the length of the wire between the light-emitting element and the second metal member when the light-emitting element is positioned over the positioning portion of the element, which prevents the wire from breaking and similar events.
[00056] The second metal member is preferably located opposite the positioning portion of the element of the metal member already mentioned as an internal terminal, and as an external terminal, it has a shape extended in a specific direction.
[00057] The metal member and the second metal member need not protrude externally from the same face as the sealing member (discussed below) (ie, in the same direction), and can protrude externally from a plurality different faces (directions). For example, the distal ends of the metal member and the second metal member (i.e., outer terminals) can be bent towards the bottom face of the light-emitting device, or they can be bent towards the opposite side. Within the sealing member, the metal member and the second metal member preferably have a folded portion (see 12e in Figure 3) that is folded towards the bottom face of the light-emitting device. The metal member preferably has a folded portion (such as a first folded portion), which is folded towards the bottom face, disposed within the sealing member (for example, within the main body part of the translucent member (discussed below) ), and in particular depending on its width, inside the flange or the main body part (discussed below). The bending of the metal member increases the area of the contact surface between the sealing member and the metal member present within the sealing member, and as a consequence, prevents the sealing member from flaking. In addition, the folded portion of the metal member acts as a retainer, and effectively prevents the separation between the sealing member and the metal member.
[00058] Furthermore, the metal member preferably has, within the sealing member, a folded portion which is folded towards the bottom face of the light-emitting device (preferably within the flange (discussed below)) (first folded portion) , and then it is folded towards the side face of the light emitting device (second folded portion) (see 12f in Figure 3), and protrudes out of the sealing member. This also helps to avoid the peeling and separation already mentioned. The first and second folded portions are preferably covered by the sealing member, and particularly, by the covering member discussed below.
[00059] If the metal member protrudes from the side face of the sealing member, the second face (bottom face) of the metal member in the projecting portion (i.e. part of the flat portion) preferably coincides with the bottom face of the sealing member (the face at the bottom), that is, it coincides with the bottom face of the light-emitting device. In other words, the bottom face of the light-emitting device is preferably in the same plane from the metal member to the sealing member. This reinforces the sealing member with the metal member, and improves the strength of the light-emitting device itself.
[00060] If the metal member has a concave portion as a positioning portion of the element, the flat portion of the metal member can be bent with a height difference greater than the depth of the concave portion, but preferably it is bent with a differential of height that coincides with the depth of the concave portion. That is, part of the second face of the flat portion of the metal member preferably substantially coincides (is substantially in the same plane) with the bottom face of the concave portion.
[00061] As shown in Figure 9, for example, the metal member preferably has a recess, a through hole 12b, or a cutout 12c (sometimes here called "recess, etc."), which anchors or determines the formation of the sealing member, formed on its surface close to the folded portion and / or the flat portion. Inside the recess, etc., the sealing member may be arranged, increasing the area of the contact surface between the two, or the recess may be able to repair part of the sealing member, for example. This further intensifies the adhesion between the metal member and the sealing member.
[00062] There are no specific restrictions as to the flat shape, outline, size, depth, and other characteristics of the recess, etc., and these can be adjusted accordingly by the size of the light emitting device, the material that is used for the limb. seal, and so on. The recess, etc., is preferably arranged outside the illumination range of the light coming from the light emitting element, which can prevent the light from crossing.
[00063] The metal member normally uses wires to electrically connect to the light-emitting element and, if desired, to a protective element. The wire, preferably, has good ohmic properties with the electrodes of the light emitting element, or good mechanical connectivity, or good electrical and thermal conductivity. The thermal conductivity is preferably at least about 0.01 cal / S ^ cmZoC / cm, and more preferably at least about 0.5 cal / S ^ cmZoC / cm. Taking into account the operational ease and other factors, the wire diameter is preferably around 10 to 45 μm. Examples of the wire material include gold, copper, platinum, aluminum, and other metals and alloys. The wire can be easily connected to the light-emitting element and the metal member for use in connecting to the wire using a wire connection device.
[00064] The metal member can comprise the first and second (that is, at least two) metal members already mentioned in a single light-emitting device. If the second face of the metal member is substantially on the same plane as the bottom face of the sealing member, there will be a smaller number of metal members, which will reduce the change in the disposition of the various members in the same plane and increase manufacturing efficiency. .
[00065] The number of metal members can be equal to one plus the number of light-emitting elements mounted on the metal members, or it can be at least twice the number of light-emitting elements mounted on the metal members. For example, if only one light-emitting element is mounted, the light-emitting element will be positioned on a metal member, an electrical connection will be established with an electrode of the light-emitting element, and the other metal member can be electrically connected. to the other electrode of the light-emitting element.
[00066] If two or more light-emitting elements are assembled, all or some light-emitting elements will be positioned on a single metal member, an electrical connection will be established, and then the other metal member can be electrically connected separately according with the various light-emitting elements.
[00067] Furthermore, the constitution can be such that several light-emitting elements are positioned on a separate and electrically connected metal member, and then one more metal member is electrically connected separately according to the various light-emitting elements.
[00068] Thus, if a plurality of light-emitting elements are assembled, and independent cabling is carried out that establishes the electrical connection with a metal member independently, it will be possible to select a cabling standard among a variety of them, such as serial or parallel , and this allows for greater latitude in the circuit design. Furthermore, in the case of independent cabling, it is easier to adjust the emission resistance of the light-emitting elements that are installed, therefore, this is particularly advantageous when using a plurality of light-emitting elements that have different emission colors, as with a colored LED. In addition, the heat dissipation pathways of the light-emitting elements can be formed without overlapping. In this way, the heat generated by the light-emitting elements can be dissipated evenly, and the thermal dissipation is better. Coverage Member
[00069] The cover member acts as a wrap for the light-emitting device along with the translucent member, which is discussed below.
[00070] The covering member is formed by a material more rigid than the translucent member. "More rigid than the translucent limb", in this case, generally means that the hardness is greater. "Hardness" here means that when the translucent member (discussed below) and the covering member are tested by the same method as the hardness test, the hardness values are greater than those of the translucent member. Presumably, all of these test methods were conducted at 25 ° C.
[00071] The hardness value of the covering member will depend on the test method, but favorably it is at least about 5%, preferably at least about 10%, and more preferably at least about 15%, greater (more rigid) than the hardness value of the translucent member.
[00072] The covering member preferably has a greater (more rigid) hardness than the hardness of the translucent material, so that a test for the covering member corresponds to its hardness, and differs from the suitable hardness to the translucent material.
[00073] Furthermore, the covering member can be formed of a material that does not have an elasticity similar to that of rubber. Alternatively, the cover member may be formed of a material that has a hardness expressed as indentation hardness. This indentation hardness is usually expressed as a hardness obtained from a Rockwell hardness test and / or a Vickers hardness test.
[00074] Rockwell and Vickers hardness tests are well-known test methods.
[00075] For example, a Rockwell hardness test is a method where a probe is used, first an initial test force is applied, then a test force is applied, and when the force returns to the initial test force , the depth penetrated by the probe is measured at the initial test force twice before and after. This hardness can be calculated from the difference in the penetration depth (indentation depth).
[00076] The Vickers hardness test is a method in which a test force is applied to a probe, the probe is pushed into the sample, and the area of the contact surface between the probe and the sample is measured. This hardness can be calculated by dividing the test force applied to the probe by the area of the contact surface.
[00077] The cover member can have a hardness obtained by a JIS-A hardness test or expressed as a Shore A hardness.
[00078] When measured by a Shore hardness test, preferably the hardness is at least about 70, and more preferably at least about 90, for example.
[00079] Shore A and JIS-As hardness tests are well-known test methods. For example, they are methods where a probe is pushed to deform the surface of a measurement sample, and the degree of deformation (depth of indentation) is measured and digitized.
