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KR101495580B1 - Leadframe, wiring board, light emitting unit, and illuminating apparatus - Google Patents
Leadframe, wiring board, light emitting unit, and illuminating apparatus Download PDF
light emitting
요지 우라노
료지 요코타니
잇코 구즈하라
겐이치로 다나카
파나소닉 주식회사
2010-04-26 Priority to JP2010101182 priority Critical
2010-04-26 Priority to JPJP-P-2010-101182 priority
2010-05-31 Priority to JP2010125097A priority patent/JP2011249737A/en
2011-03-29 Priority to JP2011072773A priority patent/JP5011442B1/en
2011-04-26 Application filed by 파나소닉 주식회사 filed Critical 파나소닉 주식회사
2011-04-26 Priority to PCT/JP2011/060193 priority patent/WO2011136236A1/en
H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
H05K1/00—Printed circuits
H05K1/02—Details
H05K1/0201—Thermal arrangements, e.g. for cooling, heating or preventing overheating
H05K1/0203—Cooling of mounted components
F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21—LIGHTING
F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
F21K9/20—Light sources comprising attachment means
F21K9/27—Retrofit light sources for lighting devices with two fittings for each light source, e.g. for substitution of fluorescent tubes
F21K9/90—Methods of manufacture
F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
F21V19/00—Fastening of light sources or lamp holders
F21V19/001—Fastening of light sources or lamp holders the light sources being semiconductors devices, e.g. LEDs
F21V19/003—Fastening of light source holders, e.g. of circuit boards or substrates holding light sources
F21V19/004—Fastening of light source holders, e.g. of circuit boards or substrates holding light sources by deformation of parts or snap action mountings, e.g. using clips
H01L24/93—Batch processes
H01L24/95—Batch processes at chip-level, i.e. with connecting carried out on a plurality of singulated devices, i.e. on diced chips
H01L24/97—Batch processes at chip-level, i.e. with connecting carried out on a plurality of singulated devices, i.e. on diced chips the devices being connected to a common substrate, e.g. interposer, said common substrate being separable into individual assemblies after connecting
H05K1/18—Printed circuits structurally associated with non-printed electric components
H05K1/181—Printed circuits structurally associated with non-printed electric components associated with surface mounted components
F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
F21V29/50—Cooling arrangements
F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
F21V29/74—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades
F21V29/76—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades with essentially identical parallel planar fins or blades, e.g. with comb-like cross-section
F21V29/767—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades with essentially identical parallel planar fins or blades, e.g. with comb-like cross-section the planes containing the fins or blades having directions perpendicular to the light emitting axis
F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
F21Y2103/00—Elongate light sources, e.g. fluorescent tubes
F21Y2103/10—Elongate light sources, e.g. fluorescent tubes comprising a linear array of point-like light-generating elements
F21Y2105/00—Planar light sources
F21Y2105/10—Planar light sources comprising a two-dimensional array of point-like light-generating elements
F21Y2107/00—Light sources with three-dimensionally disposed light-generating elements
F21Y2107/90—Light sources with three-dimensionally disposed light-generating elements on two opposite sides of supports or substrates
F21Y2115/00—Light-generating elements of semiconductor light sources
F21Y2115/10—Light-emitting diodes [LED]
H01L2224/44—Structure, shape, material or disposition of the wire connectors prior to the connecting process
H01L2224/45—Structure, shape, material or disposition of the wire connectors prior to the connecting process of an individual wire connector
H01L2224/451—Material with a principal constituent of the material being a metal or a metalloid, e.g. boron (B), silicon (Si), germanium (Ge), arsenic (As), antimony (Sb), tellurium (Te) and polonium (Po), and alloys thereof
H01L2224/45117—Material with a principal constituent of the material being a metal or a metalloid, e.g. boron (B), silicon (Si), germanium (Ge), arsenic (As), antimony (Sb), tellurium (Te) and polonium (Po), and alloys thereof the principal constituent melting at a temperature of greater than or equal to 400°C and less than 950°C
H01L2224/45124—Aluminium (Al) as principal constituent
H01L2224/45138—Material with a principal constituent of the material being a metal or a metalloid, e.g. boron (B), silicon (Si), germanium (Ge), arsenic (As), antimony (Sb), tellurium (Te) and polonium (Po), and alloys thereof the principal constituent melting at a temperature of greater than or equal to 950°C and less than 1550°C
H01L2224/45139—Silver (Ag) as principal constituent
H01L2224/45144—Gold (Au) as principal constituent
H01L2224/48225—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 non-metallic, e.g. insulating substrate with or without metallisation
H01L2224/48227—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 non-metallic, e.g. insulating substrate with or without metallisation connecting the wire to a bond pad of the item
H01L2224/48228—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 non-metallic, e.g. insulating substrate with or without metallisation connecting the wire to a bond pad of the item the bond pad being disposed in a recess of the surface of the item
H01L2224/49113—Disposition the connectors being bonded to at least one common bonding area, e.g. daisy chain the connectors connecting different bonding areas on the semiconductor or solid-state body to a common bonding area outside the body, e.g. converging wires
H01L2224/4912—Layout
H01L2224/49171—Fan-out arrangements
H01L2224/73—Means for bonding being of different types provided for in two or more of groups H01L2224/10, H01L2224/18, H01L2224/26, H01L2224/34, H01L2224/42, H01L2224/50, H01L2224/63, H01L2224/71
H01L2224/732—Location after the connecting process
H01L2224/73251—Location after the connecting process on different surfaces
H01L2224/73265—Layer and wire connectors
H01L24/44—Structure, shape, material or disposition of the wire connectors prior to the connecting process
H01L24/45—Structure, shape, material or disposition of the wire connectors prior to the connecting process of an individual wire connector
H01L25/03—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L51/00, e.g. assemblies of rectifier diodes
H01L25/04—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L51/00, e.g. assemblies of rectifier diodes the devices not having separate containers
H01L25/075—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L51/00, e.g. assemblies of rectifier diodes the devices not having separate containers the devices being of a type provided for in group H01L33/00
H01L25/0753—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L51/00, e.g. assemblies of rectifier diodes the devices not having separate containers the devices being of a type provided for in group H01L33/00 the devices being arranged next to each other
H01L2924/00011—Not relevant to the scope of the group, the symbol of which is combined with the symbol of this group
H01L2924/12—Passive devices, e.g. 2 terminal devices
H01L2924/1203—Rectifying Diode
H01L2924/12035—Zener diode
H01L2924/1204—Optical Diode
H01L2924/12041—LED
H01L2924/12042—LASER
H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
H01L33/48—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
H01L33/486—Containers adapted for surface mounting
H01L33/62—Arrangements for conducting electric current to or from the semiconductor body, e.g. lead-frames, wire-bonds or solder balls
H05K1/0271—Arrangements for reducing stress or warp in rigid printed circuit boards, e.g. caused by loads, vibrations or differences in thermal expansion
H05K1/03—Use of materials for the substrate
H05K1/05—Insulated conductive substrates, e.g. insulated metal substrate
H05K1/056—Insulated conductive substrates, e.g. insulated metal substrate the metal substrate being covered by an organic insulating layer
H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
H05K2201/10007—Types of components
H05K2201/10106—Light emitting diode [LED]
H05K3/00—Apparatus or processes for manufacturing printed circuits
H05K3/10—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
H05K3/20—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern by affixing prefabricated conductor pattern
H05K3/202—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern by affixing prefabricated conductor pattern using self-supporting metal foil pattern
Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Y02P70/60—Greenhouse gas [GHG] capture, heat recovery or other energy efficient measures relating to production or assembly of electric or electronic components or products, e.g. motor control
Y02P70/611—Greenhouse gas [GHG] capture, heat recovery or other energy efficient measures relating to production or assembly of electric or electronic components or products, e.g. motor control the product being a printed circuit board [PCB]
Y10S362/00—Illumination
Y10S362/80—Light emitting diode
The lead frame is characterized in that the wiring pattern supported on the inner side of the outer frame portion of one pitch via the supporting piece includes a die pad for mounting the solid light emitting element, a heat sink extending from the die pad to surround the die pad, And a plurality of unit units including a lead electrically connected to the other electrode of the solid light emitting element electrically connected to the heat sink, wherein the leads of one unit unit and the units of the other unit The unit's heat sink is connected and electrically connected in series. A lead frame, a wiring board, and a light emitting element, which can suppress the rise of the temperature of the solid light emitting element and achieve a high output of light output and can achieve a low cost of a light emitting unit using a plurality of solid light emitting elements connected in series, Unit, and a lighting device.
BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a lead frame, a lead frame, a light emitting unit,
The present invention relates to a lead frame, a wiring board, a light emitting unit, and a lighting apparatus.
Background Art [0002] A lead frame used for manufacturing a light emitting device using an LED chip has been proposed (for example, Japanese Patent Laid-Open Publication No. 2006-93470: Patent Document 1).
60, a heat sink 160, an LED chip 161 mounted on the heat sink 160, an LED chip 161, and a heat sink 160 are mounted on the heat sink 160. In this heat sink 160, A pair of lead portions 330 electrically connected through the bonding wires 164a and 164b and the heat sink 100 and the respective lead portions 330 are integrally held and the LED chip 161 is connected to the front surface side And a light emitting device (not shown) having a attachment lens 560 mounted on the front surface side of the resin package 400 so as to cover the light emitting part 550 with a light-transmissive resin part 550 interposed therebetween 100).
In addition, Patent Document 1 describes the structure shown in Fig. 61 as the lead frame 300 used for manufacturing the light emitting device 100 of Fig. The lead frame 300 includes a pair of elongated parallel frame portions 310 formed parallel to each other and a parallel frame portion 310 disposed at equal intervals in the longitudinal direction of the parallel frame portions 310 310), a pair of connecting frame portions (320) extending in a direction close to each other at a central portion of the adjacent connecting frame portions (320) and adapted to face each other with a predetermined distance And a support frame portion 340 extending from the pair of parallel frame portions 310 toward the ends of the respective lead portions 330 are integrally formed.
As shown in Figs. 62A and 62B, a light source device 101, a power source device 102 for supplying operating power to the light source device 101, and a mechanism body (Japanese Patent Application Laid-Open No. 2007-35890: Patent Document 2).
The light source device 101 includes a light source block BK and a case 106 for housing the light source block BK. 63, the light source block BK includes a long printed substrate 110 on which a wiring pattern 111 is formed on one surface side (front surface side) and a wiring pattern 111 on the printed substrate 110 And a plurality of light emitting diodes 4A to 4L which are surface-mounted by reflow soldering.
The light emitting diodes 4A to 4L are so-called high-brightness white light emitting diodes of a so-called face shape and have a front surface having an emission surface 40 (see FIG. 64A) (Not shown) and a cathode terminal (not shown) are exposed. In Patent Document 2, the light emitting diodes 4A to 4L are arranged at substantially equal intervals in the longitudinal direction of the printed board 110, as shown in Fig. 64A, and a pseudo line light source Quot; is used as "
The printed board 110 is a single-sided mounted board formed in a long rectangular plate shape as shown in Figs. 63A and 63B. The printed board 110 is provided with a wiring pattern 111 on the left end side, 107a to 107c (refer to A in Fig. 62). Screw holes 110b in which fixing screws S1 (see Fig. 62) for fixing the printed board 110 to the instrument main body 103 are mounted are formed at both ends and a central portion in the longitudinal direction of the printed board 110, .
Examples of the material of the printed substrate 110 include glass-fiber-based copper-clad laminate such as paper-base copper-clad laminate such as base material epoxy resin copper-clad laminate, epoxy resin copper clad laminate based on glass fabric, nonwoven fabric-based epoxy resin-coated laminate, and the like.
A wiring pattern 111 to which the light emitting diodes 4A to 4L and the like are connected is formed on the front surface side of the printed board 110 as shown in Fig.
The wiring pattern 111 is formed using a conductive material such as a copper foil. In this printed board 110, the series circuit of the light emitting diodes 4A to 4F and the series circuit of the light emitting diodes 4G to 4L are connected in parallel in the forward direction.
On the surface side of the printed substrate 110 is formed a solder resist 111 for exposing only a part necessary for connection with the light emitting diodes 4A to 4L and the like in the wiring pattern 111, resist 112 (see FIG. 64A) is formed.
