WO2010026716A1 - 発光装置、樹脂パッケージ、樹脂成形体並びにこれらの製造方法 - Google Patents
発光装置、樹脂パッケージ、樹脂成形体並びにこれらの製造方法 Download PDFInfo
- Publication number
- WO2010026716A1 WO2010026716A1 PCT/JP2009/004170 JP2009004170W WO2010026716A1 WO 2010026716 A1 WO2010026716 A1 WO 2010026716A1 JP 2009004170 W JP2009004170 W JP 2009004170W WO 2010026716 A1 WO2010026716 A1 WO 2010026716A1
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- WIPO (PCT)
- Prior art keywords
- resin
- lead frame
- light emitting
- emitting device
- light
- Prior art date
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- H01L2224/48151—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive
- H01L2224/48221—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked
- H01L2224/48245—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being metallic
- H01L2224/48257—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being metallic connecting the wire to a die pad of the item
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- H01L2924/0001—Technical content checked by a classifier
- H01L2924/00012—Relevant to the scope of the group, the symbol of which is combined with the symbol of this group
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- H01L2924/0001—Technical content checked by a classifier
- H01L2924/00014—Technical content checked by a classifier the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
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- H01L2924/10—Details of semiconductor or other solid state devices to be connected
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- H01L2933/0066—Processes relating to semiconductor body packages relating to arrangements for conducting electric current to or from the semiconductor body
Definitions
- the present invention relates to a light emitting device used for a lighting fixture, a display, a backlight of a mobile phone, a moving image illumination auxiliary light source, another general consumer light source, and a method for manufacturing the light emitting device.
- a light-emitting device using a light-emitting element emits light with a small color, power efficiency, and vivid colors.
- this light emitting element is a semiconductor element, there is no fear of a broken ball. Further, it has excellent initial driving characteristics and is strong against vibration and repeated on / off lighting. Because of such excellent characteristics, light-emitting devices using light-emitting elements such as light-emitting diodes (LEDs) and laser diodes (LDs) are used as various light sources.
- LEDs light-emitting diodes
- LDs laser diodes
- FIG. 14 is a perspective view showing a conventional method of manufacturing a light emitting device.
- FIG. 15 is a perspective view showing an intermediate body of a conventional light emitting device.
- FIG. 16 is a perspective view showing a conventional light emitting device.
- a lead frame is insert-molded with a non-translucent and light-reflective white resin, and a resin molded body having concave-shaped cups is formed at predetermined intervals through the lead frame.
- a resin molded body having concave-shaped cups is formed at predetermined intervals through the lead frame.
- a general thermoplastic resin is used from insert molding or drawing.
- a thermoplastic resin for example, a thermoplastic resin such as a liquid crystal polymer, PPS (polyphenylene sulfide), and nylon is often used as a light-shielding resin molded body (see, for example, Patent Document 2).
- thermoplastic resin has poor adhesion to the lead frame, and the resin part and the lead frame are liable to peel off.
- thermosetting resin has low fluidity of the resin, it is inappropriate for molding a resin molded body having a complicated shape and has poor light resistance.
- the output of light emitting elements has been remarkably improved in recent years, and as the output of light emitting elements is increased, the light deterioration of packages made of thermoplastic resins has become remarkable.
- FIG. 17 is a perspective view and a cross-sectional view showing a conventional light emitting device.
- FIG. 18 is a schematic cross-sectional view showing a conventional method for manufacturing a light emitting device.
- metal wiring is formed from a metal foil by a known method such as punching or etching, then the metal wiring is placed in a mold having a predetermined shape, and a thermosetting resin is injected from a resin injection port of the mold.
- transfer molding is disclosed.
- FIG. 19 is a schematic view showing a manufacturing process of a conventional light emitting device.
- This package substrate for mounting an optical semiconductor element has a plurality of concave portions, in which a flat printed wiring board is attached to a mold, a thermosetting resin composition for light reflection is injected, and heat-press molding is performed by a transfer molding machine.
- a matrix-shaped package substrate for mounting an optical semiconductor element is manufactured. It also describes that a lead frame is used instead of the printed wiring board.
- these wiring boards and lead frames have a flat plate shape, and the thermosetting resin composition is arranged on the flat plate shape, and since the adhesion area is small, the lead frame and the thermosetting resin are used when dicing. There exists a problem that it is easy to peel from a composition.
- JP 2007-35794 A (particularly [0033]) Japanese Patent Laid-Open No. 11-0877780 JP 2006-140207 A (particularly [0028]) JP 2007-235085 A
- the present invention has been made in view of the above-described problems, and an object thereof is to provide a simple and inexpensive method for producing a large number of light emitting devices in a short time with high adhesion between a lead frame and a thermosetting resin composition. .
- the term “lead”, “resin part”, and “resin package” are used for the light emitting device after being singulated, and the terms “lead frame” and “resin molded body” are used before the singulation.
- the present invention relates to a method for manufacturing a light emitting device having a resin package having a light reflectivity at a wavelength of 350 nm to 800 nm of 70% or more after thermosetting and having a resin portion and a lead formed on substantially the same surface on the outer surface.
- the step of sandwiching the lead frame provided with the notch between the upper mold and the lower mold, and the mold sandwiched between the upper mold and the lower mold contain a light reflective substance.
- a method of manufacturing a light emitting device comprising: forming a resin molded body on a lead frame by transfer molding a thermosetting resin to be cut; and cutting the resin molded body and the lead frame along a notch About.
- thermosetting resin is filled in the notch, the adhesion area between the lead frame and the thermosetting resin is increased, and the adhesion between the lead frame and the thermosetting resin is improved. Can do. Further, since a thermosetting resin having a viscosity lower than that of the thermoplastic resin is used, the notched portion can be filled with the thermosetting resin without leaving a void. In addition, a large number of light emitting devices can be obtained at a time, and the production efficiency can be greatly improved. Further, the number of runners discarded can be reduced, and an inexpensive light emitting device can be provided.
- the lead frame prefferably to plating before being sandwiched between the upper mold and the lower mold. At this time, in the manufactured light emitting device, the cut surface is not plated, and the other portions are plated. It is not necessary to perform plating treatment for each light emitting device separated into pieces, and the manufacturing method can be simplified.
- the cutout portion in the cut portion is about 1 ⁇ 2 or more of the entire surrounding circumference.
- the notch is filled with a thermosetting resin
- the hole described later is not filled with a thermosetting resin.
- the notch and the hole penetrate the lead frame, whereas the groove described later does not penetrate the lead frame.
- the lead frame before being sandwiched between the upper mold and the lower mold is provided with a hole.
- a lead frame can be reduced in weight and an inexpensive light-emitting device can be provided. Since the hole portion can be plated, exposure of the lead frame can be suppressed.
- the lead frame before being sandwiched between the upper mold and the lower mold is preferably provided with a groove.
- a lead frame can be reduced in weight and an inexpensive light-emitting device can be provided. Since the groove can be plated, exposure of the lead frame can be suppressed.
- the upper die and the lower die sandwich the lead frame in the portion where the light emitting element is placed or in the vicinity of the hole. As a result, flapping of the lead frame can be prevented and the occurrence of burrs can be reduced.