[00080] If Shore A hardness or JIS-A hardness exceeds 90, Shore D hardness is normally used.
[00081] Therefore, the covering member is preferably made of a material whose hardness is due to Shore D hardness.
[00082] Shore D hardness testing is a known test method. This method differs from the JIS-A hardness test in the size and shape of the probe and in the indentation load. The Shore D hardness test is better suited for measuring a sample whose elasticity is lower than the JIS-A hardness test.
[00083] Stating that the cover member is hard is the same as stating that the viscosity during molding (when melted) is higher than the viscosity of the translucent member, for example. The viscosity during molding will depend on the material, but when the material that constitutes the covering member is melted at a temperature suitable for that material in a common semiconductor process, the viscosity is favorably at least about 10 Pa ^ s. When effective manufacturing is taken into account, it is preferable to be less than or equal to about 100 Pa ^ s. The temperature during molding varies from 150 to 180 ° C, for example.
[00084] The difference in the linear coefficient of thermal expansion between the covering member and the metal member is preferably less than the difference in the linear coefficient of thermal expansion between the translucent member and the metal member. This eliminates the problem of cracking and separation during temperature changes. The linear coefficient of thermal expansion of the covering member is favorably equal to or less than about 100 ppm / K, and preferably is equal to or less than about 50 ppm / K. A value equal to or above 20 ppm / K is even more appropriate.
[00085] The linear coefficient of thermal expansion of the metal member is lower than that of materials normally used as a sealing member, and is about 5 to 20 ppm / K, for example. The difference in linear coefficient of thermal expansion between the cover member and the metal member is preferably about 10 to 100 ppm / K.
[00086] The difference in the linear coefficient of thermal expansion when the metal member is covered directly by the translucent member can be reduced by placing the covering member directly in contact with the metal member, and this reduces the lower adhesion caused by the heat between the sealing member and the metal member.
[00087] The covering member can be formed of polyphthalamide (PPA), epoxy resin, or similar substances.
[00088] The covering member can be a mixture obtained by adding the material mentioned above to any one of several dyes, pigments, or similar substances such as dyes or diffusion agents. The covering member is preferably arranged outside the illumination range of the light emitted by the light emitting element. Consequently, there is no reduction in the light emission of the light emitting device, even when a material with low optical reflectivity is used, such as a material in which carbon black or another substance of this kind that blocks a large amount of light is mixed as colorant, therefore, it is possible to select a material of low cost and low optical reflectivity for the covering member.
[00089] This covering member is disposed at least on the side of the second face of the metal member (see 15 in Figure 1D, for example). That is, it is favorable that at least part of the side of the second face of the flat portion of the metal member is covered. It is still preferable that part of the outer periphery of the flat portion is covered, and it would be even better if the entire outer periphery were covered (see 15 in Figures 1B and 1D, for example). The cover member exposes the first face of the flat portion.
[00090] When the covering member covers the outer periphery of the flat portion, this corresponds to covering the terminal face of the flat portion. When the end face of the flat portion is covered, the covering member extends to the side of the first face of the metal member, but it is preferable that part of the upper face of the covering member disposed around the outer periphery of the flat portion substantially coincides with the first face of the flat portion of the metal member, and is in the same plane (see Figures 1B and 1D). It is particularly favorable that the first face of the flat portion substantially coincides with the corners of the flat portion, and it is preferable that the first face of the flat portion is on the same plane around the outer periphery of the flat portion.
[00091] Consequently, when the translucent member (discussed below) is shaped by the upper and lower molds, the portion in the same plane (particularly the corners; see M in Figure 5B) can be stably squeezed between the upper and lower molds, and the sealing member material can be prevented from leaking, for example. It is preferable that the cover member is arranged so that its upper and lower faces touch the upper and lower molds and establish a stable grip between the upper and lower molds. Preferably, part of the upper face of the cover member substantially coincides with the flange ( discussed below), and the bottom face of the cover member is arranged so as to constitute the bottom face (bottom face) of the light emitting device (see Figures 1C and 1D).
[00092] The covering member preferably exposes at least the bottom face of the positioning portion of the element of the metal member, and is disposed on the outer periphery of the positioning portion of the element. If the positioning portion of the element is formed by a concave portion, it is even better that the covering member exposes the bottom face of the concave portion and is arranged on the outer periphery of the concave portion. This ensures a thermal dissipation path for the light-emitting element. In other words, it is preferable for the cover member to be wrapped so as to surround the concave portion of the metal member, and the height of the bottom face (bottom face) of the cover member substantially coincides with the height of the bottom face of the portion concave (that is, the bottom face of the covering member is substantially on the same plane as the bottom face of the concave portion). Translucent Limb
[00093] The translucent member seals the light-emitting element and, if desired, part of the metal member and the protective element, and has at least a portion of the main body 14c and a convex portion 14a as shown in Figure 2, for example . The translucent member covers at least part of the upper face of the flat portion of the metal member and the upper face of the cover member, and more preferably covers the side faces of the cover member. Therefore, part of the flat portion of the metal member is preferably disposed within the translucent member, and particularly within the flange (discussed below).
[00094] The light-emitting device (the shape of the sealing member) normally has a basic shape of a circular cylinder, an elliptical cylinder, a sphere, an egg, a triangular column, a square column, a polygonal column, or a similar to those mentioned, for example, but in general the device is shaped like a square column. Therefore, the translucent member in the present invention has a main body portion that constitutes the basic shape, and a concave portion that acts as a converging lens, for example, integrally arranged on one face of the main body portion.
[00095] The shape of the convex portion can be adjusted accordingly according to the light distribution of the light emitting device, but examples include an oval or partial sphere shape, a polygonal dome or arm shape whose bottom face is a quadrilateral, etc., and several other shapes. Among these, the preferable shape is the oval or partial sphere shape, and in particular a hemispherical shape, being even better a shape in which the center is located close to the center of the light-emitting element or the positioning portion of the light-emitting element. light. Furthermore, by increasing the size of the convex portion, it is possible to improve and at least make the efficiency of light extraction greater than that of the positioning portion of the light emitting element. It is even better to supply the concave portion and make the convex portion larger than this concave portion (see Figure 1C).
[00096] For example, as shown in Figure 2 (corresponds to the cross section of line FF 'in Figure 1C), the translucent member 14 primarily has a block-like portion of the main body 14c that integrally seals part of the metal member ( not shown) and the light-emitting element (not shown), etc. Preferably, it additionally includes a part called a concave portion 14a which is arranged to project from the main body portion 14c, above the light-emitting element (and its surrounding portion).
[00097] Furthermore, together with the main body portion and the concave portion, it is preferable that a flange 14b is integrally disposed around the outer periphery of the main body portion. That is, as shown in Figure 2, it is preferable that the surface of the flange 14b continues from the convex portion 14a, and the flange 14b is disposed on the outer periphery of the main body portion 14c. As will be discussed below, the flange does not have to be arranged around the entire convex portion. If the flange is only partially arranged, preferably a flange of substantially the same shape is arranged equidistantly around the convex portion.
[00098] As shown in Figure 2, for example, the main body portion 14c of the translucent member has a width W, a depth, and a height H, and the convex portion 14a has a diameter D and a height T at the site of the maximum value. The flange 14b favorably has a height identical to that of the main body. In this case, there are no specific restrictions on width W, depth, height H, diameter D, or height T, but it is preferable, for example, that the diameter D of the convex portion is substantially equal to the width W and / or the depth of the main body. The height T of the convex portion is preferably about 1 to 10 times, and more preferably about 5 to 10 times, the height H of the main body. More specifically, the examples include a width W of about 1 to 10 mm, a depth of about 1 to 10 mm, a height H of about 0.05 to 5 mm, a diameter D of about 1 to 10 mm , and a height T of about 0.5 to 6 mm. It is preferable that the width W is about 2 to 7 mm, that the depth is about 2 to 7 mm, that the height H is about 0.1 to 1 mm, that the diameter D is about 2 to 7 mm, and that the height T is about 1 to 3 mm. It is particularly favorable that the width W and the depth of the main body are substantially equal (for example, within a ± 5% length range). This provides the same distribution of light in the direction of the width and in the direction of the depth. Here, it is preferable that the width and depth of the convex portion are also substantially the same.