On the other hand, on the other surface side (back side) of the printed board 110, a bending prevention portion 113 is formed. The bending prevention portion 113 is formed in substantially the same shape as the wiring pattern 111 by using a copper foil, as shown in Fig. That is, the bending prevention portion 113 is a rough wiring pattern having substantially the same shape as the wiring pattern 111. [
The light emitting diodes 4A to 4L are surface mounted on the printed board 110, but this is performed by reflow soldering. The thermal expansion coefficient of the wiring pattern 111 is smaller than the thermal expansion coefficient of the printed board 110 when the printed board 110 is passed through a reflow furnace, The thermal expansion of the front surface side of the printed substrate 110 is suppressed, and a force for bending the surface of the printed substrate 110 is generated. However, since the above-described printed board 110 has the bending preventing portion 113 having substantially the same shape as the wiring pattern 111 on the back side, the thermal expansion of the bending preventing portion 113 and the printed board 110 Due to the difference in coefficient, thermal expansion is suppressed on the back side of the printed substrate 110, and a force to warp the back side of the printed substrate 110 is generated. As a result, the warp caused by the difference in thermal expansion coefficient between the wiring pattern 111 and the printed board 110 and the warpage preventing portion (the front surface and the rear surface) 113 and the printed board 110 are offset from each other and the warpage of the printed board 110 is reduced. Even if the temperature of the printed board 110 drops after passing through the reflow furnace, the temperature of the printed board 110 tends to bend due to a temperature change. However, the warpage of the printed board 110 is reduced for the same reason as described above.
The case 106, in which the light source block BK is housed, is made of a transparent synthetic resin such as acrylic resin and is formed into a long box-like shape with an opened bottom surface. And support pieces 106a and 106a for supporting the printed board 110 housed in the case 106 are integrally protruded.
A sealing material made of a resin having translucency such as silicone resin is used in order to shine the case 106 as a whole and to improve the heat radiation property and the waterproof property of the light source block BK in the case 106 of the light source device 101 P are charged and heated and cured.
In Patent Document 2, as shown in Fig. 64B, the ink for silk printing is applied to the front surface (entire surface) of the back surface side of the printed substrate 110 by the silk printing (silk screen printing) as the antireflection portion 113 Is coated on the surface of the substrate. Patent Document 2 discloses an example in which a metal material having the same material as the wiring pattern 111 or a thermal expansion coefficient substantially equal to that of the wiring pattern 111 is used as the bending prevention portion 113, It may be used that it is formed so as to cover the entire surface. In this case, it is stated that heat dissipation properties of the heat generating components such as the light emitting diodes 4A to 4L mounted on the printed board 110 can be improved.
Description of the Related Art [0002] Conventionally, a light source device having the configuration shown in Fig. 65 has been proposed as a surface light source using a visible light emitting diode chip (visible light LED chip) (Japanese Patent Application Laid-Open No. 11-162233: Patent Document 3).
65 includes a first visible light LED chip 103, a first transparent substrate 161 on which the first visible light LED chip 103 is mounted, and a second visible light LED chip 103 on the first transparent substrate 161 And a first transparent electrode (171) provided to feed the first visible light LED chip (103). The light source device includes a second visible light LED chip 104 and a second transparent substrate 162 opposed to the mounting surface side of the first transparent substrate 161 and on which the second visible light LED chip 104 is mounted And a second transparent electrode 172 provided on the second transparent substrate 162 to supply power to the second visible light LED chip 104.
65, the light from the first visible light LED chip 103 can be drawn out to the outside through the second transparent electrode 172 and the second transparent substrate 162, The light from the visible light LED chip 104 can be drawn out to the outside through the first transparent electrode 171 and the first transparent substrate 161.
66, an illumination device 600 having an LED light source 603 built therein has been proposed (Japanese Patent Application Laid-Open No. 2009-266432: Patent Document 4).
The light emitting unit main body 602 of this lighting apparatus 600 is constructed by integrally connecting and fixing a pair of mounting substrates 604 and 604 and mounting substrates 604 and 604, And a spacer 611 for forming a spacer 610. The light emitting unit main body 602 is made up of plastic wiring boards 608 and 608 for the LED luminous body 603 attached to the surface of the mounting boards 604 and 604 and mounted integrally on the mounting boards 604 and 604 605 which are mounted on the front surface side of the light-shielding cover 605. [ The mounting substrate 604 is a long thin strip plate, and an extruded shape member made of aluminum is used. 66 and 67, the wiring board 608 is provided with a plurality of LED luminous bodies 603 at predetermined intervals.
However, when the light emitting device 100 having the configuration shown in Fig. 60 is used for applications requiring relatively large light output such as general illumination, desired light output can not be obtained with one light emitting device 100. [
Thus, it is considered that a plurality of light emitting devices 100 are mounted on one wiring board to constitute, for example, a series-connected LED unit (light emitting unit). In this case, it is considered to use a metal base printed wiring board as the wiring board in order to suppress the temperature rise of the LED chip 161 in the light emitting device 100 and achieve high output of light output. In manufacturing such an LED unit, a pair of lead portions 330 of each light emitting device 100 may be soldered to a wiring pattern formed of a copper foil pattern of a metal base printed wiring board of the wiring board.
However, in this LED unit, it is necessary to mount the heat sink 160 for each light emitting device 100, and a metal base printed wiring board is required. Further, each of the light emitting devices 100 is placed on the metal base printed wiring board It is necessary to mount them together, and the cost increases.
In the light emitting unit such as the above-described light source block BK, it is possible to reduce warping of the printed substrate 110. [ However, in the light emitting unit such as the above-described light source block BK, the heat generated in the light emitting diodes 4A to 4L is dissipated through the printed substrate 110, so that the heat generated by the individual light emitting diodes 4A to 4L There is a possibility that the temperature rise of the light emitting diodes 4A to 4L can not be sufficiently suppressed when the light output of the entire light source block BK is made high by the increase of the light output or the like. Therefore, in the above-described light source block BK, there is a possibility that the increase of the light output is restricted.
65, it is considered that the heat generated in the first visible light LED chip 103 mainly dissipates through the first transparent electrode 171 and the first transparent substrate 161, and the second visible light ray It is considered that the heat generated in the LED chip 104 mainly dissipates through the second transparent electrode 172 and the second transparent substrate 162. Therefore, in this light source device, for example, when the light output of the entire light source device is made high by increasing the light output of the first visible light LED chip 103 and the second visible light LED chip 104 The temperature rise of the first visible light LED chip 103 and the second visible light LED chip 104 may not be sufficiently suppressed. Therefore, in the light source device having the configuration of Fig. 65, there is a possibility that the increase of the light output is restricted.
In the light emitting unit main body 602 and the lighting apparatus 600 of the configuration shown in FIG. 66, it is considered that the heat generated in the LED light emitting unit 603 is dissipated mainly through the wiring substrate 608 and the mounting substrate 604 do. Therefore, in the light emitting unit main body 602 and the lighting apparatus 600, the light output of the entire light emitting unit main body 602 and the entire lighting apparatus 600 can be increased by the increase of the light output of the LED light emitting unit 603 There is a possibility that the temperature rise of the LED light emitting unit 603 can not be sufficiently suppressed. Therefore, in the above-described light emitting unit main body 602 and the lighting apparatus 600, there is a possibility that the increase of the light output is restricted.
SUMMARY OF THE INVENTION The present invention has been made in view of the above-described circumstances, and an object of the present invention is to provide a lead frame, a wiring board, a light guide plate, and a light guide plate, And to provide a light emitting unit and a lighting apparatus capable of achieving high output of output.
A lead frame of the present invention is a lead frame formed by using a metal plate and having a desired wiring pattern supported on the inner side of one pitch outer frame portion via a supporting piece. The wiring pattern includes a die pad a die pad, a heat sink extending from the die pad to surround the die pad, and a lead electrically connected to the other electrode of the solid light emitting element in which one electrode is electrically connected to the heat sink Wherein the plurality of unit units include a plurality of unit units and the leads of one unit unit and the heat sinks of the other unit unit of the unit units adjacent to each other are connected and electrically connected in series.
In this lead frame, it is preferable that the lead is disposed inside the cut groove formed toward the die pad from the outer circumference edge of the heat sink.
In this lead frame, it is preferable that the plurality of unit units are arranged along the longitudinal direction of the outer frame portion.
In this lead frame, the wiring pattern includes wiring arranged on the side of the heat sink across the plurality of unit units, and the wiring is connected to the lead of the one unit unit in the longitudinal direction of the outer frame part And are electrically connected to each other.
In this lead frame, the wiring pattern includes wirings arranged on the side of the heat sink across the plurality of unit units, and the wirings are connected to the ends of the one unit unit in the longitudinal direction of the outer frame portion And is electrically connected to the lead.
In this lead frame, it is preferable that the wiring pattern includes a wiring disposed on a side of the heat sink across the plurality of unit units.
In this lead frame, it is preferable that the plurality of unit units are disposed so as to surround the center of the region surrounded by the outer frame portion.
A wiring board of the present invention comprises a module having a wiring pattern formed by using a first metal plate and capable of series connection of a plurality of solid state light emitting elements arranged on the main surface side, a second metal plate arranged on the back side of the module, And an insulating layer interposed between the module and the second metal plate to thermally couple the wiring pattern and the second metal plate to each other with insulation and thermal conductivity, wherein the wiring pattern comprises a die pad for mounting the solid light emitting element, A plurality of unit units including a heat sink extending from the die pad to surround the die pad and a lead electrically connected to the other electrode of the solid light emitting element having one electrode electrically connected to the heat sink, , Wherein the lead of one of the unit units adjacent to each other and the unit of the other unit And the heat sink is electrically connected in series, wherein the module includes a holding portion made of an insulating material for holding the die pad, the heat sink and the lead for each unit unit.
In this wiring board, it is preferable that the module has a concavo-convex structure portion provided on the side edge of the wiring pattern for improving the adhesion with the holding portion.
In the wiring board, it is preferable that a first plating layer is formed on the back surface of the wiring pattern, the first plating layer being made of a metal material having higher oxidation resistance and corrosion resistance than the first metal plate and improving adhesion to the insulating layer.
In this wiring board, it is preferable that a second plating layer made of a metal material having higher oxidation resistance and corrosion resistance than the first metal sheet is formed on a main surface of a portion electrically connected to the die pad and the solid light emitting element Do.
In this wiring board, it is preferable that the material of the first metal plate is Cu and the second plating layer is composed of a laminated film of a Ni film, a Pd film, and an Au film.
And a connecting piece for connecting the lead of one of the unit units and the heat sink of the other unit unit of the unit unit adjacent to each other in the wiring board, wherein a space is provided between the connecting piece and the insulating layer The connecting piece preferably includes a stress relieving portion bent to relax a stress acting on the wiring pattern due to a difference in coefficient of linear expansion between the first metal plate and the second metal plate.
In the light emitting unit of the present invention, the solid light emitting element is mounted on each of the die pads of the wiring board, the solid light emitting element is provided with one electrode on one side in the thickness direction and the other electrode on the other side, Wherein the one electrode is electrically connected to the heat sink through the die pad and the other electrode is electrically connected to the lead via a wire.
In the light emitting unit of the present invention, the solid light emitting element is mounted on each of the die pads of the wiring board, and the solid light emitting element is provided with the one electrode and the other electrode on one side in the thickness direction, One electrode is electrically connected to the heat sink through a first wire, and the other electrode is electrically connected to the lead via a second wire.
In this light emitting unit, a dome-shaped optical member for accommodating the solid light emitting element between the wiring board and the optical member for controlling the light distribution of the light emitted from the solid light emitting element for each unit unit, And a sealing member made of a first translucent material filled in a space surrounded by the member and the wiring board to seal the solid light emitting element, and a sealing member that is excited by the light emitted from the solid light emitting element and transmitted through the sealing member and the optical member, And a dome-shaped color conversion member formed by a second translucent material and surrounding the optical member, wherein the holding portion of the wiring board includes a light emitting element for emitting light of a color different from that of the light emitting element, Wherein the optical member is fixed to the wiring board on the outer side of the member, Wherein the weir portion extends inward from the inner circumferential surface of the weir portion and has a plurality of claws (nails) for centering the center of the weir portion and the central axis of the optical member, Is provided to be spaced apart in the circumferential direction, and also serves as a positioning portion of the color conversion member.
The present application also includes an invention of a light emitting unit capable of improving heat dissipation and capable of achieving high output of light output. In this case, the light emitting unit includes a mounting substrate, and a plurality of solid light emitting elements arranged on one side of the mounting substrate, wherein the mounting substrate is formed by a first metal plate, A wiring pattern formed by the second metal plate and disposed on the other surface side of the heat transfer plate and electrically connected to the solid light emitting device, and an insulating layer interposed between the heat transfer plate and the wiring pattern do.