- the present invention is a light-emitting device having a resin package having a light reflectance of 70% or more at a wavelength of 350 nm to 800 nm after thermosetting and having a resin portion and a lead formed on substantially the same surface on the outer surface.
- the lead relates to a light emitting device in which at least one of the bottom surface and the top surface is plated, and the outer surface has a portion not plated.
- Resin package preferably has leads exposed from four corners. Since the exposed portion of the lead can be reduced rather than providing the lead on the entire side surface of the resin package, the adhesion between the resin portion and the lead can be improved. Further, since an insulating resin portion is provided between the positive and negative leads, a short circuit can be prevented.
- the resin package is formed in an arc shape as viewed from the bottom surface side.
- a portion formed in an arc shape is subjected to a plating process, and a configuration in which a plating process is not performed on the cut surface may be employed.
- the bonding area with the solder or the like is expanded, and the bonding strength can be improved.
- the lead is preferably provided with a step.
- This step is preferably provided on the bottom surface of the resin package.
- the portion where the step is formed is plated, and the cut surface can be configured not to be plated. As a result, the bonding area with the solder or the like is expanded, and the bonding strength can be improved.
- the present invention is a method for producing a resin package, wherein the light reflectance at a wavelength of 350 nm to 800 nm after thermosetting is 70% or more, and the resin portion and the lead are formed on substantially the same surface on the outer surface, A process of sandwiching a lead frame provided with a notch between an upper mold and a lower mold, and a thermosetting containing a light-reflective substance in the mold sandwiched between the upper mold and the lower mold
- the present invention relates to a method for manufacturing a resin package, which includes a step of forming a resin molded body on a lead frame by transfer molding a resin, and a step of cutting the resin molded body and the lead frame along a notch.
- thermosetting resin is filled in the notch, the adhesion area between the lead frame and the thermosetting resin is increased, and the adhesion between the lead frame and the thermosetting resin is improved. Can do. Further, since a thermosetting resin having a viscosity lower than that of the thermoplastic resin is used, the notched portion can be filled with the thermosetting resin without leaving a void. In addition, a large number of resin packages can be obtained at one time, and the production efficiency can be greatly improved. Furthermore, runners discarded can be reduced, and an inexpensive resin package can be provided.
- the lead frame prefferably to plating before being sandwiched between the upper mold and the lower mold. At this time, the manufactured resin package is not subjected to the plating process on the cut surface, and the other part is subjected to the plating process. There is no need to perform plating for each individual resin package, and the manufacturing method can be simplified.
- the present invention is a resin package in which the light reflectance at a wavelength of 350 nm to 800 nm after heat curing is 70% or more, and the resin portion and the lead are formed on substantially the same surface on the outer surface, the lead being a bottom surface Further, the present invention relates to a resin package in which at least one of the upper surface and the upper surface is plated, and the outer surface has a portion that is not plated. As a result, it is possible to prevent exposure of leads that are not plated, and to obtain a large number of resin packages at a time. Moreover, the light extraction efficiency from the light emitting device can be improved by plating only the portion that reflects the light from the light emitting element.
- the present invention provides a resin molded product that has a light reflectance of 70% or more at a wavelength of 350 nm to 800 nm after thermosetting, a plurality of recesses, and a part of the lead frame is exposed on the inner bottom surface of the recesses.
- a method of manufacturing a body wherein a lead frame having a notch is used, and the lead frame is sandwiched between an upper mold and a lower mold having convex portions at positions where adjacent concave portions are molded in the resin molded body
- transfer-molding a thermosetting resin containing a light-reflective material In the mold sandwiched between the upper mold and the lower mold, transfer-molding a thermosetting resin containing a light-reflective material, and filling the notch portion with the thermosetting resin, And forming a resin molded body on a lead frame.
- the present invention provides a resin molded product that has a light reflectance of 70% or more at a wavelength of 350 nm to 800 nm after thermosetting, a plurality of recesses, and a part of the lead frame is exposed on the inner bottom surface of the recesses.
- the lead frame has a notch, and the notch is filled with a thermosetting resin to be a resin molded body, and has a side wall between adjacent recesses. It relates to a molded body. Thereby, the resin molding excellent in heat resistance and light resistance can be provided.
- the light emitting device and the manufacturing method thereof according to the present invention it is possible to provide a light emitting device with high adhesion between the lead frame and the resin molded body.
- a large number of light emitting devices can be obtained in a short time, and the production efficiency can be greatly improved. Further, the number of runners discarded can be reduced, and an inexpensive light emitting device can be provided.
- FIG. 1 is a perspective view showing the light emitting device according to the first embodiment.
- FIG. 2 is a cross-sectional view showing the light emitting device according to the first embodiment. 2 is a cross-sectional view taken along the line II-II shown in FIG.
- FIG. 3 is a plan view showing the lead frame used in the first embodiment.
- the light emitting device 100 has a light reflectance of 70% or more at a wavelength of 350 nm to 800 nm after thermosetting, and the resin portion 25 and the lead 22 are formed on substantially the same surface on the outer surface 20b.
- a resin package 20 is provided.
- the lead 22 is plated on at least one of the bottom surface (the outer bottom surface 20a of the resin package 20) and the top surface (the inner bottom surface 27a of the recess 27).
- the side surface of the lead 22 (the outer surface 20b of the resin package 20) is not plated.
- the resin portion 25 occupies a large area, and the leads 22 are exposed from the corners.
- the resin package 20 is mainly composed of a resin portion 25 containing a light reflective material 26 and leads 22.
- the resin package 20 has an outer bottom surface 20a on which the leads 22 are arranged, an outer side surface 20b from which a part of the leads 22 is exposed, and an outer upper surface 20c that forms a recess 27 that opens.
- the resin package 20 has a recess 27 having an inner bottom surface 27a and an inner surface 27b.
- the lead 22 is exposed on the inner bottom surface 27 a of the resin package 20, and the light emitting element 10 is placed on the lead 22.
- a sealing member 30 that covers the light emitting element 10 is disposed in the recess 27 of the resin package 20.
- the sealing member 30 contains a fluorescent material 40.
- the light emitting element 10 is electrically connected to the lead 20 via the wire 50. Leads 20 are not arranged on the outer upper surface 20 c of the resin package 20.
- a notch 21 a is provided in the lead frame 21 and the cut portion of the lead frame 21 is exposed from the resin package 20 because the notch 21 a is cut along the notch 21 a.
- Resin package 20 has leads 22 exposed from the four corners.
- the lead 22 is exposed on the outer side surface 20b and is not subjected to plating. Further, the lead 22 can have a structure exposed to the outer bottom surface 20a, and can be plated. Note that the outer surface 20b of the lead 22 can be plated after being separated into individual pieces.
- the light emitting device 100 has a light reflectance of 70% or more at a wavelength of 350 nm to 800 nm after thermosetting. This mainly indicates that the light reflectance in the visible light region is high.
- the light emitting element 10 preferably has an emission peak wavelength of 360 nm to 520 nm, but a light emitting element of 350 nm to 800 nm can also be used.
- the light emitting element 10 preferably has an emission peak wavelength in a short wavelength region of visible light of 420 nm to 480 nm.
- This resin package 20 has excellent light resistance to light on the short wavelength side of 480 nm or less and is not easily deteriorated.
- the resin package 20 is excellent in heat resistance because it hardly deteriorates even when the light emitting element 10 generates heat by supplying current.