[00099] Regardless of whether the metal member has a concave portion of the element's position or not, if the translucent member has a flange, it is interesting that the flange is formed to be disposed outside the illumination range by the light emitted from the element light emitting. Preferably, it is arranged towards the bottom face of the light-emitting device (downwards) and not towards the illumination band by the light emitted from the light-emitting element. The "range of illumination by the light emitted from the light-emitting element" is the range directly reached by the light emitted by the light-emitting element. More specifically, this band can be defined by a line that joins the light-emitting layer of the light-emitting element and the members that block the light in the surrounding area (such as the metal member). The top face of the light-emitting element can be used as a reference.
[000100] In particular, when the light-emitting element is placed in a concave portion of the element's positioning, the illumination range of the light is defined by the shape, size, etc., of the concave portion of the metal member, but it is interesting that the flange surface is arranged as close as possible to the flat portion of the metal member so that the flange will be disposed outside the region affected by the light and not within the region that the light has passed through. That is, preferably the height (position) of the upper face of the flange of the translucent member is substantially equal to the height (position) of the upper face of the flat portion of the metal member. In other words, the translucent member preferably covers the metal member and the light emitting element, etc., so that the upper face of the translucent member flange is substantially on the same plane as the upper face of the flat portion of the metal member.
[000101] The expression "substantially the same height", in this case, means that the upper face of the metal member (and the cover member) present within the translucent member in plan view is not exposed by the translucent member, but is covered in the minimum possible cover thickness, and only the minimum possible thickness differential is produced when viewed from the side face. Similarly, "substantially the same plane" means that there is only the minimum possible thickness differential, and the plane is the same or substantially the same. The "minimum possible cover thickness", in this case, means a thickness that can be obtained in the manufacturing process, for example, and more specifically, the thickness of the translucent member on the upper face of the cover member and on the flat portion of the cover member. metal is about 50 to 100 μm, it is preferable to be about 70 to 80 μm. From a different perspective, it is preferable that the thickness is about 1/5 to 1/10, and more preferable that the height of the flange of the translucent member is about 1/5 to 1/7. When the thickness of the translucent member (such as the flange) on the top face of the covering member and on the flat portion of the metal member, therefore, is the minimum possible thickness, it is preferable that this thickness is less than the thickness of the translucent member covering the side faces of the covering member.
[000102] The gap between the metal member and the translucent member is a pathway to access moisture, ionic impurities, and other elements. Therefore, covering the top face of the metal member with the translucent member, can prevent moisture, ionic impurities, etc., from having access to the top face of the light emitting device, increasing the reliability of the light emitting device.
[000103] The arrangement or formation of the flange in the exposed manner guarantees an adequate contact surface area between the translucent member and the metal member, which prevents the separation of the two and at the same time allows to maximize the efficiency of light extraction, without the light coming from the light-emitting element being blocked by the translucent member disposed on the upper face of the metal member. Furthermore, the arrangement or formation of the flange in the exposed manner suppresses the total reflection of the light on the surface of the flange, so that the absorption of light by the covering member can be avoided. In addition, the resistance of the translucent member on the flange is enhanced by the metal member and the cover member, so a relatively thin flange can be formed, and the overall thickness of the light-emitting device reduced, while still maintaining good strength. Therefore, the arrangement of the flange outside the illumination range of the light emitted by the light emitting element allows the convex surface portion to function as the extraction face of the main light, therefore when handling the light emitting device, pliers or other type of equipment. they can be placed in contact with the flange other than the main light extraction face. This prevents deformation or damage to the main light extraction face of the light emitting device, and prevents a modification of the light distribution characteristics or a reduction in light emission.
[000104] Regardless of whether the positioning portion of the element of the metal member has a concave shape or not, it is interesting that it is arranged so that its bottom face is exposed from the bottom face of the main body portion of the translucent member. If a concave portion is arranged, it is interesting that the bottom face of the concave portion is exposed from the bottom face of the main body portion. In the latter case, it is preferable that the sketch is substantially on the same plane as the bottom face of the concave portion. Exposure in the positioning portion of the element in this way allows heat to be effectively dissipated by the light-emitting element. As a result, deterioration, etc. of the light-emitting element and the translucent limb caused by heat can be avoided, and the reliability of the light-emitting device can be increased. Furthermore, if the bottom face of the translucent member is substantially on the same plane as the bottom face of the concave portion, the bottom face of the light-emitting element is reinforced by the metal member.
[000105] Therefore, the height H of the flange and the main body portion is preferably slightly greater (for example, +100 μm) than the sum of the thickness of the metal member and the depth of the concave portion.
[000106] If the cover member mentioned above exposes the positioning portion of the element of the metal member and covers the side of the second face of the flat portion located on its outer periphery, as well as the outer peripheral part of the positioning portion of the element, the translucent member preferably covers at least part of the side face and the top face of the covering member, and more preferably fully covers the side face and the upper face of the covering member. Furthermore, the translucent member can cover at least part or all of the bottom face of the covering member. By covering the covering member with the translucent member in this way, that is, by covering the rigid covering member with the most malleable translucent member (as discussed below), external stress on the covering member can be absorbed. As a result, cracking, splinters, and other inconveniences caused by external stress can be avoided, and the resistance of the light-emitting device can be increased. Furthermore, when the flange and the convex portion have the shape and outline already mentioned, the adhesion between the translucent member and the covering member tends to decrease, but if the translucent member covers not only the upper face of the covering member, but the whole the lateral face, the area of the contact surface between the translucent member and the covering member can be increased and the adhesion improved. Therefore, it is possible to obtain a light-emitting device equipped with the above structure that has greater reliability.
[000107] It is preferable that the translucent member and / or cover member that defines the bottom face of the light-emitting device is formed to remain in the same plane. This increases the resistance of the bottom face of the light-emitting device and increases reliability. Furthermore, if a concave portion is formed on the metal member, it is preferable that the translucent member and / or cover member that defines the bottom face coincides, that is, it is on the same plane as the bottom face of the concave portion. This allows to reliably expose the bottom face of the concave portion by the sealing member, and to improve thermal dissipation. In addition, the bottom face of the concave portion can be placed in contact with a mounting substrate, and the thermal dissipation path can also be used by the mounting substrate, allowing for better thermal dissipation.
[000108] The translucent member is formed of a material that is more malleable than the cover member mentioned above. In general, "more pliable than the covering member" means that the hardness is lower.
[000109] Furthermore, it is possible to affirm that the translucent member is formed by a material with elasticity similar to that of rubber. Alternatively, it is possible to state that it is formed by a material with a hardness expressed by the dynamic hardness (repulsion hardness) .The dynamic hardness is usually expressed as the hardness obtained by the Shore A hardness test or JIS-A hardness test.
[000110] The hardness of the translucent limb as found by the JIS-A hardness test is equal to or less than approximately 65, for example, and preferably is equal to or less than approximately 60. The use of a malleable material such as this reduces fatigue the wire in a thermal impact test. Furthermore, by preventing the wire from bending during the handling of the light-emitting device, the adherence of the light-emitting devices, etc., the hardness determined by the JIS-A hardness test is at least about 20, and preferably is at least about 30. The linear coefficient of thermal expansion of a translucent member with high elasticity is about 200 to 300 ppm / K, for example.