In this light emitting unit, it is preferable that the insulating layer contains a filler having a higher thermal conductivity than the thermosetting resin in the thermosetting resin.
In this light emitting unit, it is preferable that the solid light emitting element is an LED chip.
In this light emitting unit, the first metal plate is an aluminum plate, and an aluminum film of higher purity than the aluminum plate is laminated on the side of the aluminum plate opposite to the side of the insulating layer, and the refractive index It is preferable that a retroreflective film (an increase reflective film) composed of two different kinds of dielectric films are laminated.
And a color conversion unit including a phosphor and a translucent material which is excited by the light emitted from the LED chip and emits light of a color different from the color of light emitted from the LED chip in the light emitting unit, As shown in Fig.
In this light emitting unit, each of the LED chips is provided with a first electrode and a second electrode on one side in the thickness direction, and each of the first electrode and the second electrode is electrically connected to the wiring pattern through a wire And the heat transfer plate is preferably formed with a through-hole for allowing the wires to pass therethrough.
Wherein the heat transfer plate has an elongated shape and the solid light emitting elements are arranged along the longitudinal direction of the heat transfer plate, the difference in coefficient of linear thermal expansion between the second metal plate and the first metal plate is small, And a long base substrate disposed on the side opposite to the heat transfer plate side.
In this light emitting unit, it is preferable that the base substrate is made of a resin substrate in which a resin is mixed with a filler having a thermal conductivity higher than that of the resin.
In this light emitting unit, the base substrate is made of a third metal plate made of the same material as that of the first metal plate, and between the base substrate and the wiring pattern, a material made of the same material as the first insulating layer It is preferable that two insulating layers are interposed.
The present application also includes an invention of an illumination device capable of improving heat dissipation and capable of achieving high output of light output. In this case, the illumination device is characterized by including the light-emitting unit.
The present application also includes an invention of a light emitting unit and a lighting device capable of improving heat dissipation and capable of achieving high output of light output. In this case, the light emitting unit may include a pair of heat transfer plates formed by the first metal plate and spaced apart in the thickness direction, a solid light emitting element mounted on one surface of the heat transfer plates opposite to each other, A wiring pattern formed by a second metal plate and electrically connected to the respective solid light emitting elements disposed between the both heat transfer plates, and a pair of insulating layers interposed between the respective heat transfer plates and the wiring patterns .
In this light emitting unit, the first metal plate is an aluminum plate, and an aluminum film of higher purity than the aluminum plate is laminated on the side of the aluminum plate opposite to the side of the insulating layer, and the refractive index It is preferable that a retroreflective film made of two different dielectric films is laminated.
Further, the illumination device is characterized by including the light-emitting unit.
1B is a schematic plan view of a main part of a lead frame in the first embodiment, and FIG. 1C is a cross-sectional view of a lead frame according to the first embodiment. FIG. 1A is a schematic perspective view of one pitch of the lead frame in the first embodiment, 1 is a schematic plan view of a unit unit of a frame.
Fig. 2 is a schematic plan view showing an example of mounting an LED chip on a lead frame in Embodiment 1. Fig.
3 is a schematic plan view showing an example of mounting an LED chip on a lead frame in the first embodiment.
4 is a schematic perspective view of a metal plate used for manufacturing the lead frame in Example 1. Fig.
Fig. 5A is a schematic perspective view of the wiring board in the first embodiment, and Fig. 5B is a schematic plan view of a main part of the wiring board in the first embodiment.
6 is a schematic cross-sectional view showing an example of mounting an LED chip and a zener diode on the wiring board in the first embodiment.
Fig. 7A is a schematic perspective view of a part of the LED unit according to the first embodiment disassembled and broken, and Fig. 7B is a schematic plan view of the main part.
8 is a schematic sectional view of the LED unit in Embodiment 1. Fig.
9 is a schematic cross-sectional view of another example of the LED unit in the first embodiment.
FIG. 10A is a schematic perspective view for explaining the manufacturing method of the LED unit in Embodiment 1, and FIG. 10B is a schematic plan view for explaining the manufacturing method of the LED unit in Embodiment 1. FIG.
11A is a schematic perspective view for explaining the manufacturing method of the LED unit in the first embodiment, and FIG. 11B is a schematic plan view for explaining the manufacturing method of the LED unit in the first embodiment.
12A is a schematic perspective view for explaining the manufacturing method of the LED unit in the first embodiment, and FIG. 12B is a schematic plan view of a main part for explaining the manufacturing method of the LED unit in the first embodiment.
13 is a schematic plan view showing an example of mounting an LED chip on a lead frame in the first embodiment.
FIG. 14A is a schematic plan view of a main part showing another structural example of the wiring board in the first embodiment, and FIG. 14B is a schematic sectional view of a main part showing another structural example of the wiring board in the first embodiment.
15 is a schematic plan view showing an example of mounting the LED chip in another configuration example of the wiring board in the first embodiment.
16 is a schematic perspective view showing still another structural example of the wiring board according to the first embodiment.
FIG. 17A is a schematic perspective view showing another configuration example of the wiring board in the first embodiment, and FIG. 17B is a perspective view of a main part showing another configuration example of the wiring board in the first embodiment.
FIG. 18A is a schematic perspective view of two pitches of the lead frame in the second embodiment, and FIG. 18B is a schematic plan view of a main part of the lead frame in the second embodiment.
FIG. 19A is a schematic perspective view for explaining the manufacturing method of the LED unit in the second embodiment, and FIG. 19B is a schematic plan view for explaining the manufacturing method of the LED unit in the second embodiment.
20A is a schematic perspective view for explaining the manufacturing method of the LED unit in the second embodiment, and FIG. 20B is a schematic plan view for explaining the manufacturing method of the LED unit in the second embodiment.
21 is a schematic perspective view for explaining the manufacturing method of the LED unit in the second embodiment.
25A is a schematic perspective view of the main part of the light emitting unit of the third embodiment, and FIG. 25B is a partially broken perspective view of the light emitting unit of the third embodiment.
26 is a partially cutaway perspective view of the light emitting unit of the third embodiment.
27 is a schematic sectional view of a main part of the light emitting unit of the third embodiment.
28 is a schematic perspective view of a mounting substrate in the light emitting unit of the third embodiment.
29 is a schematic exploded perspective view of a mounting substrate in the light emitting unit of the third embodiment.
30 is a perspective view of a main part of a mounting substrate in the light emitting unit of the third embodiment.
31 is an explanatory diagram of a manufacturing method of a mounting substrate in the light emitting unit according to the third embodiment.
32 is an explanatory diagram of a manufacturing method of a mounting substrate in the light emitting unit of the third embodiment.
33 is a schematic sectional view of a main part of another example of the structure of the light emitting unit of the third embodiment.
34 is a schematic sectional view of a main part of another configuration example of the light emitting unit of the third embodiment.
36 is a partially cutaway perspective view of the illumination device of the third embodiment.
37 is a schematic perspective view of the light emitting unit of the fourth embodiment.
38 is a schematic exploded perspective view of the mounting substrate in the light emitting unit of the fourth embodiment.
39 is a schematic exploded perspective view of the light emitting unit of the fifth embodiment.
40 is a schematic perspective view of a main part of the illumination device of the fifth embodiment.
41 is a schematic exploded perspective view of a main part of a lighting apparatus according to a fifth embodiment.
42 is an explanatory view of a main part of a lighting apparatus according to the fifth embodiment.
Fig. 43 is a schematic sectional view of the main parts of another configuration example of the light-emitting units of Examples 3 to 5. Fig.
44 is a schematic perspective view of a main part of another configuration example of the light-emitting units of Examples 3 to 5. Fig.
45 is a schematic perspective view of the light emitting unit of the sixth embodiment.
46A is a schematic perspective view of a main part of a double-side light-emitting unit according to Embodiment 7, and FIG. 46B is a partially broken-away main part perspective view of a double-side light-
47 is a schematic perspective view of a double-side light-emitting unit of Embodiment 7. Fig.
48 is a schematic exploded perspective view of the mounting substrate in the double-sided light emitting unit according to the seventh embodiment.
49 is a schematic cross-sectional view of the double-side light-emitting unit of Embodiment 7. Fig.
50 is a perspective view of a main part of a mounting substrate in the double-sided light emitting unit according to the seventh embodiment.
51 is an explanatory diagram of a manufacturing method of a mounting substrate in the double-sided light emitting unit according to the seventh embodiment.
52 is an explanatory diagram of a manufacturing method of a mounting board in the double-sided light emitting unit according to the seventh embodiment.
53 is a schematic cross-sectional view of another example of the configuration of the double-side light-emitting unit of Embodiment 7. Fig.
54 is a schematic cross-sectional view of still another example of the configuration of the double-side light-emitting unit of Embodiment 7. Fig.
56 is a partially cut-away main part perspective view of still another example of the configuration of the double-side light-emitting unit of Embodiment 7. Fig.
57 is a schematic perspective view of the lighting apparatus of the seventh embodiment.
58 is a schematic perspective view of the double-sided light emitting unit of the eighth embodiment.
59 is a schematic exploded perspective view of the illumination device of the eighth embodiment.
60 is a schematic sectional view showing a conventional light emitting device.
61 is a schematic plan view of a lead frame used for manufacturing the above light emitting device.
62A is a cross-sectional view of a part of a conventional lighting device, and FIG. 62B is a top view of a part of a conventional lighting device.
63A is a front view of a printed board used in a conventional lighting apparatus, and FIG. 63B is a back view of a printed board used in a conventional lighting apparatus.
64A is a front view of a printed board on which a light emitting diode is mounted, and FIG. 64B is a rear view of a printed board showing another example.
65 is a schematic configuration diagram of a conventional light source device.
66 is a sectional view of a main part of a conventional illumination device.
67 is a plan view showing a part of a mounting substrate in a conventional light emitting unit main body.
First, a lead frame will be described with reference to Figs. 1 to 3. Fig.
The lead frame 230 in the present embodiment is a lead frame 230 in which a desired pattern 233 is supported via a support piece 232 on the inside of the outer frame portion 231 of one pitch. The lead frame 230 is formed by using a strip-shaped metal plate 203 (see Fig. 4). The outer frame portion 231 is formed in a rectangular frame-like shape, and has an elongated rectangular outer shape . Although the strip-shaped metal plate 203 shown in Fig. 4 is shown only at a portion corresponding to one pitch of the lead frame 230, this strip-shaped metal plate 203 is constituted by a part of the metal hoop material You can. In the present embodiment, the pattern 233 constitutes a wiring pattern.
The pattern 233 of the lead frame 230 includes a die pad 234 for mounting the LED chip 210 (see FIGS. 2 and 3) having a pair of electrodes, And the other electrode of the LED chip 210 electrically connected to the heat sink 235 is electrically connected to the other electrode of the pair of electrodes. A plurality of unit units 233a (only the unit units 233a are shown in FIG. 1C and hatching) provided with the plurality of unit units 233a and 236a The leads 236 of the unit units 233a and 233a are connected to the heat sink 235 of the other unit unit 233a and are electrically connected in series. In this embodiment, the LED chip 210 constitutes a solid light emitting element.
Here, the leads 236 of the unit unit 233a and the heat sink 235 of the unit unit 233a of the other unit are connected to each other through a connection piece 237 having a larger width than the leads 236.
In the case where a pair of electrodes are formed on one surface of the LED chip 210 in the thickness direction for each unit unit 233a of the lead frame 230, for example, as shown in Fig. 2 , One electrode of the LED chip 210 is electrically connected to the heat sink 235 through the bonding wire 214 and the other electrode of the LED chip 210 is connected to the lead 236 As shown in Fig. In the case of such an LED chip 210, one electrode is electrically connected to the die pad 234 through the first bump, and the other electrode is connected to the lead 236 through the second bump Type flip chip mounting is also possible. In this embodiment, the bonding wire 214 constitutes a wire.
3, when one of the electrodes of the LED chip 210 is mounted on the die pad 234, for example, as shown in Fig. 3, And the other electrode of the LED chip 210 may be electrically connected to the lead 236 through the bonding wire 214. [ In the lead frame 230 in this embodiment, the number of unit units 233a per pitch is eight, but the number is not particularly limited and may be a plurality.