- thermosetting resin having a light transmittance of 80% or more at 350 nm to 800 nm is preferably used, and a thermosetting resin having a light transmittance of 90% or more is particularly preferable. This is because the deterioration of the resin package 20 can be suppressed by reducing the light absorbed by the thermosetting resin.
- the light reflecting material 26 preferably reflects 90% or more of light from the light emitting element 10, and particularly preferably reflects 95% or more.
- the light reflective material 26 preferably reflects 90% or more of the light from the fluorescent material 40, and particularly preferably reflects 95% or more.
- the light extraction efficiency from the light emitting device 100 can be improved by reducing the amount of light absorbed by the light reflective material 26.
- the shape of the light emitting device 100 is not particularly limited, but may be a polygonal shape such as a substantially rectangular parallelepiped, a substantially cube, or a substantially hexagonal column.
- the recess 27 preferably extends in the opening direction, but may be cylindrical.
- the shape of the recess 27 can be a substantially circular shape, a substantially elliptical shape, a substantially polygonal shape, or the like.
- a substrate in which a semiconductor such as GaAlN, ZnS, SnSe, SiC, GaP, GaAlAs, AlN, InN, AlInGaP, InGaN, GaN, and AlInGaN is formed as a light emitting layer is preferably used. It is not limited. Those having an emission peak wavelength of 360 nm to 520 nm are preferred, but those having an emission peak wavelength of 350 nm to 800 nm can also be used. In particular, the light emitting element 10 preferably has an emission peak wavelength in a short wavelength region of visible light of 420 nm to 480 nm.
- the light emitting element a face-up structure can be used, and a face-down structure can also be used.
- the size of the light emitting element is not particularly limited, and those having ⁇ 350 ⁇ m, ⁇ 500 ⁇ m, ⁇ 1 mm, and the like can be used.
- a plurality of light emitting elements can be used, all of which may be of the same type, or of different types exhibiting red, green, and blue light emission colors that are the three primary colors of light.
- the resin package has a resin portion made of a thermosetting resin and leads, and is integrally molded.
- the resin package has a light reflectance at 350 nm to 800 nm of 70% or more, but a light reflectance at 420 nm to 520 nm is particularly preferably 80% or more.
- a light reflectance at 420 nm to 520 nm is particularly preferably 80% or more.
- the light emitting region of the light emitting element and the light emitting region of the fluorescent material have high reflectance.
- the resin package has an outer bottom surface, an outer surface, and an outer upper surface. Leads are exposed from the outer surface of the resin package.
- the resin portion and the lead are formed on substantially the same surface. This substantially the same surface means that it was formed in the same cutting step.
- the outer shape of the resin package is not limited to a substantially rectangular parallelepiped, and may be a substantially cube, a substantially hexagonal column, or another polygonal shape. Further, when viewed from the outer upper surface side, shapes such as a substantially triangular shape, a substantially rectangular shape, a substantially pentagonal shape, and a substantially hexagonal shape can be employed.
- the resin package has a recess having an inner bottom surface and an inner side surface.
- a lead is disposed on the inner bottom surface of the recess.
- the concave portion can take various shapes such as a substantially circular shape, a substantially elliptical shape, a substantially rectangular shape, a substantially polygonal shape, and a combination thereof, as viewed from the outer upper surface side.
- the recess preferably has a shape that expands in the opening direction, but may have a cylindrical shape.
- the concave portion may be provided with a smooth slope, but it may be provided with fine irregularities on the surface to scatter light.
- the leads are provided at a predetermined interval so as to form a pair of positive and negative.
- the lead on the inner surface of the recess and the lead on the outer bottom surface of the resin package are plated. Although this plating process can be performed before cutting out the resin molded body, it is preferable to use a lead frame that has been previously plated. On the other hand, the side surface of the lead is not plated. (Resin part, resin molding) It is preferable to use a triazine derivative epoxy resin which is a thermosetting resin as the material of the resin part and the resin molded body.
- the thermosetting resin can contain an acid anhydride, an antioxidant, a release material, a light reflecting member, an inorganic filler, a curing catalyst, a light stabilizer, and a lubricant.
- the light reflecting member is made of titanium dioxide and is filled at 10 to 60 wt%.
- the resin package is not limited to the above-described form, and is formed of at least one selected from the group consisting of epoxy resins, modified epoxy resins, silicone resins, modified silicone resins, acrylate resins, and urethane resins among thermosetting resins. It is preferable. Particularly preferred are epoxy resins, modified epoxy resins, silicone resins, and modified silicone resins.
- an epoxy resin composed of triglycidyl isocyanurate, hydrogenated bisphenol A diglycidyl ether, etc. and an acid anhydride composed of hexahydrophthalic anhydride, 3-methylhexahydrophthalic anhydride, 4-methylhexahydrophthalic anhydride, etc.
- the lead frame is a flat metal plate that has been punched or etched.
- the etched lead frame has irregularities in the cross-sectional shape, and can improve the adhesion to the resin molded body.
- a step or uneven shape is formed. Is small.
- the etching process it is possible to form a concavo-convex shape on the entire cross section (etched portion) of the lead frame, so that the bonding area between the lead frame and the resin molded body can be increased, and a resin package with higher adhesion can be obtained. Can be molded.
- the cost required for replacement parts increases due to the wear of the die accompanying the punching, and the manufacturing cost of the lead frame increases.
- the etching process a punching die is not used, and when the number of packages taken per frame is large, the lead frame manufacturing cost per package can be reduced.
- Etching may be performed so as to penetrate the lead frame, or may be performed from only one side so as not to penetrate.
- the notch is formed such that when the resin molded body is separated into a resin package, the leads are a pair of positive and negative. Further, the notch is formed so as to reduce the area for cutting the lead when the resin molded body is cut. For example, a notch portion is provided in the lateral direction so as to form a pair of positive and negative leads, and a notch portion is provided at a position corresponding to a cutout portion when the resin molded body is separated into pieces.
- a part of the lead frame is connected in order to prevent a part of the lead frame from dropping or to expose the lead on the outer surface of the resin package. In order to dice the resin molding using a dicing saw, it is preferable that the notch is linearly formed vertically and horizontally or diagonally.
- the lead frame is formed using a good electrical conductor such as iron, phosphor bronze, or copper alloy, for example. Further, in order to increase the reflectance of light from the light emitting element, metal plating such as silver, aluminum, copper, and gold can be performed. It is preferable to apply metal plating before sandwiching between the upper die and the lower die, such as after providing a notch or after etching, but before the lead frame is integrally formed with the thermosetting resin. Metal plating can also be applied. (Sealing member)
- the material of the sealing member is a thermosetting resin.
- thermosetting resins it is preferably formed of at least one selected from the group consisting of epoxy resins, modified epoxy resins, silicone resins, modified silicone resins, acrylate resins, and urethane resins, particularly epoxy resins and modified epoxy resins. Silicone resins and modified silicone resins are preferred.
- the sealing member is preferably a hard member in order to protect the light emitting element. Moreover, it is preferable to use resin excellent in heat resistance, a weather resistance, and light resistance for a sealing member.
- the sealing member can be mixed with at least one selected from the group consisting of a filler, a diffusing agent, a pigment, a fluorescent material, and a reflective material in order to have a predetermined function. A diffusing agent may be contained in the sealing member.