[000111] The expression "the translucent member is malleable" means, for example, that the viscosity during molding (when melted) is lower than the viscosity of the covering member. The viscosity during molding will depend on the material, but when the material that constitutes the translucent member is melted at a temperature convenient to that material in a common semiconductor process, the viscosity is favorably equal to or less than about 9 Pa ^ s, and preferably is equal to or less than about 5 Pa ^ s. The use of this type of material prevents molding defects. When effective manufacturing is taken into account, a value equal to or greater than about 2.5 Pa ^ s is preferable. For example, a silicone resin whose viscosity at 25 ° C is approximately 3 Pa ^ s can be used.
[000112] The translucent member is chosen from those materials capable of providing electrical insulation between the light-emitting element and the metal member.
[000113] Therefore, a translucent silicone resin is a favorable example of a material that exhibits the mentioned hardness and characteristics. This resin allows to anticipate long-term reliability, as it is practically elastic like rubber, has thermal resistance, withstands high temperatures above 200 ° C, exhibits a low rate of deformation and decomposition at high temperatures (that is, its temperature dependence low), and has little effect on other members.
[000114] The translucent member can be partially a mixture obtained by adding the material mentioned above to any dyes, pigments, or similar substances such as dyes or diffusion agents. Examples include colorants such as Cr2O3, MnO2, Fe2O3, and carbon black, and diffusion agents such as calcium carbonate, aluminum oxide, and titanium oxide. It is preferable to use a material that has not been mixed with a colorant or diffusing agent. This prevents the light from dispersing by the colorant or diffusing agent, and suppresses the total reflection on the surface of the translucent member, so that the light extraction efficiency can be improved. Translucent Cover Member
[000115] With the light-emitting device of the present invention, after arranging the light-emitting element on the metal member, a translucent cover member can be arranged to cover the light-emitting element. The translucent cover member is normally arranged in contact with the light-emitting element. For example, if the metal member has a concave portion for positioning the element, the translucent cover member may be arranged to protrude from all or part of the concave portion.
[000116] The translucent cover member is preferably formed of a material that will protect the light-emitting element against external force, moisture, and others, and which is capable of protecting the wires that connect the light-emitting element and the light limb. metal.
[000117] Examples of the translucent cover member include epoxy resin, silicone resin, acrylic resin, urea resin, combinations of the above, and other such transparent resins with excellent weather resistance, and glass. The translucent cover member can be of any hardness. The translucent cover member preferably has the same composition and is made of the same material as the sealing member, but a diffusing agent or fluorescent substance can be added. The use of a material identical to the material of the sealing member allows the sealing member and the translucent covering member to have substantially the same thermal expansion coefficient. Therefore, the impact resistance of the wires disposed on the sealing member and on the translucent covering member can be improved. Furthermore, as the refractive index is also substantially the same, there is less loss of light in the passage from the translucent covering member to the sealing member, which can increase the efficiency of light extraction.
[000118] The translucent cover member can be made of a different material, have a different composition, etc. In particular, with a transparent resin, even if moisture penetrates the translucent cover member during processing or storage, the moisture contained in the resin can be released to the outside atmosphere by cooking for at least about 14 hours at about 100 ° Ç. Therefore, the explosion of steam and the separation of the light-emitting element and the translucent resin mentioned above can be avoided. In view of the adhesion and similar events between the translucent member and the translucent cover member under the effect of the heat produced by the light-emitting element and others, the translucent cover member is preferably selected so that there is little difference in the thermal expansion coefficient between both.
[000119] The translucent cover member may contain a diffusing agent or a fluorescent substance. A diffusion agent is used to diffuse the light, and can moderate the direction from the light-emitting element, and increase the angle of observation. A fluorescent substance is used to convert the light from the light-emitting element, and can convert the wavelength of the light emitted by the light-emitting element out of the sealing member. If the light from the light-emitting element is visible light with a short wavelength and high energy, then a derivative of perylene (a fluorescent organic substance), ZnCdS: Cu, YAG: Ce, Caθ-Al2θ3-Siθ2 containing nitrogen activated by Cr and / or Eu, or another fluorescent substance of the type can be used with advantages. With the present invention, when white light is to be obtained, and particularly when a YAG: Ce fluorescent substance is used, depending on its content, it is possible to emit light from a blue light emitting element and complementary yellow light by absorbing part of that blue light, making it relatively simple to obtain reliable white light. In addition, when a Eu CaO-AhO3-SiO2 fluorescent substance containing nitrogen activated by Cr and / or Eu is used together, depending on its content, it is possible to emit red light in addition to the light coming from a blue light emitting element and complementary yellow light absorbing part of that blue light, making it relatively simple to reliably obtain white light with enhanced color rendering.
[000120] The diffusing agent and the fluorescent substance are preferably contained only in the translucent cover member, and not in the translucent member. This prevents the light from escaping to the side of the bottom face or to the side faces of the light emitting device due to light scattering caused by the diffusing agent or fluorescent substance. The translucent cover member can be shaped when it is wrapped in a concave portion as discussed above, and can be formed only around the light-emitting element by screen printing, electrophoretic deposition, or similar processes. Here, the translucent cover member may consist of a fluorescent substance alone. Protective Element
[000121] There are no specific restrictions on the protective element, and it can be of any known type that is mounted on a light-emitting device. For example, it may be an element capable of "short-circuit reverse" in the voltage applied to the light-emitting element, or of "short-circuit forward" in the voltage above the specified voltage, which is higher than the operating voltage of the light-emitting element. More specifically, it can be a Zener diode, a transistor diode, or the like.
[000122] With the light emitting device of the present invention, the protective element is preferably placed outside the illumination range of the light emitted by the light emitting element. This suppresses the absorption of light by the protective element. In addition, the protective element is preferably placed on a metal member that is isolated from the metal member provided with the positioning portion of the light-emitting element, and from the metal member to which the wires of the light-emitting element are connected. In addition, it is preferably positioned on a metal member arranged in a location that is below the upper face of the metal member provided with the positioning portion of the light emitting element (see Figure 1B). This prevents the joining member of the protective element from circulating to the light-emitting element or to the portion where its wires are connected.
[000123] The protective element can be placed on the first metal member (the metal member on which the light-emitting element is placed). In this case, the joining member of the protective element can be prevented from escaping to the concave portion by having the protective element placed on the first metal member and in a location opposite to the light-emitting element, with an intermediate recess. Usually only one protective element is installed, but two or more are allowed. Other Parties
[000124] The light emitting device of the present invention can comprise a reflective member, antireflective member, light diffusing member, or various other parts that draw light from the light emitting element more efficiently. Light Emitting Device Manufacturing Method
[000125] As the current light-emitting devices need to be smaller and thinner, in their manufacture, as in molding manufacture in which a metal member is squeezed between the upper and lower molds (dies) that form a cavity, and a sealing member is injected into this cavity, with the light emitting device of the present invention the area of the metal member squeezed between the upper and lower molds is immensely reduced in size. For this reason, the metal member tends to float (gap, displacement, etc.) within the upper and lower molds, and it is difficult to firmly hold the metal member in the upper and lower molds. In particular, when a concave portion and a bent portion are formed in the metal member and these are embedded in a sealing member to improve the adhesion between the metal member and the sealing member, it is generally even more difficult to firmly secure the metal member in the upper and lower molds. Furthermore, as the properties of the translucent member mentioned above are such that its viscosity is extremely low during molding, it penetrates the tiny gaps between the metal member and the molds in which it is clamped. Consequently, sometimes a thin film was formed by the translucent member, even in the portions of the metal member that acted as an external terminal. Furthermore, due to its properties, once the thin film of the translucent limb was formed in unwanted locations, it could not be reliably removed by explosion or any other simple cauterization procedure.