In the lead frame 230 described above, a plurality of unit units 233a are arranged along the longitudinal direction of the outer frame portion 231 (the left-right direction of B in Fig. 1). The pattern 233 of the lead frame 230 is provided with a linear wiring 238 disposed on the side of the heat sink 235 across the plurality of unit units 233a. The wiring 238 is connected to a unit unit 233a (the unit at the left end of Fig. 1 (A) in Fig. 1) in the longitudinal direction of the outer frame portion 231 Unit 233a), and are electrically connected to each other. Therefore, in a state in which the pattern 233 in which one LED chip 210 is mounted is separated from the outer frame portion 231 for each unit unit 233a, the unit 233a at the other end in the arrangement direction of the plurality of unit units 233a Power can be supplied to the series circuit of all the LED chips 210 by supplying power between the heat sink 235 and the wiring 238 of the unit 233a (unit unit 233a at the right end of A in Fig.
The above-described lead 236 is disposed inside the cutting groove 235a formed toward the die pad 234 from the outer peripheral edge of the heat sink 235. [ In the lead frame 230 shown in Fig. 1, two leads 236 are provided for each unit unit 233a, and two cut grooves 235a are formed in the heat sink 235 in the direction in which the two cut grooves 235a approach each other, And is formed by shifting the position of the center line. One of the leads 236 of the two leads 236 is formed in a straight line and is disposed inside the one cut groove 235a. The other lead 236 is connected to a first linear portion disposed in the other of the cut grooves 235a and an end portion of the first portion opposite to the die pad 234, 237 and a second portion disposed along the outer edge of the heat sink 235.
As the material of the metal plate 203 (see Fig. 4) serving as a base of the lead frame 230, copper is preferable as the material having a relatively high thermal conductivity among the metal materials (the copper thermal conductivity is about 398 W / mK) For example, phosphor bronze or the like. The material of the metal plate 203 may be a copper alloy (for example, 42 alloy or the like). The thickness of the metal plate 203 is preferably set to a range of, for example, about 100 m to 1500 m. Since the distance between the inner circumferential surface of the cutting groove 235a and the outer edge of the lead 236 becomes longer by increasing the thickness of the metal plate 203, the upper limit of the thickness of the metal plate 203 is preferably about 1500 占 퐉. The unit 233a may be provided with the lead 236 on the outer side of the heat sink 235 without providing the cut groove 235a in the heat sink 235. [ In this case, however, the distance between the LED chip 210 and the lead 236 becomes long, so that the entire length of the bonding wire 214 becomes long. For example, as shown in FIG. 1, the heat sink 235 has a cut groove 235a It is preferable to arrange the lead 236 so as to be intertwined with the inside of the cut groove 235a.
5 and 6, a wiring board 240 manufactured using the above-described lead frame 230 will be described with reference to the LED unit 250 manufactured using the wiring board 240, 7 and Fig. 6 is a schematic cross-sectional view of the LED chip 210 and a Zener diode (ZD) to be described later mounted on the wiring board 240. FIG.
The wiring board 240 includes a module 241 having a pattern 233 formed by using the lead frame 230 and capable of series connection of a plurality of LED chips 210 arranged on the main surface side. That is, the wiring board 240 has the pattern 233 of the lead frame 230 formed by using the metal plate 203 (hereinafter referred to as the first metal plate 203) shown in FIG.
The pattern 233 of the wiring board 240 has a plurality of unit units 233a including the above-described die pad 234, the heat sink 235, and the leads 236, The leads 236 of the unit unit 233a and the heat sink 235 of the unit unit 233a of the other unit are connected and electrically connected in series. The module 241 of the wiring board 240 includes a holding portion 244 made of an insulating material which surrounds and holds the die pad 234, the heat sink 235 and the lid 236 for each unit unit 233a Respectively. The holding portion 244 is formed so as to cover the surface of the pattern 233 except the die pad 234 and a part of each of the lead 236, the heat sink 235 and the wiring 238, The surface of the pattern 233 may be entirely exposed as shown in Fig. 6, at least the rear surface of the pattern 233 and the mounting portions of the electronic parts (the LED chip 210, the zener diode ZD, the connector CN described later, and the like) As shown in FIG.
The holding portion 244 described above is formed by injection molding. As the insulating material of the holding portion 244, a material having a small difference in coefficient of linear expansion with respect to the first metal plate 203 is preferable, and a liquid crystal polymer is used, but the present invention is not limited thereto. For example, a polyamide- Other resin materials such as resin, and ceramics such as alumina may be employed. As the insulating material of the holding portion 244, a white material having a high reflectivity with respect to light emitted from the LED chip 210 is preferable.
The wiring board 240 includes the second metal plate 242 disposed on the back side of the module 241 and the insulation between the module 241 and the second metal plate 242 in addition to the above- Layer 243 as shown in FIG. Here, the insulating layer 243 has electrical insulation and thermal conductivity, and has a function of thermally coupling the pattern 233 and the second metal plate 242. The second metal plate 242 functions as a heat radiating plate (heat transfer plate). As the material of the second metal plate 242, a metal material having high heat conductivity such as copper or aluminum is preferably employed. The thickness of the second metal plate 242 may be set within a range of, for example, about 0.5 mm to 10 mm. The thermal conductivity of aluminum is about 237 W / m · K.
The above-described insulating layer 243 is formed of a B-stage epoxy resin layer containing a filler composed of a filler such as silica or alumina and having a property of low viscosity (low viscosity) at the time of heating and high fluidity, Is formed by thermally curing an epoxy resin layer of a thermosetting sheet-like adhesive (for example, an adhesive sheet TSA manufactured by Toray Co., Ltd.) in which a film (PET film) is laminated. Here, the epoxy resin layer of the sheet-like adhesive has electrical insulating properties, high thermal conductivity, high fluidity at the time of heating, and high adhesiveness to uneven surfaces. Therefore, it is possible to prevent the occurrence of voids between the insulating layer 243 and the pattern 233 and the second metal plate 242, thereby improving the reliability of the adhesion and, at the same time, Generation can be suppressed. Therefore, compared with the case where a rubber sheet type heat radiation sheet such as Sakon (registered trademark) is sandwiched between the pattern 233 and the second metal plate 242, the distance from each LED chip 210 to the second metal plate 242 The heat resistance of the LED chip 210 can be reduced and the heat resistance can be reduced, so that heat dissipation is improved and temperature rise of the junction temperature of each LED chip 210 can be suppressed, So that high output power of the optical output can be achieved. The thickness of the above-described epoxy resin layer is set to 100 占 퐉, but this value is an example and is not particularly limited. For example, it may be suitably set within a range of about 50 占 퐉 to 150 占 퐉. The thermal conductivity of the epoxy resin layer described above is preferably 4 W / m · K or more. The plastic film of the sheet-like adhesive is peeled off from the epoxy resin layer before the module 241 and the second metal plate 242 are overlapped. That is, after one surface of the epoxy resin layer opposite to the plastic film side is fixed to the object, the plastic film is peeled off.
Here, when the insulating layer 243 is formed, the second metal plate 242, the epoxy resin layer, and the module 241 may be appropriately pressed in a superposed state. Depending on the size of the heat capacity of the second metal plate 242, if the heating temperature of the epoxy resin layer is raised to about 170 ° C and hardened, the fixing performance between the module 241 and the second metal plate 242 is lowered, When the temperature is lowered to about 150 ° C, the electric insulation between the module 241 and the second metal plate 242 may be lowered. That is, the fixing performance and the electric insulation have a trade-off relationship. Thus, if the second metal plate 242 can not satisfy both the fixing performance and the electrical insulation due to the large heat capacity, for example, the epoxy resin layers of the two sheet-type adhesives are superimposed, The resin layer may be cured at 170 占 폚 to ensure electrical insulation and thermal conductivity and the other epoxy resin layer may be cured at 150 占 폚 to secure adhesion and thermal conductivity. Further, after one epoxy resin layer is fixed to one surface of the second metal plate 242 as an object at 170 ° C, the other epoxy resin layer and the module 241 are overlapped with each other to form the other epoxy resin layer May be cured at 150 占 폚.
The outer size determining the outer shape of each of the insulating layer 243 and the second metal plate 242 coincides with the outer size of the outer frame portion 231 of the lead frame 230,
The wiring board 240 is provided on the back surface of the pattern 233 with a first plating layer having a high adhesion to the insulating layer 243 made of a metal material having higher oxidation resistance and corrosion resistance than the first metal plate 203 (Not shown). Here, when the material of the first metal plate 203 is Cu, for example, Ni or the like may be employed as the material of the first plating layer. Since the first plating layer is formed on the back surface of the pattern 233, the wiring board 240 can suppress oxidation and corrosion of the pattern 233 and can fix the pattern 233 to the insulating layer 243 Deterioration of the performance can be suppressed. As a result, it is possible to suppress the change of the thermal resistance between the die pad 234 and the heat sink 235 and the second metal plate 242 over time.
The module 241 is provided with an uneven structure portion 239 (see FIG. 6) for improving the adhesion with the holding portion 244 at the side edge of the pattern 233. That is, in the lead frame 230 described above, the uneven structure portion 239 is formed at the edge of the pattern 233 at the time of manufacturing. The concavoconvex structure portion 239 is formed by providing a step for thinning the thickness of at least one of both surfaces of the lead frame 230 in the thickness direction. As such a method of forming the concavoconvex structure portion 239, for example, a pressing method, an etching method, or the like may be suitably employed. In any case, the lead frame 230 is formed by patterning the first metal plate 203 by press working, etching, or the like.
The module 241 described above can improve the adhesion between the pattern 233 and the holding portion 244 by providing the uneven structure portion 239 on the side edge of the pattern 233. [ Therefore, when the module 241 is cut from the lead frame 230, it is possible to prevent the holding portion 244 from peeling off or falling off from the pattern 233. [ The circuit board 240 has a concavoconvex structure 239 at the side edge of the pattern 233 so that the surface of the circuit board 240 between the LED chip 210 mounted on the die pad 234 and the second metal plate 242 The distance (creeping distance) can be lengthened.
The wiring board 240 is electrically connected to the die pad 234 and the LED chip 210 in the pattern 233 at a portion of the lead 236, ), A region where the zener diode (ZD) can be mounted, a region where a power supply connector CN to be described later can be mounted, and the main surface of each of the first and second metal plates 203, A second plating layer 247 (see FIG. 10B) made of a high metal material is formed. Therefore, adhesion between the LED chip 210, the Zener diode ZD, and the connector CN due to the oxidation of the pattern 233 may be deteriorated due to oxidation of the pattern 233, The deterioration of the fixing performance of the diode ZD and the connector CN can be suppressed. If the material of the first metal plate 203 is Cu and the second plating layer 247 is composed of a Ni film and a laminated film of a Pd film and an Au film, A part of the light emitted from the second plating layer 247 can be reflected by the second plating layer 247 and the light extraction efficiency can be improved.
The wiring board 240 is formed of a Ni film formed simultaneously with the Ni film as the lowermost layer of the second plating layer 247 on the portion of the main surface side of the pattern 233 where the second plating layer 247 is not formed A third plating layer (not shown) is formed.
Although the second metal plate 242 is formed in a long plate shape, a plurality of pins may be provided on the side opposite to the module 241 side. The pins in this case may be formed along the longitudinal direction of the second metal plate 242 and arranged at the same pitch in the width direction of the second metal plate 242, for example.
In the LED unit 250, the LED chip 210 is mounted on each of the die pads 234 of the wiring board 240 described above. The LED chip 210 is provided with a pair of electrodes 211 and 212 (see FIG. 6) on one side in the thickness direction. One of the electrodes 211 is connected to the lead 236 through the bonding wire 214 And the other electrode 212 is electrically connected to the heat sink 235 through the bonding wire 214. [ In this case, one of the electrodes is electrically connected to the heat sink 235 through the die pad 234 and the other electrode is electrically connected to the heat sink 235. In this case, So that the electrode is electrically connected to the lead 236 through the bonding wire (see FIG. 3).
In order to prevent an overvoltage from being applied to the LED chip 210, a surface mount type Zener diode ZD for preventing overvoltage is connected to the heat sink 235 and a bonding wire (Not shown) of the lead frame 214. Therefore, the Zener diode ZD is electrically connected to the heat sink 235 and the lead 236. [ The Zener diode ZD is formed by electrically connecting a pair of external connection electrodes of the Zener diode ZD to the second plating layer 247 of each of the heat sink 235 and the lead 236 by soldering or the like Respectively.