- the sealing member can also contain a fluorescent material that absorbs light from the light emitting element and converts the wavelength.
- the fluorescent substance may be any substance that absorbs light from the light emitting element and converts the wavelength into light of a different wavelength.
- nitride phosphors / oxynitride phosphors / sialon phosphors mainly activated by lanthanoid elements such as Eu and Ce, lanthanoid phosphors such as Eu, and transition metal elements such as Mn.
- Organic earth mainly activated by lanthanoid elements such as alkaline earth silicon nitride, germanate or rare earth aluminate, rare earth silicate or Eu mainly activated by lanthanoid elements such as Ce and It is preferably at least one selected from organic complexes and the like.
- the following phosphors can be used, but are not limited thereto.
- Nitride-based phosphors mainly activated with lanthanoid elements such as Eu and Ce are M 2 Si 5 N 8 : Eu, MAlSiN 3 : Eu (M is selected from Sr, Ca, Ba, Mg, Zn) At least one or more).
- An oxynitride phosphor mainly activated by a lanthanoid element such as Eu or Ce is MSi 2 O 2 N 2 : Eu (M is at least one selected from Sr, Ca, Ba, Mg, Zn) Etc.).
- the sialon phosphors mainly activated by lanthanoid elements such as Eu and Ce are M p / 2 Si 12-pq Al p + q O q N 16-p : Ce, M-Al—Si—O—N (M is at least one selected from Sr, Ca, Ba, Mg, and Zn. Q is 0 to 2.5, and p is 1.5 to 3).
- Alkaline earth halogen apatite phosphors mainly activated by lanthanoid compounds such as Eu and transition metal elements such as Mn include M 5 (PO 4 ) 3 X: R (M is Sr, Ca, Ba). X is at least one selected from F, Cl, Br and I. R is any one of Eu, Mn, Eu and Mn. Etc.).
- the alkaline earth metal borate phosphor has M 2 B 5 O 9 X: R (M is at least one selected from Sr, Ca, Ba, Mg, Zn. X is F, Cl , Br, or I. R is Eu, Mn, or any one of Eu and Mn.).
- Alkaline earth metal aluminate phosphors include SrAl 2 O 4 : R, Sr 4 Al 14 O 25 : R, CaAl 2 O 4 : R, BaMg 2 Al 16 O 27 : R, BaMg 2 Al 16 O 12 : R, BaMgAl 10 O 17 : R (R is Eu, Mn, or any one of Eu and Mn).
- alkaline earth sulfide phosphor examples include La 2 O 2 S: Eu, Y 2 O 2 S: Eu, and Gd 2 O 2 S: Eu.
- rare earth aluminate phosphors mainly activated with lanthanoid elements such as Ce include Y 3 Al 5 O 12 : Ce, (Y 0.8 Gd 0.2 ) 3 Al 5 O 12 : Ce, Y 3
- Tb 3 Al 5 O 12 : Ce, Lu 3 Al 5 O 12 : Ce, etc. in which a part or all of Y is substituted with Tb, Lu or the like.
- phosphors include ZnS: Eu, Zn 2 GeO 4 : Mn, MGa 2 S 4 : Eu (M is at least one selected from Sr, Ca, Ba, Mg and Zn). is there.
- These phosphors can be used alone or in combination of two or more to achieve colors such as blue, green, yellow, and red, as well as their intermediate colors such as blue-green, yellow-green, and orange. it can.
- a Zener diode can be further provided as a protective element.
- the Zener diode can be placed on the lead on the inner bottom surface of the recess apart from the light emitting element. Further, the Zener diode may be mounted on the lead on the inner bottom surface of the recess, and the light emitting element may be mounted thereon. In addition to the 280 ⁇ m size, a ⁇ 300 ⁇ m size can also be used.
- FIG. 4 is a schematic cross-sectional view illustrating the method for manufacturing the light emitting device according to the first embodiment.
- FIG. 5 is a plan view showing the resin molded body according to the first embodiment.
- the manufacturing method of the light emitting device includes a step of sandwiching the lead frame 21 provided with the notch 21a between the upper mold 61 and the lower mold 62, and the upper mold 61 and the lower mold 62.
- the mold 60 composed of the upper mold 61 and the lower mold 62 used for the transfer mold will be described.
- the upper die 61 includes a flat plate main body portion that constitutes an upper portion of the upper die, an outer wall portion formed in a frame shape from an end portion of the main body portion, a plurality of protruding portions protruding from the main body portion, and an outer wall portion And an injection port penetrating a part in the horizontal direction.
- the outer wall portion protrudes perpendicularly from the end portion of the main body portion, and the first outer wall portion, the second outer surface, the third outer surface, and the fourth outer surface of the resin molded body are respectively molded.
- Two outer wall portions, a third outer wall portion, and a fourth outer wall portion are provided. That is, the outer wall portion is a portion for molding the outline of the resin molded body, and is formed in a rectangular shape in plan view. What is necessary is just to form the shape of an outer wall part suitably according to the shape of a desired resin molding.
- the protruding portion is a portion that comes into contact with the lead frame 21 during transfer molding. By preventing the thermosetting resin 23 from flowing into the contact portion, a part of the lead frame 21 is removed from the resin molded body 24. An exposed portion that is exposed can be formed.
- the protruding portion protrudes downward from the main body portion and is formed so as to be surrounded by the outer wall.
- the protruding portion is formed flat at a portion that contacts the lead frame 21.
- protrusions are formed in one direction and at equal intervals, and in each protrusion, protrusions are formed at 90 ° direction and at equal intervals from the one direction. Preferably it is formed.
- the injection port is for injecting the thermosetting resin 23, and is formed in the horizontal direction so as to penetrate the substantially lower end of the outer wall portion.
- the injection port has a semicircular cross section, and is formed so that the width becomes narrower from the inlet portion toward the outlet portion of the inlet.
- a pin insertion hole penetrating the main body is formed in the upper part of the upper mold 61.
- the pin insertion hole is a hole for inserting a pin when the resin molded body 24 is removed from the upper mold 61.
- the lower mold 62 is a plate material having a predetermined thickness and has a flat surface. The lower mold 62 molds the space portion by being brought into contact with the upper mold 61.
- the lead frame 21 is subjected to a metal plating process after providing the notch 21a.
- the lead frame 21 provided with the notch 21 a is sandwiched between the upper mold 61 and the lower mold 62.
- a space is provided in the mold 60 by being sandwiched between the upper mold 61 and the lower mold 62.
- the cutout portion 21a at the position where the concave portion 27 is formed is arranged so as to be sandwiched between the protruding portion of the upper mold 61 and the lower mold 62. Thereby, the fluttering of the lead frame 21 in the notch 21a is suppressed, and the generation of burrs can be reduced.
- thermosetting resin 23 containing the light-reflective material 26 is transferred and molded in a mold sandwiched between the upper mold 61 and the lower mold 62, and a resin molded body is formed on the lead frame 21.
- the thermosetting resin 23 containing the light-reflecting material 26 is injected from the injection port into the space provided in the mold 60 that forms the layer 24, and transfer molding is performed by applying a predetermined temperature and pressure. . Since the upper die 61 and the lower die 62 sandwich the lead frame 21 in the vicinity of the notch 21a, the lead frame 21 does not flutter when the thermosetting resin 23 is transferred and molded. Generation of burrs can be suppressed at the inner bottom surface 27a.