[000126] In view of the above, with the present invention, particularly when the translucent member mentioned above is used, which is relatively malleable or has a low viscosity during molding, a cover member which is relatively hard or has a high viscosity during the molding is previously arranged on one side of the second face of the flat portion of the metal member, and preferably on the outer periphery of the flat portion. The integrated metal member and cover member subsequently increase the area of the contact surface between the upper and lower molds and these metallic members, etc., during the molding of the translucent member, thereby securing them firmly in the upper and lower molds . This prevents the penetration of the translucent member into unnecessary areas during molding and prevents the undesirable formation of a thin film at the outer terminals of the metal member, etc., providing a higher throughput and enhancing manufacturing efficiency.
[000127] For this reason, the method of the present invention for the manufacture of a light-emitting device comprises the steps of: (a) arranging in molds a metal member that has a positioning portion of the element on which an element is positioned emitting light on a first face, and a flat portion arranged around the positioning portion of the element, and forming a cover member that covers at least one side of the second face of the flat portion of the metal member; (b) mounting a light-emitting element on the positioning portion of the element of the metal member; and (c) arranging the metal member covered by the cover member within the second molds, squeezing the top and bottom face of the cover member with the second molds, and thereby forming a translucent member that covers the side faces and the upper face of the cover member and part of the metal member. Step (a)
[000128] The metal member is arranged in molds and a cover member is formed.
[000129] As mentioned above, the metal member has a positioning portion of the element on which a light-emitting element is positioned on a first face, and a flat portion arranged around the positioning portion of the element. The cover member covers at least one side of the second face of the flat portion of the metal member.
[000130] As discussed above, the covering member used in the present case is favorably produced from a relatively hard resin so that when the metal member is squeezed between the upper and lower molds, even if the area of the contact surface between them it is small and the metal member is not sufficiently fastened, and if a gap, therefore, is present in the tight portion between the metal member and the upper and lower molds, no penetration occurs in this gap. That is, it is important that the viscosity of the material of the cover member during molding of the cover member is higher than the viscosity of the material of the translucent member during the molding of the translucent member.
[000131] Consequently, as mentioned above, the covering member will not penetrate the gap between the molds and the metal member they are clamping, and as will be discussed below, when the metal member is clamped by the second molds, the area of the contact surface can be increased between at least one of the second molds and the metal member (strictly speaking, the metal member and the cover member). As a result, fixing and tightening can be carried out in a more stable manner, and even when molding with a resin that is malleable or has a relatively low viscosity, the formation of a thin film of the sealing member at undesired locations of the member metal can be effectively avoided. Step (b)
[000132] A joining member is normally used in the assembly of the light-emitting element to the metal member. For example, an epoxy resin, silicone, or other similar material can be used with a light-emitting element that emits blue and green light and is produced by the development of a nitrite semiconductor on a sapphire substrate. When deterioration caused by heat or light from the light-emitting element is considered, a layer of aluminum metal or similar element can be provided previously on the rear face of the light-emitting element, or no resin can be used and eutectic welding of Au-Sn or another solder, or a metal with a low melting point or other strong solder of the type can be used. With a light-emitting element where electrodes are formed on both sides, such as a light-emitting element that emits red light and is formed by GaAs or similar, crystal welding can be carried out with a conductive paste of silver, gold, palladium , or similar element.
[000133] Only one light-emitting element can be mounted on a metal member, or two or more can be mounted.
[000134] In addition, the light-emitting element can be placed on the metal member by means of a support (sub-assembly). For example, a support made of ceramic is molded into the required shape and then ignited. The conductive cabling that is connected to the light-emitting element is provided on one side of the upper face of the bracket. Conductive cabling is usually formed, for example, by vapor deposition or sputtering and photolithography, or by printing or similar method, or by electroplating or similar method. Conductive cabling can be provided inside the holder. Conductive cabling is formed, for example, by a pasty material obtained by adding a metal with a high melting point, such as tungsten or molybdenum, to a resin binder. The pasty material is placed in the desired shape through through orifices provided in a green leaf by printing on canvas or by any other similar method, and then ignited to form the conductive cabling arranged on the ceramic support and on the surface or inside. In addition, the support can be molded in resin from an insert, using a pair of positive and negative cable electrodes as conducting members. A light-emitting element can be placed on the top face of this support and electrically connected to the conductive wiring of the support. When such a support is used, the conductive wiring from the support is electrically connected to the metal member discussed below.
[000135] The light-emitting element can be mounted inverted, in which case it is preferable to use the aforementioned support. That is, the light-emitting element is preferably mounted inverted on the support, and the conductive cabling of the support is connected by wire to the metal member.
[000136] Step (b) can be performed before step (a), as long as it is performed before step (c).
[000137] After step (b), and before step (c), the entire surface of the light-emitting element is preferably covered with a translucent cover member.
[000138] This translucent cover member is preferably formed by a simple method, such as filling, for example. With this method, the undesirable pressure caused by the translucent cover member is not exerted on the light-emitting element, as in the case of mold formation, therefore, the breaking of the wires, etc., can be effectively avoided. In addition, the light-emitting element, its surroundings, or the interior of the concave portion can be easily covered by adjusting appropriately the amount of resin used during filling. Step (c)
[000139] The metal member covered by the cover member is disposed within the second molds, a translucent member being formed that covers part of the metal member and the top and side faces of the cover member. The top and bottom faces of the cover member are clamped by the second molds.
[000140] In step (a) above, when the first face of the flat portion is exposed to form the covering member, it is preferable that the first face of the flat portion and the upper face of the covering member, and the lower face of the limb cover are tightened by the second molds, respectively, in step (c).
[000141] When the bottom face of the positioning portion of the element is exposed to form the cover member in step (a), then in step (c) it is preferable to form the translucent member that exposes the bottom face of the portion of positioning of the element promoting the correct tightening with the second molds.
[000142] The translucent member used here can be one of the relatively malleable resins mentioned above, as a material that is more malleable than the cover member. The viscosity of the translucent member during the formation of the translucent member is preferably lower than the viscosity of the cover member during the formation of the cover member.
[000143] This allows the formation of a translucent member formed by at least a portion of the main body and a convex portion, and which covers at least part of the covering member and part of the metal member and the light-emitting element.
[000144] A translucent member arranged in this way in a suitable location prevents the formation of a thin film in an undesired location, and the covering of the covering member prevents cracking, splinters, and other defects caused by the hardness of the covering member.
[000145] Examples of the light emitting device of the present invention and a method for its manufacture will now be described in depth with reference to the drawings. Mode 1 Light Emitting Device
[000146] As Figures 1A to 1D show, the light emitting device 10 in this embodiment is a type of surface mount of the light emitting device, and primarily comprises the light emitting elements 11, a metal member 12 and a second metal member 13, a cover member 15 made of polyphthalamide (PPA) that covers part of metal member 12 and the second metal member 13, and a translucent member 14 produced in silicone resin.
[000147] The light-emitting elements 11, the metal member 12, and the second metal member 13 are integrally sealed by the cover member 15 and the translucent member 14.
[000148] Light-emitting elements 11 are produced by laminating a n-type contact layer formed of n-type GaN, a light-emitting layer formed of GaN, InGaN, AlGaN, InGaAlN, or another nitrite semiconductor, a layer of p-type cleavage formed from InGaN or p-type AlGaN, and a p-type contact layer formed from p-type GaN, in that order, on a sapphire substrate to form a GaN-based semiconductor that emits blue light with a main wavelength of approximately 470 nm.
[000149] The crystal welding of the light-emitting elements 11 is carried out with a silver paste or an epoxy resin, for example. In addition, the flat portion of the metal member 12 is connected to the electrodes (see Figure 1C) formed in the light-emitting elements 11, by gold wires with a diameter of 30 μm.
[000150] As shown in Figure 3, the metal member 12 has a concave positioning portion of the element 12a for mounting the light-emitting elements 11, and a flat portion 12d is arranged around it. The concave positioning portion of the element 12a has a diameter of about 2.4 mm, for example.