The LED unit 250 includes an optical member 260 for controlling the light distribution of the light emitted from the LED chip 210 for each unit unit 233a of the pattern 233. [ The optical member 260 is formed in a dome shape by a translucent material and fixed to the main surface side of the wiring board 240 in such a manner as to house the LED chip 210 between the optical member 260 and the wiring board 240.
A sealing portion 255 made of a first translucent material sealing a bonding wire 214 electrically connected to the LED chip 210 and the LED chip 210 is formed in a space surrounded by the optical member 260 and the wiring board 240, . Here, it is preferable that the sealing portion 255 is made of, for example, a gel resin by employing a silicone resin as the first light transmitting material.
The LED unit 250 is excited by the light emitted from the LED chip 210 and transmitted through the sealing part 255 and the optical member 260 to emit light of a color different from that of the LED chip 210 And a dome-shaped color conversion member 270 formed of a fluorescent material emitting light and a second translucent material. Here, the color conversion member 270 is provided so as to surround the LED chip 210 and the like between the main surface side of the wiring board 240 and the wiring board 240. The color conversion member 270 is provided so that an air layer 280 is formed between the light exit surfaces 260b of the optical member 260 on the one surface side of the wiring board 240. [ The holding portion 244 of the wiring board 240 is formed on the outer surface of the optical member 260 on the one surface so as to have an annular shape covering the first translucent material when the optical member 260 is fixed to the wiring board 240 A weir portion 245 of the second guide plate 24 is protruded.
The weir portion 245 has a plurality of (four in this embodiment) claw portions 242 extending inward from the inner circumferential surface of the weir portion 245 and centering the center of the weir portion 245 and the central axis of the optical member 260 246 are spaced apart from each other in the circumferential direction, and also serves as a positioning portion of the color conversion member 270.
The LED unit 250 described above includes the unit unit 233a, the holding unit 244, the LED chip 210, the sealing unit 255, the optical member 260, and the color conversion member 270 And the adjacent light emitting devices 201 in the array direction of the unit units 233a are connected to each other by a connecting piece 237 and electrically connected in series have.
Hereinafter, each component will be further described.
The LED chip 210 is a GaN-based blue LED chip that emits blue light. The LED chip 210 is formed of a GaN-based compound semiconductor material on the main surface side of a substrate for crystal growth and is formed, for example, in a stacked structure having a double heterostructure A supporting substrate (for example, a Si substrate or the like) for supporting a light emitting portion after epitaxially growing a light emitting portion or the like made of a structural portion is fixed to a light emitting portion and then a substrate for crystal growth or the like is removed. The structure of the LED chip 210 is not particularly limited. For example, a light emitting portion is provided on the main surface side of a crystal growth substrate made of an n-type SiC substrate or an n-type GaN substrate, Or may be provided with an electrode. Each of the electrodes is composed of, for example, a laminated film of a Ni film and an Au film. However, these materials are not particularly limited and may be any material that can obtain good ohmic characteristics. For example, .
As compared with the case where a SiC substrate or a GaN substrate is used as the LED chip 210 and a support substrate such as a Si substrate is used as described above, a sapphire substrate which is an insulator is used as a substrate for crystal growth, It is possible to reduce the thermal resistance from the die pad 234 to the die pad 234. [ The light emitted from the LED chip 210 is not limited to blue light, and may be, for example, purple light, ultraviolet light, or the like.
The LED chip 10 is mounted on the die pad 234 of the wiring board 240 as shown in Fig. Therefore, heat generated in the LED chip 210 can be dissipated through the path of the die pad 234, the insulating layer 243, and the second metal plate 242.
9, the LED chip 210 includes a sub-mount member 210 for relieving stress acting on the LED chip 210 due to a difference in coefficient of linear expansion between the LED chip 210 and the die pad 234, Or may be mounted on the die pad 234 through the through hole 215. Here, the sub-mount member 215 is formed in a rectangular plate shape having a plane size larger than the chip size of the LED chip 210.
The sub-mount member 215 has a heat conduction function to heat the heat generated by the LED chip 210 in a wider range than the chip size of the LED chip 210 in the unit unit 233a as well as to mitigate the stress . Accordingly, the LED unit 250 can dissipate heat generated from the LED chip 210 through the sub-mount member 215 and the unit unit 233a and the second metal plate 242 with good efficiency. The light emitting device 201 is provided with the submount member 215 so that the stress acting on the LED chip 210 due to the difference in coefficient of linear expansion between the LED chip 210 and the die pad 234 can be reduced have.
As the material of the sub-mount member 215, AlN having a relatively high thermal conductivity and insulating property is employed. The LED chip 210 and the submount member 215 may be joined by using a solder such as SnPb, AuSn, or SnAgCu, or a silver paste. However, it is also possible to use a lead-free solder such as AuSn or SnAgCu It is preferable to bond them. When the sub-mount member 215 is made of AlN and is bonded using AuSn, a pre-treatment is required to form a metal layer made of Au or Ag in advance on the bonding surfaces of the sub-mount member 215 and the LED chip 210 . The sub-mount member 215 and the die pad 234 are preferably bonded using, for example, lead-free solder such as AuSn or SnAgCu. Here, in the case of bonding using AuSn, pre-treatment for forming a metal layer made of Au or Ag in advance was required on the bonding surface of the die pad 234.
The material of the sub-mount member 215 is not limited to AlN, but may be a material having a relatively small coefficient of linear expansion with respect to the LED chip 210 and having a relatively high thermal conductivity. For example, a composite SiC, Si, CuW, You can. It is preferable that the thickness dimension of the sub-mount member 215 is set such that the surface of the sub-mount member 215 is spaced from the unit unit 233a more than the surface of the weir portion 245 of the wiring board 240. [ By setting the sub-mount member 215 to such a thickness dimension, it is possible to prevent light emitted from the LED chip 210 from being sideward from being absorbed by the holding portion 244 through the inner peripheral surface of the weir portion 245 .
The sub-mount member 215 is provided around the bonding site (that is, a portion overlapping the LED chip 210) on the surface of the side where the LED chip 210 is bonded to the LED chip 210, A reflection film for reflecting the light emitted from the chip 210 is formed. Therefore, the light emitted from the side surface of the LED chip 210 can be prevented from being absorbed by the sub-mount member 215, and the light extraction efficiency to the outside can be further increased. Here, the reflective film in the sub-mount member 215 may be composed of, for example, a laminated film of a Ni film and an Ag film, but the material of the reflective film is not particularly limited. For example, It is appropriate to select the wavelength depending on the wavelength of light emitted from the light source. When the LED chip 210 is provided with electrodes on both sides in the thickness direction, the electrode disposed on the sub-mount member 215 side of the LED chip 210 is electrically connected to the sub- And the conductor pattern and the heat sink 235 may be electrically connected to each other through a bonding wire made of a metal wire (for example, gold wire or aluminum wire).
The holding portion 244 of the wiring board 240 is provided for each of the unit units 233a as described above and the die pad 234 and each lead 236 A circular second opening portion 244b (see B in Fig. 5) for exposing a portion for mounting the Zener diode ZD is formed, while a circular first opening portion 244a Is formed. The second opening 244B is formed so as to expose a part of a portion of the lead 236 disposed along the outer peripheral edge of the heat sink 235 and a portion of the heat sink 235 near the part of the heat sink 235 . The holding portion 244 is formed with a rectangular third opening portion 244c (see FIG. 5B) for exposing a portion for mounting a connector CN to be described later. The third opening 244c is formed so as to expose a part of the wiring 238 and a part in the vicinity of the part of the heat sink 235.
The wiring board 240 is also formed by laminating the Ni film, the Pd film, and the Au film on the exposed surface of the pattern 233 by the second opening 244b and the third opening 244c, A second plating layer 247 made of a film is formed. On the surface side of the pattern 233, a third plating layer made of a Ni film is formed except the portion where the second plating layer 247 is formed.
Although the silicone resin is used as the first translucent material of the sealing portion 255 described above, it is not limited to the silicone resin, and for example, an acrylic resin or the like may be used. Glass may be used as the first light transmitting material.
The optical member 260 is formed into a dome shape as a molded article of a translucent material (e.g., silicone resin, acrylic resin, glass, or the like). Here, in the present embodiment, since the optical member 260 is formed of a molded product of silicone resin, the refractive index difference and the linear expansion rate difference between the optical member 260 and the sealing portion 255 can be reduced. When the material of the sealing portion 255 is an acrylic resin, the optical member 260 is also preferably formed of an acrylic resin.
The optical member 260 has a convex curved surface on which the light incident surface 260b does not totally reflect light incident from the light incident surface 260a on the boundary between the light outgoing surface 260b and the air layer 280 described above And the optical axis of the LED chip 210 is aligned with the optical axis. The light emitted from the LED chip 210 and incident on the light incident surface 260a of the optical member 260 is not totally reflected at the boundary between the light exit surface 260b and the air layer 280, ), And it is possible to increase the total luminous flux (luminous flux). The light emitted from the side surface of the LED chip 210 propagates through the sealing portion 255 and the optical member 260 and the air layer 280 to reach the color conversion member 270, Or scattered by the fluorescent material, or does not collide with the fluorescent material, and transmits the color conversion material 270. [ The optical member 260 is formed so that its thickness is uniform along the normal direction regardless of its position.
The color conversion member 270 is made of a mixture of a mixture of particles of a second translucent material such as silicone resin and particles of a yellow phosphor that is excited by blue light emitted from the LED chip 210 to emit broad yellow light And is formed of a molded product. Therefore, the LED unit 250 can emit white light because the blue light emitted from the LED chip 210 and the light emitted from the yellow phosphor are emitted through the outer surface 270b of the color conversion member 270. The second translucent material used as the material of the color conversion member 270 is not limited to a silicone resin. For example, acrylic resin, glass, organic or inorganic materials mixed and bonded at an nm level or a molecular level, An inorganic hybrid material or the like may be employed. The particles of the phosphor mixed with the second translucent material used as the material of the color conversion member 270 are not limited to the yellow phosphor. For example, even when the red phosphor and the green phosphor are mixed, white light can be obtained, When the phosphor and the green phosphor are mixed, the color rendering property can be enhanced.
The color conversion member 270 has an inner surface 270a formed in a shape along the light exit surface 260b of the optical member 260. [ The distance between the light exit surface 260b in the normal direction and the inner surface 270a of the color conversion member 270 becomes a substantially constant value regardless of the position of the light exit surface 260b of the optical member 260 . The color conversion member 270 is formed so as to have a uniform thickness along the normal direction regardless of its position. The color conversion member 270 may be formed by applying an adhesive agent (for example, silicone resin, epoxy resin, or the like) to the wiring board 240 at the edge of the wiring board 240 It can be fixed by using.
The weir part (245) also serves as a positioning part of the color conversion member (270). Although the number of the centering pawls 246 described above is not limited to four, it is preferable that at least three pawl portions 246 are provided. The width dimension of the claw portion 246 is preferably small in order to increase the allowable amount of the first translucent material that can be gathered between the weft portion 245 and the optical member 260. It is also possible to provide an annular concave groove for determining the position of the color conversion member 270 on the wiring board 240 without providing the weir portion 245.
The cutout portion 271 (see Fig. 8) engaged with the weir portion 245 is formed at the edge of the color conversion member 270 on the side of the wiring board 240 all over the periphery. Therefore, in the light emitting device 201 of this embodiment, the positioning accuracy of the color conversion member 270 with respect to the holding portion 244 of the wiring board 240 can be enhanced, and the color conversion member 270 The distance from the optical member 260 can be shortened. The cutting portion 271 is opened on the edge side and the inner surface 270a side of the color conversion member 270. [
A light emitting device 201 having the unit unit 233a at one end in the arrangement direction of a plurality of unit units 233a among the plurality of light emitting devices 201 of the LED unit 250 The connector CN is mounted on the light emitting device 201 (the light emitting device 201 on the right end in Fig. 7A) including the unit unit 233a on the other end. Here, the connector CN is a surface mount type connector, and one of the pair of contacts is electrically connected to the heat sink 235 by soldering, and the other contact is connected to the wiring 238 by soldering and electrically connected. A pair of connectors (hereinafter referred to as output connectors) 291 which are detachably connected to the connector CN of the light emitting device 201 at the right end of the LED unit 250 292 of the electric wire 290 is connected to the connector of the output terminal of the unillustrated lighting apparatus so that the LED chip 210 of the LED unit 250 It is possible to supply power to the serial circuit so as to be turned on. 7, the connector CN of the light emitting device 201 at the right end of the LED unit 250 and the input connector 292 are respectively connected to the female connector, the output connector 291, Each of the connectors CN of the light emitting device 201 at the left end of the connector 250 is a male connector. However, the female connector and the male connector may be reversed. Since the connector CN can be mounted for each of the light emitting devices 201, it is possible to manufacture a plurality of LED packages 250 that can be manufactured per one pitch of the lead frame 230 It is also possible to cut off any number of the light emitting devices 201 of the light emitting devices 201 of FIG.