- ⁇ ⁇ Pins are inserted into the pin insertion portion, and the resin molded body 24 is removed from the upper mold 61. It is preferable that a predetermined temperature is applied in the mold 60 to perform temporary curing, and then the mold 60 is removed from the mold 60, and then the main curing is performed by applying a temperature higher than the temporary curing.
- the light emitting element 10 is placed on the lead frame 21 on the inner bottom surface 27 a of the recess 27 formed in the resin molded body 24, and is electrically connected to the lead frame 21 by the wire 50.
- the step of mounting the light emitting element 10 can be performed after the resin molded body 24 is removed from the mold 60, and the light emitting element 10 is mounted on the resin package 20 cut and separated into individual pieces. May be. Further, the light emitting element may be mounted face down without using a wire.
- the sealing member 30 containing the fluorescent material 40 is filled in the recess 27 and cured.
- the resin molded body 24 and the lead frame 21 are cut along the notch 21a.
- the resin molded body 24 in which the plurality of recesses 27 are formed is cut in the longitudinal direction and the lateral direction so that the side walls between the adjacent recesses 27 are separated at a substantially central position.
- dicing is performed from the resin molded body 24 side using a dicing saw.
- the resin molded body 24 and the lead frame 21 are substantially flush with the cut surface, and the lead frame 21 is exposed from the resin molded body 24.
- the cutout portion 21 a in this way, the lead frame 21 to be cut is reduced, and peeling between the lead frame 21 and the resin molded body 24 can be suppressed.
- FIG. 6 is a perspective view showing a light emitting device according to the second embodiment.
- FIG. 7 is a plan view showing a lead frame used in the second embodiment.
- FIG. 8 is a plan view showing a resin molded body according to the second embodiment. A description of the configuration almost the same as that of the light emitting device according to the first embodiment may be omitted.
- the light emitting element 10 is placed in a recess provided in the resin package 120.
- the outer upper surface 120c of the resin package 120 has a corner formed in an arc shape.
- the side surface of the lead 122 is formed in an arc shape when viewed from the upper surface, and the lead 122 is provided with a step so as to slightly protrude from the resin portion 125 when viewed from the upper surface.
- the upper surface and outer bottom surface 120a of the protruding lead 122 and the arc-shaped surface portion are plated.
- the outer surface 120b other than the arc shape of the lead 122 is not plated.
- the lead frame 121 is provided with a notch 121a and a hole 121b.
- the shape of the hole 121b is preferably a circular shape, but may be a polygonal shape such as a square shape or a hexagonal shape, an elliptical shape, or the like.
- the position of the hole 121b in the lead frame 121 is preferably on the extension line of the notch 121a and in the vicinity of a point where they intersect each other.
- the size of the hole 121b is not particularly limited, but a wide opening is preferable when the hole 121b is used as an electrode and increases the bonding strength with the conductive member.
- the adhesion area with the conductive member can be increased, and the bonding strength can be increased.
- a hole slightly larger than the shape of the hole 121b is provided so as to cover the vicinity of the hole 121b of the lead frame 121.
- the lead frame 121 provided with the notch 121a is sandwiched between the upper mold and the lower mold. At this time, the vicinity of the hole 121b is also sandwiched between the molds. Thereby, at the time of transfer molding, the thermosetting resin does not flow into the hole 121b, and it is not necessary to remove the thermosetting resin in the hole 121b.
- thermosetting resin containing a light reflecting material is transfer-molded to form a resin molded body 124 on the lead frame 121.
- the plating process is performed on the exposed portion of the lead frame 121 of the resin molded body 124. Plating is performed on the inner bottom surface of the recess, the outer bottom surface 120a of the resin package 120, the circular inner surface of the lead frame 121, and the upper surface extending therefrom.
- the resin molded body 124 and the lead frame 121 are cut along the notch 121a.
- the light emitting device according to the second embodiment can be provided through the above steps. Since the hole 121b is provided on the extension line of the notch 121a, when the dicing is performed using the dicing saw, the lead frame 121 to be cut can be reduced, so that the cutting time can be shortened. According to this manufacturing method, it is possible to provide a light emitting device having many portions plated on the lead frame 121 in a simple and short time.
- FIG. 9 is a perspective view showing a light emitting device according to the third embodiment.
- FIG. 10 is a plan view showing a lead frame used in the third embodiment. A description of the configuration almost the same as that of the light emitting device according to the first embodiment may be omitted.
- the light reflectance at a wavelength of 350 nm to 800 nm after thermosetting is 70% or more, and the resin portion 225 and the lead 222 are formed on substantially the same surface on the outer surface 220b.
- the light emitting device has the resin package 220.
- the lead 222 is plated on the bottom surface and the top surface, and the outer surface has a portion that is not plated.
- the lead 222 has a predetermined thickness, and a step is provided near the outer surface of the resin package 220. Plating is applied to the side of the step that is deepened by one step and the bottom that slightly protrudes outward.
- the bonding area increases, and the bonding strength with a conductive member such as solder can be improved.
- the thickness of the lead 222 at the portion to be cut using a dicing saw can be reduced, the cutting time can be shortened. Further, since dicing is performed from the outer top surface side of the resin package 220 using a dicing saw, burrs extending in the direction of the outer bottom surface are likely to occur on the cut surfaces of the leads 222.
- the light emitting device may be tilted by the burr when mounting the light emitting device, but by providing a step on the lead cut surface, the burr is The light emitting device does not tilt due to burrs.
- the step is composed of a first surface exposed at the outer bottom surface 220a of the resin package 220, a second surface formed substantially perpendicular to the upper direction from the outer bottom surface 220a, and a second surface.
- a third surface formed substantially perpendicularly to the outer surface direction of the resin package 220 from the surface, and a fourth surface exposed on the outer surface of the resin package 220.
- the first surface, the second surface, and the third surface are plated, but the fourth surface is not plated.
- the second and third surfaces can be a single curved surface. By making the second surface and the third surface curved, the solder easily spreads in the stepped portion.
- the resin package 220 has a substantially square shape on the outer upper surface 220 c and is covered with the resin portion 225.
- a substantially frustoconical concave portion is provided on the outer upper surface 220 c side of the resin package 220.
- the lead frame 221 is provided with a substantially straight groove 221c on the side corresponding to the outer bottom surface side of the light emitting device.
- the depth of the groove 221c is preferably about half of the thickness of the lead frame 221, but may be about 1/4 to 4/5.
- the width of the groove 221c is variously changed depending on the distance to the adjacent recesses, the size of the light emitting device, and the like. However, when the center of the groove is cut, it can be recognized that there is a step in the light emitting device. I just need it.
- the lead frame 221 provided with the notch 221a is sandwiched between the upper mold and the lower mold.
- the notch portion 221a is sandwiched between the upper die and the lower die so as not to flutter during transfer molding.
- thermosetting resin containing a light reflecting material is transfer-molded to form a resin molded body on the lead frame 221.
- ⁇ Plating is performed on the exposed portion of the lead frame 221 of the resin molded body. Plating is performed on the inner bottom surface of the recess, the outer bottom surface 220a of the lead frame 221, and the groove 221c.