[000151] The second metal member 13 is disposed opposite the positioning portion of element 12a of metal member 12,
[000152] The metal member 12 and the second metal member 13 have a folded portion 12e which is folded towards the bottom face at about 60 ° within the cover member 15 and / or the translucent member 14 or within a flange 14b (discussed below), and also has a folded portion 12f which is folded towards the side face at about 120 °. In this way, their ends are the side faces of the translucent member 14 and the cover member 15, are designed to remain substantially on the same plane as the bottom face of the light emitting device 10, and are constituted to operate as external terminals.
[000153] The metal member 12 and the second metal member 13 are formed using a press to pierce a silver-plated copper sheet with a thickness of 0.25 mm, for example. The height differential produced by the two-stage bending of the metal member 12, in this case, is about 0.35 mm.
[000154] As shown in Figure 1D (the light-emitting elements 11 are not shown), the light-emitting elements 11 in the concave positioning portion of the element 12a of the metal member 12 are embedded in a translucent cover member 17 formed by a silicone resin containing a fluorescent substance (such as YAG: Ce) and a diffusion agent (such as titanium oxide). The translucent cover member 17 is formed by filling.
[000155] As shown in Figures 1B, 1C, and 1D, for example, the cover member 15 exposes the bottom face of the element positioning portion 12a of the metal member 12, covers the outer periphery of the element positioning portion 12a (the second face of the flat portion 12d of the metal member 12), additionally covers the outer periphery of the flat portion of the metal member 12, and a part is formed along the entire length up to the side of the first face of the metal member 12 The cover member 15 still covers part of the second face of the second metal member 13, and is disposed between the metal member 12 and the second metal member 13. The upper face of the cover member 15, in this case, is in the same plane and coincides with the first face of the part of the second metal member 13 and with the first face of the flat portion 12d of the metal member 12.
[000156] The PPA used for the covering member 15 is more rigid than the translucent member. In addition, its linear coefficient of thermal expansion is a few tens of ppm / K, for example.
[000157] As Figures 1A and 2 in particular show, the translucent member 14 primarily embeds them integrally, and comprises a substantially cubic portion of the main body 14c, a lenticular convex portion 14a which is arranged over the main body portion 14c and above the light-emitting elements 11, and a flange 14b which is arranged around the outer periphery of the flange 14b. In particular, the side face and the top face of the covering member 15 are completely covered by the translucent member 14 (see Figure 5B).
[000158] Furthermore, as shown in Figure 2, the main body portion 14c of the translucent member 14 has a width W of about 5 mm, a depth of about 5 mm, and a height H of about 0.6 mm . The convex portion 14a has a diameter D of about 4.7 mm and a height T of about 2.15 mm.
[000159] The length along one side of the light-emitting device 10, that is, the length along one side of the main body portion 14c of the translucent member 14 (width W = depth), is substantially equal to the diameter D of the convex portion. Therefore, in plan view, flange 14b is disposed only in four diagonally opposed locations on the outer periphery of the main body portion 14c.
[000160] The silicone resin used for the translucent member 14 is more malleable than the covering member 15, and its hardness is about 50 to 60 on the JIS-A hardness scale, for example. The linear coefficient of its thermal expansion coefficient is about 200 to 300 ppm / K, for example.
[000161] Other locations of the convex portion 14a, namely, the first face of the second metal member 13 and the flat portion 12d of the metal member 12 within the flange 14b, are covered by the translucent member 14, but in this case the coverage is adjusted so that the minimum thickness is reached. For example, the thickness of the film is about 75 μm. With this film thickness, if the top face of the translucent member 14 is arranged substantially on the same plane as the flat portion of the metal member 12, or if the height of the top face of the translucent member 14 from the bottom face of the emitting device of light substantially coincides with the height of the upper face of the flat portion 12d of the metal member 12, then the arrangement will be out of the illumination range of the light, and the light from the light-emitting element will not be blocked.
[000162] Furthermore, as the translucent member 14 substantially covers the side faces and the upper face of the covering member 15, cracking, splinters, and other defects caused by the hardness of the covering member 15 can be effectively avoided. The linear coefficients of thermal expansion of the metal members 12 and 13 can be approximated using a material for the covering member 15 that has a lower coefficient of thermal expansion lower than the translucent member 14. Therefore, separations and cracks during temperature changes can be eliminated, and a more reliable light-emitting device can be obtained. Light Emitting Device Manufacturing Method
[000163] First, a sheet of metal is perforated and folded using established methods to prepare the metal members that will serve as the second metal member 13 and as the metal member 12 which has the flat portion 12d and the positioning portion of the element 12a (see Figure 4B).
[000164] As Figures 4A and 4B show, the metal members that function as the metal member 12 and the second metal member 13 are arranged in the upper and lower molds 26 and 27. The lower mold 27 comes into contact with the face bottom of the concave portion (the positioning portion of the element 12a), and at the same time comes in contact with the bottom face of the metal member extended laterally and which acts as an external terminal. The upper mold 26 comes into contact with the upper face of the concave portion and the flat portion 12d of the metal members that act as the metal member 12 and as the second metal member 13. The inside of the concave portion is a cavity where the cover member (discussed below) is not injected. The upper mold 26 contacts the lower mold 27 in a portion where the cover member 15 is not formed.
[000165] The resin that will constitute the covering member 15 is injected into molds 26 and 27 in a state in which the metal members 12 and 13 have been fixed. In this case, the resin is usually a PPA resin, which is relatively hard and is enshrined as a sealing member in a semiconductor device. The resin is then cured and removed from the mold.
[000166] This sealing of the cover member forms a cover member that covers the flat portion and its outer periphery on the side of the second face of the metal member. As shown in Figure 4B, etc., this cover member is substantially on the same plane as the first face of the metal member in the region that extends to the outer periphery of the flat portion of the metal member (see 15a in Figures 1B and 4B ), but a step can also be formed on its outer periphery. The bottom face of the cover member is substantially the same as the second face (bottom face) of the terminal and the concave portion.
[000167] Next, the light-emitting elements 11 are assembled using a known method in the concave portion formed as part of the metal member 12, and the electrical connections are made by joining the wires. When a protective element is installed, it is installed and attached to the wire before, after or simultaneously with the assembly of the light-emitting elements.
[000168] The translucent cover member 17 containing a fluorescent substance is then immersed within the concave portion to cover the light-emitting elements 11.
[000169] Next, as shown in Figures 5A and 5B, the metal members then obtained are arranged inside the second upper and lower molds 36 and 37. The cavity is filled with the translucent cover member 17. Although not shown in the Figure 5A, the light-emitting elements 11 are mounted in the cavity filled with the translucent cover member 17.
[000170] The lower mold 37 comes into contact with the bottom face of the flat portion 12d, and at the same time, comes into contact with the bottom face of the metal member that functions as an external terminal and extends to the side, and it also comes into contact with the bottom face of the cover member. The upper mold 36 comes into contact with the flat portion 12d of the metal members that function as the metal member 12 and the second metal member 13, and at the same time, comes in contact with part of the upper face and the side face of the member previously sealed roof cover 15 (see M in Figure 5B). The resin that will make up the translucent member is injected into the mold in a state in which the metal members have been fixed. The resin in this case is a silicone resin that is relatively malleable, for example.
[000171] A tiny gap is provided between the upper mold 36 and the upper face of the covering member 15 in Figure 5A, but as shown in Figure 6, it is preferable that the upper face of the covering member 15 comes in complete contact with a upper mold 39. In this case, if a material with a low viscosity is used as material for the translucent member 14, the material of the translucent member 14 will penetrate between the upper mold 39 and the cover member 15, forming the translucent member 14 that covers the top face and the side faces of the covering member 15 continuously. Furthermore, it is preferable that a release film 38 is sandwiched between the bottom face of the covering member 15 and the metal members 12 and 13 and the lower mold. This provides a structure with which makes the translucent member 14 easily formed between the upper mold 39 and the cover member 15, and the translucent member 14 is not formed between the cover member 15 and the metal members 12 and 13 and the bottom mold 37.