Hereinafter, a method of manufacturing the LED unit 250 will be briefly described with reference to Figs. 10 to 12, Figs. 5 and 7. Fig.
First, a pattern forming step (previous step) for forming the lead frame 230 shown in Fig. 1 is performed by performing a press working or an etching work on the first metal plate 203 shown in Fig. 4, A first plating process is performed in which a first plating layer made of an Ni film is formed on the back surface of the pattern 233 and a third plating layer made of an Ni film is formed on the main surface of the pattern 233. Then, A second plating step of forming a Pd film and an Au film of the second insulating film 247 is performed to obtain the structure shown in Fig. In the first plating step, a first plating layer and a third plating layer are also formed in a portion of the supporting piece 232 of the lead frame 230 which is positioned inside the outer peripheral edge of the holding portion 244. Further, in the second plating step, the third plating layer is formed by the spot plating method, so that the amount of Au used can be reduced and the cost can be reduced.
11 in which the module 241 is supported on the outer frame portion 231 through the support pieces 232 by performing a molding process for injection molding (injection molding) the holding portion 244 after the second plating process Structure is obtained.
12, the module 241 is cut from the support piece 232 of the lead frame 230, and the module 241 and the second metal plate 242 are connected to the insulating layer 243 ), Thereby obtaining a wiring board 240 having the structure shown in Fig.
Thereafter, the LED chip 210 is mounted on the die pad 234, the zener diode ZD and the connector CN are mounted, and the LED chip 210 is mounted on the proper portion of the unit unit 233a (Only the lead 236 and the heat sink 235 in FIG. 3, and the lead 236 in FIG. 3) are electrically connected by the bonding wire 214. Thereafter, a sealing process for sealing the LED chip 210 and the bonding wire 214 with the sealing portion 255 is performed. In this sealing step, first, a liquid first light-transmitting material (for example, a sealing material) is formed as a part of the sealing portion 255 in the gap between the outer surface of the LED chip 210 and the inner surface of the first opening 244a A silicone resin, an acrylic resin, a glass, or the like) is injected and cured. Next, a liquid first light-transmissive material (for example, silicone resin, acrylic resin, glass or the like) to be the remaining part of the sealing part 255 described above is injected into the dome-shaped optical member 260. The optical member 260 is disposed at a predetermined position in the wiring board 240 to cure the first transparent material to form the sealing portion 255 and fix the optical member 260 to the wiring board 240. [ In this sealing step, it is possible to prevent bubbles (voids) from being generated in the sealing portion 255 in the manufacturing process by generously injecting the liquid first light-transmissive material into the optical member 260 . In the mounting process (first mounting process) before the sealing process, only the LED chip 210 is mounted, and a second mounting process for mounting the Zener diode ZD and the connector CN next to the sealing process is performed You can.
After the mounting of the LED chip 210, the zener diode ZD and the connector CN is completed and the formation of the sealing portion 255 is completed, the color conversion member 270 is fixed to the wiring board 240 By performing the fixing process, the LED unit 250 having the structure shown in Fig. 7 is obtained.
The lead frame 230 in the above-described embodiment has the pattern 233 supported on the inner side of the outer frame portion 231 of one pitch via the support piece 232, A pad 234 and a heat sink 235 extending from the die pad 234 to surround the die pad 234 and an LED chip 210 electrically connected to the heat sink 235 A plurality of unit units 233a each having a lead 236 electrically connected to the other electrode of the unit unit 233a of the one unit unit 233a, And the heat sink 235 of the other unit unit 233a are connected and electrically connected in series. Therefore, the lead frame 230 in the present embodiment can suppress the rise of the temperature of the LED chip 210, thereby making it possible to increase the output of the light output. Further, the plurality of LED chips 210 are connected in series The cost of the LED unit 250 to be used can be reduced. For example, the LED unit 250 manufactured by using the lead frame 230 can be manufactured by using the light emitting device 100 of the structure of FIG. 60 manufactured using the lead frame 300 of FIG. 61 as a metal base printed wiring board In comparison with an LED unit in which a plurality of LED chips 161 are mounted in series and connected in series.
Since the lead frame 230 in the present embodiment has the lead 236 disposed inside the cut groove 235a formed from the outer peripheral edge of the heat sink 235 toward the die pad 234, The distance between the pad 234 and the lead 236 can be shortened. As a result, the distance between the LED chip 210 and the lead 236 can be shortened, and the length of the bonding wire 214 connected to the LED chip 210 can be shortened, The size of the member 270 can be reduced.
The lead frame 230 of the present embodiment can be used for manufacturing the elongated LED unit 250 because the plurality of unit units 233a are arranged along the longitudinal direction of the outer frame portion 231. [
The lead frame 230 in the present embodiment has the wiring 238 in which the pattern 233 is arranged on the side of the heat sink 235 over the plurality of unit units 233a and the wiring 238 Is connected to the lead 236 of the unit unit 233a at one end in the longitudinal direction of the outer frame portion 231 and is electrically connected. The LED chip 210 is mounted on the lead frame 230 for each unit unit 233a such that the pattern 233 is separated from the outer frame portion 231 The power is supplied between the heat sink 235 and the wiring 238 of the unit unit 233a at the other end in the arrangement direction of the plurality of unit units 233a so as to be connected to the series circuit of all the LED chips 210 .
The wiring board 240 in this embodiment is a module having a pattern 233 formed by using the first metal plate 203 and capable of series connection of a plurality of LED chips 210 arranged on the main surface side A second metal plate 242 disposed on the back side of the module 241 and a second metal plate 242 interposed between the module 241 and the second metal plate 242 with electrical insulation and heat conductivity, 2 metal plate 242. The pattern 233 is cut from the lead frame 230 described above. The wiring board 240 is formed so that the module 241 covers the die pad 234, the heat sink 235 and the lead 236 for each unit unit 233a of the pattern 233, The LED unit 250 which can use a plurality of LED chips 210 connected in series can be used because the temperature rise of the LED chip 210 can be suppressed and the output of the light output can be increased, Can be reduced.
The LED unit 250 in the present embodiment has the LED chip 210 mounted on each of the die pads 234 of the wiring board 240 described above and is provided on one side in the thickness direction of the LED chip 210 The electrodes of the LED chip 210 are electrically connected to the leads 236 and the heat sink 235 via the bonding wires 214 as shown in FIG. Therefore, in the LED unit 250 of the present embodiment, the heat generated from the LED chip 210 is transferred from the die pad 234 and the heat sink 235 formed using the lead frame 230 described above to the second metal plate 242 And the temperature rise of the LED chip 210 can be suppressed, so that high output of the light output can be achieved, and the cost can be reduced.
3, one electrode of the LED chip 210 is electrically connected to the heat sink 250 through the die pad 234, The other electrode is electrically connected to the sink 235 and the other electrode is electrically connected to the lead 236 through the bonding wire 214. In this configuration, the temperature rise of the LED chip 210 can be suppressed So that high output of the light output can be achieved and the cost can be reduced.
In each of the light emitting devices 201 of the LED unit 250 in this embodiment, since the air layer 280 is interposed between the dome-shaped color conversion member 270 and the optical member 260, And is incident on the color conversion member 270 through the sealing portion 255 and the optical member 260 and is scattered toward the optical member 260 in the light scattered by the phosphor particles of the color conversion member 270 The amount of light transmitted through the optical member 260 can be reduced and the light extraction efficiency of each light emitting device 201 to the outside can be improved.
In the LED unit 250 of the present embodiment, since the second opening 244b and the third opening 244c are formed in the holding portion 244 of the wiring board 240, the lead 236, The second plating layer 247 may be formed by spot plating on a portion exposed by the second opening portion 244b and the third opening portion 244c in each of the first wiring layer 235 and the wiring 238, It is possible to mount the zener diode ZD and the connector CN with good positional accuracy with the opening 244b and the third opening 244c as targets.
In the example described above, one LED chip 210 having a chip size of 1 mm square is mounted on one unit unit 233a, but the chip size and number of the LED chip 210 are not particularly limited , For example, an LED chip 210 having a chip size of 0.3 mm square may be used. As shown in FIG. 13, a plurality of (two in the illustrated example) LED chips 210 may be used for one unit unit 233a ) LED chip 210 may be mounted. In this case, two LED chips 210 are connected in parallel to one unit unit 233a, and the parallel circuits of the two LED chips 210 are connected in series by the number of unit units 233a. In addition, a plurality of LED chips 210 may be mounted on the sub-mount member 215 shown in Fig.
In the wiring board 240 using the lead frame 230 described above, the pattern 233 includes the wiring 238 disposed on the side of the heat sink 235 across the plurality of unit units 233a, The wiring 238 is electrically connected to the lead 236 of the unit unit 233a at one end in the longitudinal direction of the outer frame portion 231. However, the wiring 238 is not limited to this. For example, the lead frame 230 may be formed so that the wiring 238 can be used as a feed wire without connecting the wiring 238 to the lead 236 of the unit unit 233a at one end . In the case of manufacturing the wiring board 240 using the lead frame 230 as described above, it is possible to mount a connector for the feeder wiring provided with a contact electrically connected to each of the leads 236 and the wiring 238 separately , The second plating layer 247 (the two second plating layers 247 on the upper left side in Fig. 14A) formed on the leads 236 and the wirings 238 may be exposed as shown in Fig. 14 . In this case, a plurality of LED units 250 are aligned on a straight line, and between adjacent LED units 250, a plurality of LED units 250 are connected to the unit unit 233a at one end of one LED unit 250, And the connector CN mounted on the other unit unit 233a of the other LED unit 250 are electrically connected to each other by a connector cable so that all the LED units 250 It is possible to supply power and light it.
In the lead frame 230 used for manufacturing the wiring board 240 shown in Fig. 14, the two cut grooves 235a of the heat sink 235 are aligned in the direction in which they approach each other and the positions of the center lines are aligned , The degree of freedom in designing the arrangement of the LED chips 210 when a plurality of LED chips 210 are mounted on the die pad 234 as shown in Fig.
In the wiring board 240 and the LED unit 250 described so far, the pattern 233 formed by using the lead frame 230 is connected to one of the unit units 233a of the unit units 233a adjacent to each other, And the connecting piece 237 connecting the lead 236 of the unit unit 233a and the heat sink 235 of the other unit unit 233a. Thus, the cost of the LED unit 250 can be reduced.
However, in the above-described wiring board 240 and LED unit 250, since substantially the entire pattern 233 is bonded to the insulating layer 243, for example, the first metal plate 203 and the second metal plate 242 Due to the stress acting on the pattern 233 due to the difference in coefficient of linear expansion between the first metal plate 203 and the second metal plate 242 in the use temperature range, for example, when a material having a different linear thermal expansion coefficient is used, The pattern 233 may be peeled off from the insulating layer 243.
16, a space 248 is provided between the connecting piece 237 and the insulating layer 243 in the wiring board 240, and the connecting piece 237 is connected to the first metal plate (not shown) The stress relieving section 237b may be provided so as to relieve the stress acting on the pattern 233 due to the difference in coefficient of linear expansion between the first metal plate 203 and the second metal plate 242. [ Since the pattern 233 of the wiring board 240 shown in Fig. 16 is also provided with the wiring 238, the wiring 238 is also connected to the wiring 237 with respect to the portion located on the side of the connecting piece 237 The stress acting on the pattern 233 due to the difference in coefficient of linear expansion between the first metal plate 203 and the second metal plate 242 is relaxed so as to have a space 249 between the first metal plate 238 and the insulating layer 243, And a stress relieving portion 238b which is bent so as to be bent. 16, the longitudinal direction of the second metal plate 242 (i.e., the aligned direction of the unit unit 233a) is defined as the x-axis direction, the width direction of the second metal plate 242 is defined as the y- The connecting piece 237 and the wiring 238 are bent in the z-axis direction before the pattern 233 and the insulating layer 243 are bonded, if the thickness direction of the two metal plates 242 is the z-axis direction And the stress relieving parts 237b and 238b. Here, the stress relieving parts 237b and 238B in Fig. 16 are formed by bending such that the cross section (xz plane) orthogonal to the y-axis direction is inverted V-shaped. Since the stress relieving portions 237b and 238b are formed by the wiring board 240 as shown in the drawing (16), when the first metal plate 203 and the second metal plate 242 are made of materials having different coefficients of linear thermal expansion The pattern 233 is prevented from being peeled off from the insulating layer 243 due to the stress acting on the pattern 233 due to the difference in coefficient of linear expansion between the first metal plate 203 and the second metal plate 242 Lt; / RTI >
The shape of the stress relieving portions 237b and 238b is not limited to the example of Fig. 16, and may be a shape as shown in Fig. 17, for example. The stress relieving portions 237b and 238b in Fig. 17 are arranged such that each of the connecting piece 237 and the wiring 238 is arranged in a plane parallel to the bonding surface of the second metal plate 242 with the insulating layer 243 (xy plane Like shape in a V-shape. Here, the stress relieving portion 237b of the connecting piece 237 and the stress relieving portion 238b of the wiring 238 are each bent so that their central portions are spaced apart from each other at both ends.