- the plating treatment of the groove 221c corresponds to the first surface, the second surface, and the third surface of the step in the light emitting device.
- the light emitting device according to the third embodiment can be provided. According to this manufacturing method, it is possible to provide a light emitting device having many portions plated on the lead frame 121 in a simple and short time.
- FIG. 11 is a perspective view showing a light emitting device according to the fourth embodiment. A description of the configuration almost the same as that of the light emitting device according to the first embodiment may be omitted.
- the lead 322 on the outer side surface 320b of the resin package 320 has a step that is partially recessed from the outer side surface 320b.
- the step includes a first surface provided on the outer bottom surface 320 a of the resin package 320, a second surface formed substantially perpendicular to the upper direction from the outer bottom surface 320 a, and a second surface.
- a third surface formed substantially perpendicular to the outer surface direction of the resin package 320 from the surface and a fourth surface of the outer surface of the resin package 320.
- the outer upper surface 320 c of the resin package 320 is formed in a substantially rectangular shape including the resin portion 325.
- the outer bottom surface 320a, the first surface, the second surface provided with a step, the third surface, and the inner bottom surface of the recess are plated.
- the outer surface 320b not provided with a step is not subjected to plating.
- the lead 322 uses an etched lead frame. On the cut surface of the resin molded body, the etched lead 322 has irregularities. This unevenness improves the adhesion between the resin part and the lead.
- FIG. 12 is a perspective view showing a light emitting device according to the fifth embodiment. A description of the configuration almost the same as that of the light emitting device according to the first embodiment may be omitted.
- a part of the lead 422 on the outer side surface 420b of the resin package 420 has a step that is recessed from the outer side surface 420b.
- the step is formed by a first surface provided on the outer bottom surface 420a of the resin package 420, a second surface formed substantially perpendicular to the upper direction from the outer bottom surface 420a, and a second surface.
- a third surface formed substantially perpendicular to the outer surface direction of the resin package 420 from the surface, and a fourth surface of the outer surface of the resin package 420.
- the outer surface 420b of the resin package 420 has six leads 422 separated. Each of the leads 422 may be separated or connected.
- the lead 422 is preferably provided with a notch portion rather than a flat plate shape because the bonding strength between the resin portion 425 and the lead 422 becomes higher.
- An outer upper surface 420 c of the resin package 420 is formed in a substantially rectangular shape including the resin portion 425.
- the outer bottom surface 420a, the first surface, the second surface provided with a step, the third surface, and the inner bottom surface of the recess are plated.
- the outer side surface 420b not provided with a step is not plated.
- FIG. 13 is a perspective view showing a resin package according to the sixth embodiment.
- the description of the resin package according to the first embodiment and the resin package according to the fifth embodiment may be omitted as it adopts substantially the same configuration.
- the resin package according to the sixth embodiment has a step with a recessed corner at the lead 522 on the outer surface 520b of the resin package 520.
- This step has an arc shape when viewed from the outer bottom surface 520a side in the lead 522 exposed from the resin package 520.
- This arc shape is a circle divided into four parts. This arc shape is obtained by performing an etching process up to about half of the thickness so as not to penetrate the lead 522, and then dividing into four parts.
- the arc-shaped portion is plated.
- the plating process on the arc-shaped portion and the plating process on the outer bottom surface 520a are performed before being divided into four.
- the outer side surface 520b that is not provided with a step is not plated.
- the resin package 520 has a substantially square shape when viewed from the outer upper surface 520c, and the resin portion 525 is exposed.
- the bonding area with the conductive member can be increased, and the bonding strength can be increased. Further, even when burrs are generated at the stepped portion when the resin molded body is cut, it is above the outer bottom surface 520a and therefore does not wobble at the time of joining with the conductive member. Furthermore, since the lead frame is provided with a recess, it is easy to cut, and the time required for cutting can be shortened.
- FIG. 1 is a perspective view showing the light emitting device according to the first embodiment.
- FIG. 2 is a cross-sectional view showing the light emitting device according to the first embodiment. 2 is a cross-sectional view taken along the line II-II shown in FIG.
- FIG. 3 is a plan view showing the lead frame used in the first embodiment.
- the light emitting device 100 includes the light emitting element 10 and a resin package 20 in which a resin portion 25 containing a light reflecting material 26 and a lead 22 are integrally formed.
- the light-emitting element 10 is a nitride semiconductor light-emitting element that has a light emission peak wavelength at 450 nm and emits blue light.
- the resin package 20 has a substantially rectangular parallelepiped shape with a mortar-shaped recess 27.
- the size of the resin package 20 is 35 mm in length, 35 mm in width, and 0.8 mm in height.
- the approximate diameter of the recess 27 on the outer upper surface 20 c side is 2.9 mm, the approximate diameter of the inner bottom surface 27 a is 2.6 mm, and the depth is 0.6 mm.
- the thickness of the lead 22 is 0.2 mm. Titanium oxide is used for the light reflecting material 26. An epoxy resin that is a thermosetting resin is used for the resin portion 25. Titanium oxide is contained in the epoxy resin by about 20% by weight.
- the resin package 20 has a light reflectance of 81% at a wavelength of 450 nm after thermosetting.
- the resin portion 25 and the lead 22 are formed on substantially the same surface on the outer surface 20 b of the resin package 20.
- the leads 22 are exposed from the four corners of the resin package 20.
- the lead 22 is plated on the outer bottom surface 20 a of the resin package 20 and the inner bottom surface 27 a of the recess 27. On the other hand, the lead 22 is not plated on the outer surface 20 b of the resin package 20.
- the recess 27 is filled with a sealing member 30 containing a fluorescent material 40 that emits yellow light.
- a fluorescent material 40 that emits yellow light.
- (Y, Gd) 3 (Al, Ga) 5 O 12 : Ce is used as the fluorescent material 40.
- a silicone resin is used as the sealing member 30.
- This light emitting device is manufactured as follows.
- the lead frame is provided with a notch 21a by etching. Although not shown, the cutout portion 21a has an uneven surface. Ag is attached to the lead frame by electrolytic plating. A lead frame 21 provided with a notch 21a and plated is used.
- the lead frame 21 having a predetermined size is sandwiched between the upper mold 61 and the lower mold 62.
- the lead frame 21 has a flat plate shape, and is provided with a notch 21a corresponding to the size of the light emitting device to be separated.
- the notches 21a are provided vertically and horizontally so that the four corners are exposed when the resin package 20 is divided into pieces, and the other corners are not exposed.
- the notch 21 a is provided in the lateral direction so as to be electrically insulated when separated into the resin package 20, and the notch 21 a is formed by the upper mold 61 and the lower mold 62. Is sandwiched.
- thermosetting resin 23 containing the light-reflective material 26 is transfer-molded in the mold 60 sandwiched between the upper mold 61 and the lower mold 62 to form the resin molded body 24 on the lead frame 21.
- the thermosetting resin 23 containing the light reflecting material 26 is formed into a pellet, and heat and pressure are applied and poured into the mold 60. At this time, the notch 21a is also filled with the thermosetting resin 23.
- the upper mold 61 is removed, and further heat is applied to perform the main curing.
- a resin molded body 24 in which the lead frame 21 and the thermosetting resin 23 are integrally molded is manufactured.