[000172] The release film 38 is used so that the resin can be easily dismembered from the mold. The material of this film is the required thermal resistance and good release properties with the mold and resin, such as an FEP sheet film or a PET sheet film. After that, the resin is cured and removed from the mold.
[000173] This sealing of the translucent member can form a translucent member 14 formed by the main body portion 14c, the convex portion 14a, and the convex portion 14a, covering at least part of the covering member 15 and part of the metal members and elements light emitters (not shown).
[000174] Finally, the metal members are cut to obtain the light emitting device 10 shown in Figures 1A to 1D.
[000175] Thus, externally covering a rigid sealing member with a sealing member that is malleable and elastic, even if the light-emitting device falls, or if the light-emitting devices collide with each other inside a bag or box during When shipping the light-emitting devices, the malleable sealing member will absorb the impact force and effectively prevent cracks, chips, and other defects in the cover member.
[000176] The efficiency of light extraction can also be improved.
[000177] In other words, with a light-emitting device in which a translucent member is used, such as the translucent member that covers the metal members transmitted light from the light-emitting element, that light was sometimes extracted in one direction , except the direction of the front face, which is the light extraction face of the light emitting device. However, even though the translucent member is formed by a translucent material, part of the light is absorbed by the material of the translucent member and depending on the shape, etc.
[000178] On the other hand, with the light emitting device of the present invention, the translucent member on the metal member is kept at the minimum possible thickness of the film on the flange of the sealing member, that is, the upper face of the flange is installed close to the cover member and the flat portion of the metal member, therefore the flange is disposed outside the light illumination range by the light emitting element. Therefore, this light is not extracted after passing through the flange. As a result, the light extraction from the light emitting element can be converged to the convex portion, and the light extraction efficiency of the light emitting device can be greatly improved.
[000179] In addition, the light extraction efficiency was simulated with two types of light emitting device with different film coverage thicknesses of the flat portion of the metal member on the flange, and size of the convex portion. As a consequence, it was confirmed that the light extraction efficiency increased when the diameter of the convex portion was increased and the thickness of the covering film of the flat portion on the flange was reduced.
[000180] More specifically, the light extraction efficiency was 95.2% for a first light emitting device in which the length along one side of the light emitting device (the length along one side of the portion of the main body of the sealing member) was about 5 mm, the diameter of the lenticular convex portion was about 5 mm, the height of the flange was about 0.5 mm, and the thickness of the covering film of the flat portion flange was about 75 μm.
[000181] The light extraction efficiency was 88.1% for a second light emitting device in which the length along one side of the light emitting device was also 5 mm, the diameter of the lenticular convex portion was about 3.5 mm, the height of the flange was about 0.85 mm, and the thickness of the covering film of the flat portion of the flange was about 0.35 mm.
[000182] It was confirmed, therefore, that the light extraction efficiency of the first light-emitting device was approximately 8% higher than that of the second light-emitting device.
[000183] In addition, the adhesion between the translucent member and the metal member can be increased. That is, as discussed above, if the flange is installed close to the cover member and the flange, the flange will be thinner, so this can lead to a reduction in the strength of the flange and the adhesion between the translucent member and the limb of metal and the cover member. In particular, the material of the translucent member is more elastic than the material of the covering member, and tends to deform more immediately when subjected to high temperatures, external force, and other factors, so it is complex to achieve the correct adhesion and strength. If there is not enough adhesion between the metal member and the translucent member, a gap between the metal member and the translucent member will serve as an access route for humidity, ionic impurities, etc., which compromises the reliability of the light emitting device. .
[000184] On the other hand, with the light emitting device of the present invention, the metal member is folded inside the cover member or inside the translucent member (and particularly close to the flange), which allows to increase the surface area of the contact between the sealing member and the metal member. In addition, the fixation of the metal member by means of folding can be reinforced, and the adhesion between the metal member and the sealing member can be improved. In addition, the strength of the flange can also be increased, making the light-emitting device more reliable. Also, as the flange is thinner and its strength is maintained, the height of the light emitting device can be reduced.
[000185] In the past, while light-emitting devices were reduced and thinned, in their manufacture, in the course of molding the mold in which a metal member was clamped between the upper and lower molds and a sealing member was injected in this cavity, the surface area of the metal member clamped between the upper and lower molds was immensely reduced in size, so the metal member tended to float between the upper and lower molds. For this reason, it was difficult to hold the metal member firmly in the upper and lower molds. Furthermore, since the properties of the translucent member mentioned above included an extremely low viscosity during molding, it would penetrate the tiny gap formed between the metal member and the molds in which it was tightened. Consequently, an undesirable thin film was sometimes formed by the translucent member even in the portions of the metal member that function as an external terminal. Furthermore, because of its properties, as a thin film of the translucent limb was formed in undesirable places, it could not be reliably removed by explosion or other simple techniques of cauterization procedures.
[000186] On the other hand, with the modality provided above, a specific location on the side of the second face of the metal member, which does not interfere in any way with the extraction light, is covered by a covering member with a relatively high hardness ( relatively high viscosity during molding) before formation of the translucent member, which has relatively low hardness (relatively low viscosity during molding). Thereafter, even though the metal member is clamped in the upper and lower molds to form the translucent member, as the upper and lower molds can also squeeze part of the cover member that was formed, the metal member (and the cover member ) can be tightened by the upper and lower molds with sufficient strength. In this way, although the translucent member is formed by a malleable resin with low viscosity and relatively low hardness, the resin can be prevented from penetrating unnecessary locations, and can also prevent the formation of a thin film in unwanted locations of the metal member. . This prevents the drop in yield and improves manufacturing efficiency. Mode 2
[000187] As shown in Figure 7, the entire surface of one metal member 12 and the second metal member 13 formed of copper sheets was plated with gold in a thickness of 0.005 μm, and after that the entire internal face of the portion positioning element 12a (diameter of about 3.0 mm) and the outer periphery (width of about 0.2 mm) from the positioning portion of element 12a to the flat portion received a silver deposition film 28 with a thickness of 3 μm. The silver deposition film 28 within the positioning portion of the element 12a was covered by the translucent covering member 17, but the silver deposition film 28 formed on the outer periphery was exposed by the translucent covering member 17 and came into contact with the translucent member 14.
[000188] As the threaded portion was plated with gold, which has better adhesion to the thread than silver, the adhesion between the thread and the metal member can be improved. In addition, the adhesion between the translucent member 14 and the metal member can be further improved due to the better adhesion of silver to resin than gold.
[000189] The effects obtained with this modality are identical to those of Modality 1. Mode 3
[000190] As shown in Figures 8A and 8B, this light emitting device has substantially the same constitution as Modality 2, except in the form of a translucent member 24 and a cover member 25, and can be manufactured using the same method of manufacturing.
[000191] The translucent member 24 is formed in a shape that adapts to a step on the outer periphery of the cover member 25, and protrusions 25b are formed on the side faces of the cover member 25 (see Figure 8C).
[000192] The provision of these protrusions 25b allows the protrusions 25b to be fixed by the metal members 12 and 13, and allows the metal members 12 and 13 and the cover member 25 to be more stably fixed in the formation of the translucent member 24. Consequently, the translucent member 24 is further prevented from reaching the rear faces of the metal members 12 and 13,
[000193] The effects obtained with this modality are identical to those of Modalities 1 and 2, Mode 4
[000194] As shown in Figure 9, this light emitting device has substantially the same constitution as Modality 1, except for an orifice 12b and a cutout 12c that are formed in the flat portion 12d of the metal member 12 to allow adhesion to the cover member 15, and can be manufactured using the same fabrication method.