The shapes of the stress relieving parts 237b and 238b are not limited to a V shape in particular, and may be other shapes. 16 and 17, the pattern 233 is provided with the wiring 238, but it is not always necessary to provide the wiring 238. In this case,
The basic structure of the lead frame 230 of this embodiment shown in Figs. 18A and 18B is substantially the same as that of the first embodiment, and a plurality of unit units 233a are arranged in a region surrounded by the outer frame portion 231 And the points arranged to surround the center are different. The same components as those in the first embodiment are denoted by the same reference numerals, and the description thereof will be omitted. 18A is a schematic perspective view of the lead frame 230 for two pitches.
Since the lead frame 230 in the present embodiment has the plurality of unit units 233a (in the illustrated example, ten unit units) divided into two concentric virtual circles, The number of die pads 234 on the imaginary circle located on the outer side relative to the number of die pads 234 on the circle is increased. Therefore, the die pad 234 such as the lead frame 230 is also arranged in the wiring board 240 (see FIG. 22) manufactured by using the lead frame 230. In the LED unit 250 (see Fig. 24) manufactured using the wiring board 240, the number of the LED chips 210 (see Figs. 8 and 9) mounted on each die pad 234 is set to be the same (For example, one), the number of the LED chips 210 on the imaginary circle located on the outer side relative to the number of the LED chips 210 on the imaginary circle relatively located on the inner side, (210).
The pattern 233 of the lead frame 230 includes two feed lines 139 extending from each of the heat sinks 235 of the two unit units 233a for feeding the series circuit of the LED chip 210, .
22) having a stacked structure of a Ni film, a Pd film, and an Au film is formed on the main surface of the front end of the two feed lines 139 in the wiring board 240 . Therefore, for example, by connecting power supply wires from point lighting devices (not shown) to each of the second plating layers 247 of the two power supply lines 139, it is possible to supply power to the series circuit of the LED unit 210 So that it can be turned on.
24, the second metal plate 242 is formed in a circular plate shape in the wiring board 240 and the LED unit 250, and a pair of power supply wires A wire insertion hole 242c is formed to allow the wire insertion hole 242c to be inserted therethrough. In the periphery of the second metal plate 242, there are provided a plurality of (four in the illustrated example, four in the illustrated example) screws for inserting the screws used when the LED unit 250 is mounted on another member such as a mechanism body of the lighting apparatus Are formed at substantially equal intervals in the circumferential direction of the second metal plate 242.
Hereinafter, a method of manufacturing the LED unit 250 will be described with reference to Figs. 18 to 24. However, the same steps as those of the first embodiment will be appropriately omitted.
First, after the pattern forming process for forming the lead frame 230 shown in Fig. 18 is performed by performing the press working or the etching process on the first metal plate 203, for example, the Ni film And a third plating layer of a Ni film is formed on the main surface of the pattern 233. Subsequently, a Pd film and an Au film of the second plating layer 247 are formed By performing the second plating process, the structure shown in Fig. 19 is obtained.
21, the module 241 is cut from the support piece 232 of the lead frame 230, and the module 241 and the second metal plate 242 are connected to the insulating layer 243 To obtain a wiring board 240 having the structure shown in Fig. The second metal plate 242 and the insulating layer 243 are of a multi-cavity type.
Thereafter, the LED chip 210 is mounted on the die pad 234 and the Zener diode ZD (see Fig. 23) is mounted, and the bonding wire of the LED chip 210 and the unit unit 233a, A mounting step of performing electrical connection by the insulating film 214 is performed. Thereafter, a sealing process for sealing the LED chip 210 and the bonding wire 214 (see Figs. 2 and 3) with the sealing portion 255 (see Figs. 8 and 9) is performed. In this sealing step, first, a liquid-phase first light-transmitting material (not shown) which becomes a part of the sealing portion 255 in the gap between the outer surface of the LED chip 210 and the inner surface of the first opening 244a (For example, a silicone resin, an acrylic resin, glass, or the like) is injected and cured. Next, a liquid first light-transmissive material (for example, a silicone resin, a silicone resin, or the like) which becomes the remaining portion of the sealing portion 255 described above is provided inside the dome-shaped optical member 260 (see Figs. 8, 9, Acrylic resin, glass, etc.). The optical member 260 is disposed at a predetermined position in the wiring board 240 to cure the first transparent material to form the sealing portion 255 and fix the optical member 260 to the wiring board 240. [ In the mounting step (first mounting step) before the sealing step, only the LED chip 210 is mounted, and after the sealing step, the second mounting step for mounting the Zener diode ZD and the connector CN may be performed do.
After the mounting of the LED chip 210, the zener diode ZD and the connector CN is completed and the formation of the sealing portion 255 is completed, the color conversion member 270 is fixed to the wiring board 240 A plurality of LED units 250 are obtained as shown in Fig. Thereafter, the LED unit 250 is cut into individual LED units 250 to obtain the LED unit 250 shown in Fig.
Since the plurality of unit units 233a are arranged so as to surround the center of the region surrounded by the outer frame portion 231 in the lead frame 230 in the present embodiment described above, The cost of the circular LED unit 250 used in series connection can be reduced.
The wiring board 240 in the present embodiment can also suppress the temperature rise of the LED chip 210 and can increase the output of the light output as in the first embodiment. ) Can be connected in series to reduce the cost of the LED unit 250 used.
In the LED unit 250 of the present embodiment, the heat generated by the LED chip 210 is transmitted to the die pad 234 and the heat sink 235, which are formed using the lead frame 230 described above, The temperature rise of the LED chip 210 can be suppressed by efficiently radiating heat from the second metal plate 242 through the second metal plate 242. Thus, high output of the light output can be achieved and the cost can be reduced.
In the wiring board 240 and the LED unit 250 of the present embodiment, the space 248, the stress relieving portion 237b, and the like described above with reference to FIG. 16 and FIG. 17 may be provided.
In the above embodiments, the light emitting device 201 is provided with the color conversion member 270, but in the case where the LED chip 210 can emit white light as a single body or the phosphor is dispersed in the sealing portion 255 It is possible to adopt a structure in which the above-described color conversion member 270 is not provided.
Hereinafter, the light emitting unit 1 of this embodiment will be described with reference to Figs. 25 to 32. Fig.
The light emitting unit 1 includes a mounting substrate 2 and a plurality of solid light emitting elements 3 arranged on one surface side of the mounting substrate 2. [
The mounting substrate 2 is provided with a heat transfer plate 21 on which one solid-state light-emitting element 3 is mounted on one surface and a wiring pattern (not shown) disposed on the other surface side of the heat transfer plate 21 and electrically connected to the solid- 22 and an insulating layer 23 (first insulating layer 23) interposed between the heat transfer plate 21 and the wiring pattern 22 are provided. Here, the heat transfer plate 21 is formed by a first metal plate, and the wiring pattern 22 is formed by a second metal plate having a coefficient of linear expansion different from that of the first metal plate. The mounting substrate 2 includes a base substrate 24 having a difference in coefficient of linear expansion between the second metal plate and the first metal plate and disposed on the side opposite to the side of the heat transfer plate 21 in the wiring pattern 22, And a second insulating layer 25 interposed between the first substrate 22 and the base substrate 24.
Hereinafter, each component of the light emitting unit 1 will be described in detail.
A plurality of solid light emitting elements 3 are arranged along the longitudinal direction of the mounting substrate 2 on the one surface side.
The heat transfer plate 21 is formed in an elongated shape (in this case, an elongated rectangular plate shape). As the material of the first metal plate serving as a base of the heat transfer plate 21, a metal having a high thermal conductivity such as aluminum or copper is preferable. However, the material of the first metal plate is not limited to these, and may be, for example, stainless steel or steel.
It is preferable that the heat transfer plate 21 has a function as a reflection plate, and it is more preferable to adopt aluminum as the material of the first metal plate. The heat transfer plate 21 is composed of an aluminum plate having a higher purity than the aluminum plate on the side opposite to the side of the first insulating layer 23 in the aluminum plate and having a refractive index different from that of the aluminum plate Reflection film made of a dielectric film of the above-mentioned type is preferably laminated. Here, as the two kinds of dielectric films, for example, it is preferable to adopt a SiO 2 film and a TiO 2 film. By using such a heat transfer plate 21, it becomes possible to make the reflectance with respect to visible light 95% or more. As this heat transfer plate 21, for example, MIRO2 and MIRO (registered trademark) of Alanod Co., Ltd. can be used. As the above-mentioned aluminum plate, a plate whose surface is subjected to an anode oxidation treatment may be used. The thickness of the heat transfer plate 21 may be suitably set within a range of, for example, about 0.2 to 3 mm.
As the solid light emitting element 3, an LED chip is used, but the present invention is not limited thereto. For example, the LED chip may be housed in a package. As the solid light-emitting element 3, for example, a laser diode (semiconductor laser), an organic EL element, or the like may be used.
27, a first electrode (anode electrode) 31 and a second electrode (cathode electrode) 32 are provided on one surface side in the thickness direction of the solid light emitting device 3, And the other side is bonded to the heat transfer plate 21 through the bonding portion 35. [ Each of the first electrode 31 and the second electrode 32 of the solid light emitting device 3 is electrically connected to the wiring pattern 22 through a wire (bonding wire) 26. Here, the heat transfer plate 21 is formed with a through hole 21b through which the wires 26 pass. The through holes 21b are formed on both sides of the mounting region of the solid light emitting element 3 in the width direction of the heat transfer plate 21. [ The through hole 21b has a circular opening shape. The inner diameter of the through hole 21b is set to 0.5 mm, but this value is merely an example and is not particularly limited. The shape of the through hole 21b is not limited to a circular shape but may be, for example, a rectangular shape, an elliptical shape, or the like. When the solid light emitting device 3 is an LED chip, the bonding portion 35 may be formed by a die bonding material.
The LED chip is a GaN-based blue LED chip that emits blue light and uses a sapphire substrate as a substrate. However, the substrate of the LED chip is not limited to the sapphire substrate but may be a GaN substrate, a SiC substrate, a Si substrate, or the like. The structure of the LED chip is not particularly limited.
The chip size of the LED chip is not particularly limited. For example, a chip size of 0.3 mm?, 0.45 mm? Or 1 mm? Can be used.
The material of the light emitting layer of the LED chip and the light emitting color are not particularly limited. That is, the LED chip is not limited to the blue LED chip, and for example, a purple light LED chip, an ultraviolet LED chip, a red LED chip, a green LED chip, or the like may be used.
As the die bond material, for example, a silicone-based die bond material, an epoxy-based die bond material, a silver paste, or the like can be used.
As the wire 26, for example, gold wire, aluminum wire, or the like can be used.
27, when the LED chip is used as the solid light-emitting element 3, the light-emitting unit 1 is provided with the solid-state light-emitting element 3 And a sealing portion 36 that seals the wire 26. [0050] In Fig. 27, a silicone resin which is the first translucent material is used as the material of the sealing portion 36. Fig. The first translucent material is not limited to a silicone resin, and for example, an epoxy resin, an acrylic resin, glass, or the like may be used.
When the LED chip is used as the solid-state light-emitting element 3, the light-emitting unit 1 is required to have a color conversion having a wavelength conversion material that emits light of a different color from that of the LED chip, It is preferable to provide the above- As such a color conversion section 37, for example, a phosphor that is excited by light emitted from the LED chip and emits light of a color different from the emission color of the LED chip is used as a wavelength conversion material, It is preferable to include a light-transmitting material.