- the light emitting element 10 is mounted on the lead 22 on the inner bottom surface 27a of the recess 27 using a die bond member. After placing the light emitting element 10, the light emitting element 10 and the lead 22 are electrically connected using the wire 50. Next, the sealing member 30 containing the fluorescent material 40 is filled into the recess 27.
- the resin molded body 24 and the lead frame 21 are cut along the cutout portions 21 a and separated into individual light emitting devices 100. As a result, the lead 22 is not plated at the cut portion.
- the present invention can be used for lighting fixtures, displays, mobile phone backlights, moving picture illumination auxiliary light sources, and other general consumer light sources.
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Abstract
Description
弧状に形成されている部分は、メッキ処理が施されており、切断面にはメッキ処理が施されていない構成を採ることもできる。これにより半田等との接合面積が拡がり、接合強度を向上することができる。
(発光装置)
第1の実施の形態に係る発光装置を説明する。図1は、第1の実施の形態に係る発光装置を示す斜視図である。図2は、第1の実施の形態に係る発光装置を示す断面図である。
図2は図1に示すII-IIの断面図である。図3は、第1の実施の形態に用いられるリードフレームを示す平面図である。
(発光素子)
発光素子は、基板上にGaAlN、ZnS、SnSe、SiC、GaP、GaAlAs、AlN、InN、AlInGaP、InGaN、GaN、AlInGaN等の半導体を発光層として形成したものが好適に用いられるが、これに特に限定されない。発光ピーク波長が360nm~520nmにあるものが好ましいが、350nm~800nmのものも使用することができる。特に、発光素子10は420nm~480nmの可視光の短波長領域に発光ピーク波長を有するものが好ましい。
(樹脂パッケージ)
樹脂パッケージは、熱硬化性樹脂からなる樹脂部とリードとを有し、一体成形している。樹脂パッケージは、350nm~800nmにおける光反射率が70%以上であるが、420nm~520nmの光反射率が80%以上であることが特に好ましい。また、発光素子の発光領域と蛍光物質の発光領域とにおいて高い反射率を有していることが好ましい。
(樹脂部、樹脂成形体)
樹脂部及び樹脂成形体の材質は熱硬化性樹脂であるトリアジン誘導体エポキシ樹脂を用いることが好ましい。また、熱硬化性樹脂は、酸無水物、酸化防止剤、離型材、光反射部材、無機充填材、硬化触媒、光安定剤、滑剤を含有できる。光反射部材は二酸化チタンを用い、10~60wt%充填されている。
に硬化反応させBステージ化した固形状エポキシ樹脂組成物を使用することができる。
(リード、リードフレーム)
リードフレームは平板状の金属板を用いることができるが、段差や凹凸を設けた金属板も用いることができる。
(封止部材)
封止部材の材質は熱硬化性樹脂である。熱硬化性樹脂のうち、エポキシ樹脂、変性エポキシ樹脂、シリコーン樹脂、変性シリコーン樹脂、アクリレート樹脂、ウレタン樹脂からなる群から選択される少なくとも1種により形成することが好ましく、特にエポキシ樹脂、変性エポキシ樹脂、シリコーン樹脂、変性シリコーン樹脂が好ましい。封止部材は、発光素子を保護するため硬質のものが好ましい。また、封止部材は、耐熱性、耐候性、耐光性に優れた樹脂を用いることが好ましい。封止部材は、所定の機能を持たせるため、フィラー、拡散剤、顔料、蛍光物質、反射性物質からなる群から選択される少なくとも1種を混合することもできる。封止部材中には拡散剤を含有させても良い。具体的な拡散剤としては、チタン酸バリウム、酸化チタン、酸化アルミニウム、酸化珪素等を好適に用いることができる。また、所望外の波長をカットする目的で有機や無機の着色染料や着色顔料を含有させることができる。さらに、封止部材は、発光素子からの光を吸収し、波長変換する蛍光物質を含有させることもできる。
(蛍光物質)
蛍光物質は、発光素子からの光を吸収し異なる波長の光に波長変換するものであればよい。例えば、Eu、Ce等のランタノイド系元素で主に賦活される窒化物系蛍光体・酸窒化物系蛍光体・サイアロン系蛍光体、Eu等のランタノイド系、Mn等の遷移金属系の元素により主に付活されるアルカリ土類ハロゲンアパタイト蛍光体、アルカリ土類金属ホウ酸ハロゲン蛍光体、アルカリ土類金属アルミン酸塩蛍光体、アルカリ土類ケイ酸塩、アルカリ土類硫化物、アルカリ土類チオガレート、アルカリ土類窒化ケイ素、ゲルマン酸塩、又は、Ce等のランタノイド系元素で主に付活される希土類アルミン酸塩、希土類ケイ酸塩又はEu等のランタノイド系元素で主に賦活される有機及び有機錯体等から選ばれる少なくともいずれか1以上であることが好ましい。具体例として、下記の蛍光体を使用することができるが、これに限定されない。
発光装置には、さらに保護素子としてツェナーダイオードを設けることもできる。ツェナーダイオードは、発光素子と離れて凹部の内底面のリードに載置することができる。また、ツェナーダイオードは、凹部の内底面のリードに載置され、その上に発光素子を載置する構成を採ることもできる。□280μmサイズの他、□300μmサイズ等も使用することができる。
(第1の実施の形態に係る発光装置の製造方法)
第1の実施の形態に係る発光装置の製造方法について説明する。図4は、第1の実施の形態に係る発光装置の製造方法を示す概略断面図である。図5は、第1の実施の形態に係る樹脂成形体を示す平面図である。
金型60内に設けられた空間に、注入口から光反射性物質26が含有される熱硬化性樹脂23を注入して、所定の温度と圧力とを加えてトランスファ・モールドする。上金型61と下金型62とで切り欠き部21a付近のリードフレーム21を挟み込んでいるため、熱硬化性樹脂23をトランスファ・モールドする際に、リードフレーム21がバタつかず、凹部27の内底面27aにおいてバリの発生を抑制できる。
また、ワイヤを用いず発光素子をフェイスダウンして実装してもよい。発光素子10をリードフレーム21に実装した後、蛍光物質40を含有した封止部材30を凹部27内に充填し硬化する。
複数の凹部27が形成された樹脂成形体24は、隣接する凹部27の間にある側壁を略中央で分離されるように長手方向及び短手方向に切断する。切断方法はダイシングソーを用いて樹脂成形体24側からダイシングする。これにより切断面は樹脂成形体24とリードフレーム21とが略同一面となっており、リードフレーム21が樹脂成形体24から露出している。このように切り欠き部21aを設けることにより、切断されるリードフレーム21は少なくなりリードフレーム21と樹脂成形体24との剥離を抑制することができる。また、リードフレーム21の上面だけでなく、切り欠き部21aに相当する側面も樹脂成形体24と密着するため、リードフレーム21と樹脂成形体24との密着強度が向上する。