[000195] The effects obtained with this modality are identical to those of Modality 1. Mode 5
[000196] As shown in Figure 10, the constitution in this case is substantially the same as the Constitution of Modality 1, except for a positioning portion of element 22a that does not have a concave portion, the light-emitting elements are positioned on a flat portion that is continuous to a flat portion 22d, the light-emitting elements 11 are installed by means of a ceramic support 29, and a cover member 35 is arranged on the side of the second face of a metal member 22 in a region (a corresponding region to the flat portion 22d), except for the region corresponding to the region where the support 29 is mounted (element positioning portion 22a). The upper face of the flange 14b of the translucent member 14 is arranged in a lower location than the upper face of the support 29.
[000197] When the support 29 is provided in this way, the flange 14b is disposed outside the illumination range of the light emitted by the light emitting elements.
[000198] With a light emitting device constituted in this way, there is a slight increase in the half-value angle, but a good emission efficiency is achieved.
[000199] In addition, part of the flat portion can project into the convex portion, and the positioning portion of the element can be arranged higher than the flange. In this case the support can be omitted.
[000200] The light emitting device of this modality can also be manufactured in substantially the same way as in Modality 1.
[000201] The effects obtained with this modality are identical to those of Modality 1. Industrial Applicability
[000202] The present invention can be used in various types of light sources, such as lighting light sources, various indicator light sources, automotive light sources, display light sources, liquid crystal backlight sources, signaling devices, automotive parts, and signal channel letters. translucent 14 convex flow 14b flange 14c main body portion 15, 25, 35 cover member 16 protective element 17 translucent cover member 26, 27 upper and lower molds 28 silver deposition film 29 support 36, 37 upper and lower mold 38 release film

权利要求:
Claims (17)
[0001]
1.Light-emitting device comprising: a light-emitting element (11); a metal member (12, 22) which has a first face on which the light-emitting element (11) is mounted, and a second face which is on the side opposite the first face; and a translucent member (14, 24) that seals part of the metal member (12, 22) and the light-emitting element (11), the metal member (12,22) has a positioning portion of the element (12a, 22a) on which the light-emitting element (11) is placed, and a flat portion (12d, 22d) disposed around the element positioning portion (12a, 22a), characterized by the fact that a covering member ( 15, 25, 35) is arranged on the side of the second face of the flat portion (12d, 22d), and on which the cover member (15, 25, 35) exposes the first face of the flat portion (12d, 22d), and the translucent member (14, 24) covers the entire lateral face and the upper face of the covering member (15, 25, 35).
[0002]
2. Light-emitting device according to claim 1, characterized by the fact that the translucent member (14, 24) is more malleable than the cover member (15).
[0003]
3. Light-emitting device according to claim 1, characterized by the fact that the covering member (15) exposes the first face of the flat portion (12d, 22d).
[0004]
4. Light-emitting device according to claim 1, characterized by the fact that the covering member (15) covers the second face of the flat portion (12d, 22d) and an outer periphery of the flat portion (12d, 22d) , the upper face of the covering member (15) coincides with the first face of the flat portion (12d, 22d), and the upper face of the covering member (15) and the upper face of the flat portion (12d, 22d) are covered by the translucent member (14, 24).
[0005]
5. Light-emitting device according to claim 1, characterized by the fact that the translucent member (14, 24) has a convex portion (14a) and a flange (14b) arranged around the convex portion (14a), and the flange (14b) is disposed outside the illumination range of the light emitted by the light emitting element (11).
[0006]
6. Light-emitting device according to claim 5, characterized in that part of the flat portion (12d, 22d) of the metal member (12, 22) is disposed within the flange (14b).
[0007]
7. Light-emitting device according to claim 1, characterized by the fact that the metal member (12, 22) has a first curved portion that curves continuously from the flat portion (12d, 22d) to the side of the bottom face of the light emitting device, and a second curved portion that curves further to the side of the side face of the light emitting device, and is covered by the cover member (15, 25, 35) from the first curved portion until the second curved portion.
[0008]
8. Light-emitting device according to claim 5, characterized by the fact that the thickness of the flange (14b) on the upper face of the cover member (15, 25, 35) and the flat portion (12d, 22d) is less than the thickness of the translucent member (14, 24) on the side face of the covering member (15, 25, 35).
[0009]
9. Light-emitting device according to claim 1, characterized by the fact that the thickness of the translucent member (14, 24) on the upper face of the covering member (15, 25, 35) and on the flat portion (12d, 22d) is 50 to 100 μm.
[0010]
10. Light-emitting device according to claim 1, characterized by the fact that the cover member (15, 25, 35) also covers the outer periphery of the flat portion (12d, 22d).
[0011]
11. Light-emitting device according to claim 1, characterized by the fact that the covering member (15, 25, 35) exposes the bottom face of the element positioning portion (12a, 22a) of the metal member (12, 22), and is disposed on the outer periphery of the positioning portion of the element (12a, 22a).
[0012]
12. Light-emitting device according to claim 1, characterized in that the positioning portion of the element (12a, 22a) of the metal member (12, 22) has a concave portion that is folded up to the side of the bottom face of the light emitting device in relation to the flat portion (12d, 22d).
[0013]
13. Light-emitting device according to claim 12, characterized by the fact that the covering member (15, 25, 35) is wrapped so as to surround the concave portion, and the height of the lower face of the covering member (15, 25, 35) substantially coincides with the height of the lower face of the concave portion.
[0014]
14. Method for manufacturing a light-emitting device characterized by the fact that it comprises the steps of: (a) arranging, in molds, a metal member (12, 22) that has a positioning portion of the element (12a, 22a) on a first face on which a light-emitting element is placed, and a flat portion (12d, 22d) arranged around the element positioning portion (12a, 22a), and forming a cover member (15, 25, 35 ) covering at least a second face, which is opposite the first face, from the flat portion (12d, 22d) of the metal member (12, 22); (b) installing a light-emitting element (11) on the element positioning portion (12a, 22a) of the metal member (12, 22); and (c) arranging the metal member (12, 22) covered by the covering member (15, 25, 35) in a second mold, securing the upper and lower faces of the covering member (15, 25, 35) with the second molds, and form a translucent member (14, 24) that covers part of the metal member (12, 22) and the top and outer side face of the cover member (15, 25, 35), in which the cover member (15, 25, 35) exposes the positioning portion of the element (12a, 22a), and the translucent member (14, 24) covers the entire side and top face of the cover member (15, 25, 35).
[0015]
15. Method for manufacturing a light-emitting device according to claim 14, characterized in that, in step (a), a first face of the flat portion (12d, 22d) is exposed to form the cover member ( 15, 25, 35), and, in step (c), the first face of the flat portion (12d, 22d), the upper face of the covering member (15, 25, 35) and the lower face of the covering member ( 15, 25, 35) are trapped by the second molds.
[0016]
16. Method for manufacturing a light-emitting device according to claim 14, characterized in that, in step (a), the bottom face of the positioning portion of the element (12a, 22a) is exposed to form the cover member (15, 25, 35), and in step (c), the translucent member (14, 24) which exposes the bottom face of the element positioning portion (12a, 22a) is formed.
[0017]
17. Method for manufacturing a light-emitting device according to claim 14, characterized by the fact that the material viscosity of the cover member (15, 25, 35) when the cover member (15, 25, 35) is formed is higher than the viscosity of the material of the translucent member (14, 24), when the translucent member (14, 24) is formed.

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法律状态:
2018-12-18| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|

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2019-10-15| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|

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2020-12-01| B09A| Decision: intention to grant|

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2021-03-02| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 20/10/2011, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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JP2010293295|2010-12-28|

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JP2010-293295|2010-12-28|

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PCT/JP2011/074139|WO2012090576A1|2010-12-28|2011-10-20|Light-emitting apparatus and method of manufacturing thereof|

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