<第2の実施の形態>
第2の実施の形態に係る発光装置について説明する。図6は、第2の実施の形態に係る発光装置を示す斜視図である。図7は、第2の実施の形態に用いられるリードフレームを示す平面図である。図8は、第2の実施の形態に係る樹脂成形体を示す平面図である。第1の実施の形態に係る発光装置とほぼ同様の構成を採るところは説明を省略することもある。
(第2の実施の形態に係る発光装置の製造方法)
第2の実施の形態に係る発光装置の製造方法において、リードフレーム121には切り欠き部121a及び孔部121bを設ける。この孔部121bの形状は円形状であることが好ましいが、四角形状、六角形状などの多角形状や楕円形状などを採ることができる。
リードフレーム121における孔部121bの位置は切り欠き部121aの延長線上であって、互いに交差する点付近に設けることが好ましい。孔部121bの大きさは特に問わないが、電極として用い導電性部材との接合強度を高める場合、広口の方が好ましい。また、導電性部材との密着面積を拡げ、接合強度を高めることができる。
第3の実施の形態に係る発光装置について説明する。図9は、第3の実施の形態に係る発光装置を示す斜視図である。図10は、第3の実施の形態に用いられるリードフレームを示す平面図である。第1の実施の形態に係る発光装置とほぼ同様の構成を採るところは説明を省略することもある。
(第3の実施の形態に係る発光装置の製造方法)
第3の実施の形態に係る発光装置の製造方法において、リードフレーム221には発光装置の外底面側に相当する側に略直線上の溝221cを設ける。この溝221cの深さはリードフレーム221の厚みの半分程度であることが好ましいが、1/4~4/5程度の深さでもよい。この溝221cの幅は、隣り合う凹部までの距離、発光装置の大きさ等により、種々変更されるが、その溝の中心を切断した場合に発光装置に段差があると認識できる程度のものであればよい。
第4の実施の形態に係る発光装置について説明する。図11は、第4の実施の形態に係る発光装置を示す斜視図である。第1の実施の形態に係る発光装置とほぼ同様の構成を採るところは説明を省略することもある。
<第5の実施の形態>
第5の実施の形態に係る発光装置について説明する。図12は、第5の実施の形態に係る発光装置を示す斜視図である。第1の実施の形態に係る発光装置とほぼ同様の構成を採るところは説明を省略することもある。
一方、段差を設けていない外側面420bは、メッキ処理を施していない。
<第6の実施の形態>
第6の実施の形態に係る樹脂パッケージについて説明する。図13は、第6の実施の形態に係る樹脂パッケージを示す斜視図である。第1の実施の形態に係る樹脂パッケージ、第5の実施の形態に係る樹脂パッケージとほぼ同様の構成を採るところは説明を省略することもある。
封止部材30としてシリコーン樹脂を使用する。
20、120、220、320、420、520 樹脂パッケージ
20a、120a、220a、320a、420a、520a 外底面
20b、120b、220b、320b、420b、520b 外側面
20c、120c、220c、320c、420c、520c 外上面
21、121、221 リードフレーム
21a、121a、221a 切り欠き部
121b 孔部
221c 溝
22、122、222、322、422、522 リード
23 熱硬化性樹脂
24 樹脂成形体
25、125、225、325、425、525 樹脂部
26 光反射性物質
27 凹部
27a 内底面
27b 内側面
30 封止部材
40 蛍光物質
50 ワイヤ
60 金型
61 上金型
62 下金型
70 ダイシングソー
100 発光装置
Claims (15)
- 熱硬化後の、波長350nm~800nmにおける光反射率が70%以上であり、外側面において樹脂部とリードとが略同一面に形成されている樹脂パッケージを有する発光装置の製造方法であって、
切り欠き部を設けたリードフレームを上金型と下金型とで挟み込む工程と、
上金型と下金型とで挟み込まれた金型内に、光反射性物質が含有される熱硬化性樹脂をトランスファ・モールドして、リードフレームに樹脂成形体を形成する工程と、
切り欠き部に沿って樹脂成形体とリードフレームとを切断する工程と、
を有する発光装置の製造方法。 - 上金型と下金型とで挟み込む前に、リードフレームにメッキ処理を施す請求項1に記載の発光装置の製造方法。
- リードフレームは、切断部分における切り欠き部が全包囲周の約1/2以上である請求項1又は2のいずれかに記載の発光装置の製造方法。
- 上金型と下金型とで挟み込まれる前のリードフレームは、孔部が設けられている請求項1乃至3のいずれか一項に記載の発光装置の製造方法。
- 上金型と下金型とで挟み込まれる前のリードフレームは、溝が設けられている請求項1乃至4のいずれか一項に記載の発光装置の製造方法。
- 上金型と下金型とは、発光素子が載置される部分、若しくは、孔部の近傍の部分のリードフレームを挟み込んでいる請求項1乃至5のいずれか一項に記載の発光装置の製造方法。
- 熱硬化後の、波長350nm~800nmにおける光反射率が70%以上であり、外側面において樹脂部とリードとが略同一面に形成されている樹脂パッケージを有する発光装置であって、
リードは底面及び上面の少なくともいずれか一面にメッキ処理が施されており、かつ、外側面はメッキ処理が施されていない部分を有する発光装置。 - 樹脂パッケージは、四隅からリードが露出されている請求項7に記載の発光装置。
- 樹脂パッケージは、底面側から視認して四隅が弧状に形成されている請求項7又は8のいずれかに記載の発光装置。
- リードは、外側面及び外底面より凹んだ段差が設けられている請求項7乃至9のいずれか一項に記載の発光装置。
- 熱硬化後の、波長350nm~800nmにおける光反射率が70%以上であり、外側面において樹脂部とリードとが略同一面に形成されている樹脂パッケージの製造方法であって、
切り欠き部を設けたリードフレームを上金型と下金型とで挟み込む工程と、
上金型と下金型とで挟み込まれた金型内に、光反射性物質が含有される熱硬化性樹脂をトランスファ・モールドして、リードフレームに樹脂成形体を形成する工程と、
切り欠き部に沿って樹脂成形体とリードフレームとを切断する工程と、
を有する樹脂パッケージの製造方法。 - 上金型と下金型とで挟み込む前に、リードフレームにメッキ処理を施す請求項11に記載の樹脂パッケージの製造方法。
- 熱硬化後の、波長350nm~800nmにおける光反射率が70%以上であり、外側面において樹脂部とリードとが略同一面に形成されている樹脂パッケージであって、
リードは底面及び上面の少なくともいずれか一面にメッキ処理が施されており、かつ、外側面はメッキ処理が施されていない樹脂パッケージ。 - 熱硬化後の、波長350nm~800nmにおける光反射率が70%以上であり、凹部が複数形成され、該凹部の内底面は、リードフレームの一部が露出されている、樹脂成形体の製造方法であって、
切り欠き部を設けたリードフレームを用い、樹脂成形体において隣り合う凹部が成形される位置に凸部を有する上金型と下金型とでリードフレームを挟み込む工程と、
上金型と下金型とで挟み込まれた金型内に、光反射性物質が含有される熱硬化性樹脂をトランスファ・モールドして、切り欠き部に熱硬化性樹脂を充填させ、かつ、リードフレームに樹脂成形体を形成する工程と、
を有する樹脂成形体の製造方法。 - 熱硬化後の、波長350nm~800nmにおける光反射率が70%以上であり、凹部が複数形成され、該凹部の内底面は、リードフレームの一部が露出されている、樹脂成形体であって、
リードフレームは切り欠き部を有しており、該切り欠き部に樹脂成形体となる熱硬化性樹脂が充填されており、隣り合う凹部の間に側壁を有している樹脂成形体。
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