For example, when the blue LED chip is used as the LED chip and the yellow phosphor is used as the phosphor of the color conversion unit 37, the light emitting unit 1 can obtain white light. That is, in the light emitting unit 1, the blue light emitted from the LED chip and the light emitted from the yellow phosphor are emitted through the surface of the color conversion portion 37, so that white light can be obtained. A silicon resin is used as the second translucent material used as the material of the color conversion portion 37. However, the present invention is not limited to this. For example, acrylic resin, glass, , A combined organic-inorganic hybrid material, or the like may be employed. The phosphor used as the material of the color conversion portion 37 is not limited to the yellow phosphor. For example, it is possible to enhance the color rendering property by using the yellow phosphor and the red phosphor or by using the red phosphor and the green phosphor. The phosphor used as the material of the color conversion portion 37 is not limited to one kind of yellow phosphor and two kinds of yellow phosphors having different emission peak wavelengths may be used.
In the case where the LED chip single body and the white light can be emitted or the phosphor is dispersed in the sealing portion 36 or the color of the light desired to be obtained by the light emitting unit 1 is the same as the light emitting color of the LED chip, It is possible to adopt a structure that does not include the portion 37. [
In the light-emitting unit 1, it is preferable that the color conversion portion 37 is in contact with the heat transfer plate 21. Thus, in the light emitting unit 1, not only heat generated in the LED chip but also heat generated in the color conversion portion 37 can be dissipated through the heat transfer plate 21, and high output of light output can be achieved. In the example shown in Fig. 27, the color conversion section 37 is formed in a semi-cylindrical shape, and the LED chip and the sealing section 36 are provided between the heat transfer plates 21 on the one surface side of the heat transfer plate 21 And is installed in a surrounding form. More specifically, the color conversion portion 37 is provided so that a gas layer (for example, an air layer) 38 is formed between the sealing portions 36 on the one surface side of the heat transfer plate 21. 33, the light-emitting unit 1 has the hemispherical shape of the color conversion portion 37 and the LED chip and the wire 26 as the solid light-emitting element 3 are connected by the color conversion portion 37 It may be sealed. 34, the color conversion section 37 is formed into a dome shape, and the color conversion section 37 converts the LED chip and the wire 26 (solid light emitting element 3) ) May be sealed. 35, the color conversion section 37 is formed into a layered shape and the color conversion section 37 converts the LED chip and the wire 26 (solid light emitting element 3) ) May be sealed. The color conversion portion 37 as shown in Fig. 27 or Fig. 34 is a molded product and the end edge (peripheral edge of the opening portion) on the heat transfer plate 21 side is bonded to the heat transfer plate 21 with, for example, For example, a silicone resin, an epoxy resin, or the like).
The color conversion section 37 as shown in Fig. 33 can be formed by, for example, a molding method. 35 can be formed by, for example, a coating method using a dispenser, a screen printing method, or the like.
The wiring pattern 22 is formed by a second metal plate having a coefficient of linear expansion different from that of the heat transfer plate 21 as described above. Here, the second metal plate uses a lead frame 120 (see C in Fig. 32) formed by punching a metal hoop material by press.
As the material of the second metal plate, a copper having a relatively high thermal conductivity (copper thermal conductivity: about 398 W / m · K) is preferable, but the material is not limited to copper and may be phosphor bronze or the like, , 42 alloy, etc.). The thickness of the second metal plate is preferably set to, for example, about 100 m to 1500 m.
The lead frame 120 is formed such that the wiring pattern 22 is supported on the inner side of the outer frame portion 121 through the support piece 122 (see D in FIG. 32).
The wiring patterns 22 are formed in such a manner that the first pattern 22a to which the first electrode 31 of the solid state light emitting element 3 is connected and the second pattern 22b to which the second electrode 32 is connected form the heat transfer plate 21 As shown in Fig. The wiring pattern 22 has a predetermined number (for example, 16) of the first pattern 22a and the second pattern 22b, respectively. As shown in FIG. 30, the first pattern 22a And the second pattern 22b are arranged side by side in the longitudinal direction of the heat transfer plate 21. [ The first pattern 22a and the second pattern 22b are formed in a rectangular shape and arranged so as to coincide with the heat transfer plate 21 in the longitudinal direction. The first pattern 22a of the wiring pattern 22 is divided into two sets of first patterns 22a aligned in the longitudinal direction of the heat transfer plate 21 so that the first patterns 22a are connected by the connecting piece 22c have. The wiring pattern 22 has a second pattern 22b in which a predetermined number (for example, 16) of second patterns 22b aligned in the longitudinal direction of the heat transfer plate 21 are divided into two sets, Are connected and electrically connected to each other by a connecting piece 22d. The connecting pieces 22c and 22d are formed of a first linear portion 22ca and a second linear portion 22da arranged along the width direction of the heat transfer plate 21 and a pair of connecting portions 22c and 22d extending from both longitudinal ends of the first portions 22ca and 22da Second portions 22cb and 22db extending in the reverse direction in the longitudinal direction, and third portions 22cc and 22dc. The connecting piece 22c is formed narrower than the first pattern 22a and the connecting piece 22d is formed narrower than the second pattern 22b. Here, the wiring pattern 22 includes two first patterns 22a forming a set, a connecting piece 22c connecting the two first patterns 22a, two second patterns 22b forming a set, The connecting piece 22d connecting the two second patterns 22b constitutes one unit pattern 22u. In the above-described lead frame 120, a plurality of unit units 22u are arranged along the longitudinal direction of the outer frame portion 121. [ The wiring patterns 22 are formed in such a manner that adjacent first unit patterns 22u in the lengthwise direction of the heat transfer plate 21 are spaced apart from the first unit patterns 22a of the unit patterns 22u and the unit patterns 22u Are connected by a contact piece 22e and are electrically connected to each other. The contact piece 22e is narrower than the first pattern 22a and the second pattern 22b.
The wiring patterns 22 can be formed by connecting a predetermined number (for example, six) of the solid light emitting elements 3 arranged in parallel in the longitudinal direction of the heat transfer plate 21 for each unit pattern 22u in parallel to form a parallel circuit And parallel circuits formed for adjacent unit patterns 22u can be connected in series. Therefore, power can be supplied to all the solid light-emitting elements 3 by supplying power between the first pattern 22a at one end in the longitudinal direction of the heat transfer plate 21 and the second pattern 22b at the other end.
The first insulating layer 23 is composed of an epoxy resin layer (thermosetting resin) having a property of containing a filler made of a filler such as silica or alumina and having a low viscosity and high fluidity at the time of heating, (For example, an adhesive sheet TSA manufactured by Toray Industries, Inc.) having a thermosetting adhesive layer (PET film) laminated thereon. As the filler, an insulating material having a higher thermal conductivity than an epoxy resin as a thermosetting resin may be used. Here, the epoxy resin layer of the sheet-like adhesive has electrical insulating properties, high thermal conductivity, high fluidity at the time of heating, and high adhesiveness to uneven surfaces. Therefore, it is possible to prevent the occurrence of voids between the first insulating layer 23 and the heat conductive plate 21 and the wiring pattern 22, thereby improving the reliability of the adhesion and, at the same time, Can be suppressed. Therefore, compared with the case where a rubber sheet-type heat radiation sheet such as Sakon (registered trademark) is sandwiched between the heat transfer plate 21 and the wiring pattern 22, the wiring pattern 22 from each solid light emitting element 3, It is possible to reduce the thermal resistance from the solid light-emitting element 3 to the solid-state light-emitting element 3, and at the same time to reduce the unevenness of the thermal resistance, And high output power of the light output can be achieved. The thickness of the above-described epoxy resin layer is set to be 100 占 퐉, but this value is merely an example and is not particularly limited. For example, it may be suitably set within a range of about 50 占 퐉 to 150 占 퐉. The thermal conductivity of the above-described epoxy resin layer is preferably 4 W / m · K or more. The plastic film of the sheet-like adhesive is peeled off from the epoxy resin layer before superimposing the wiring pattern 22 and the heat transfer plate 21. [ That is, after one surface of the epoxy resin layer opposite to the plastic film side is fixed to the object, the plastic film is peeled off.
Here, when the first insulating layer 23 is formed, the heat transfer plate 21, the epoxy resin layer, and the lead frame 120 having the wiring pattern 22 may be appropriately pressed in a state of overlapping.
The external size of the first insulating layer 23 may be suitably set in accordance with the external size of the lead frame 120. Here, the first insulation layer 23 has electrical insulation and thermal conductivity, and has a function of electrically insulating the heat transfer plate 21 and the wiring pattern 22, and a function of thermally coupling.
The first insulating layer 23 is formed with a through hole 23b communicating with each of the through holes 21b of the heat transfer plate 21. [ The wire 26 is bonded to the wiring pattern 22 through the through hole 21b of the heat transfer plate 21 and the through hole 23b of the first insulating layer 23, can do. In manufacturing the light emitting unit 1, the first electrode 31 and the second electrode 32 of the solid light emitting element 3 and the first pattern 22a and the second pattern 22b are connected to the wires 27) is filled in the through hole 21b and the through hole 23b by a dispenser or the like so that the wire 26 is electrically connected to the first The sealing portion 36 may be formed so as not to contact the metal plate.
The wiring pattern 22 is formed of a metal material having higher oxidation resistance and corrosion resistance than the second metal sheet and has a surface treatment layer (not shown) having high adhesion with the first insulating layer 23 . When the material of the second metal plate is Cu, it is preferable to form, for example, a Ni film, a lamination film of an Ni film and an Au film, a Ni film, a lamination film of a Pd film and an Au film, Do.
The surface treatment layer may be formed by plating, for example. The base substrate 24 is formed in an elongated shape (in this case, an elongated rectangular plate shape). The base substrate 24 is preferably formed of a material having a smaller coefficient of linear expansion than that of the second metal plate with respect to the first metal plate. In this embodiment, the base plate 24 is formed of a third metal plate made of the same material as the first metal plate. Therefore, as the material of the third metal plate, a metal having a high thermal conductivity such as aluminum or copper is preferable. However, the material of the third metal plate is not limited to these, and for example, it may be stainless steel, steel, or the like. The thermal conductivity of aluminum is about 23 ppm, and the thermal conductivity of copper is about 17 ppm.
It is preferable to use the same material as the first insulating layer 23 as the material of the second insulating layer 25 interposed between the wiring pattern 22 and the base substrate 24.
However, depending on the size of the heat capacity of the heat transfer plate 21, when the heating temperature of the epoxy resin layer described above is raised to about 170 ° C and hardened, the fixing performance between the heat transfer plate 21 and the wiring pattern 22 is lowered, The electric insulation between the heat transfer plate 21 and the wiring pattern 22 may be deteriorated. That is, the fixing performance and the electric insulation have a trade-off relationship. Thus, in the present embodiment, as described later, the epoxy resin layers 123a and 133a (see FIG. 31C and FIG. 32B) of the sheet-like adhesives 123 and 133 (see FIG. 31B and FIG. And the other epoxy resin layer 133a is cured at 150 DEG C so as to improve the fixing performance and the thermal conductivity To secure the city. The other epoxy resin layer 133a and the lead frame 120 are overlapped with each other so that the other epoxy resin layer 133a and the lead frame 120 are stacked, The resin layer 133a may be cured at 150 deg. Thus, at the time of manufacturing the light emitting unit 1 of the present embodiment, it becomes possible to satisfy both the fixing performance and the electric insulation requirement regardless of the heat capacity of the heat transfer plate 21. [
Hereinafter, a method of manufacturing the mounting substrate 2 will be briefly described with reference to FIGS. 31 and 32. FIG.
First, a through hole 21b or the like is formed in the heat transfer plate 21 to obtain the structure shown in Fig. 31A.
31A, a sheet-like adhesive 123 is superimposed on the other surface of the heat transfer plate 21 so that the epoxy resin layer 123a is in contact with the heat transfer plate 21, and a columnar rubber roller (For example, 110 占 폚 to 120 占 폚) which is lower than the curing temperature of the epoxy resin layer 123a while being pressed at a predetermined pressure (for example, 0.5 MPa) 123 are temporarily fixed to the heat transfer plate 21. Then, the sheet-like adhesive 123 is cut to an appropriate length.
Thereafter, the heat transfer plate 21 on which the sheet-like adhesive 123 is fixed is naturally cooled. Subsequently, as shown in Fig. 31C, the plastic film 123b is peeled from the epoxy resin layer 123a.
Thereafter, the heat transfer plate 21, to which the epoxy resin layer 123a is attached and hardened, is charged into a drying furnace (not shown), and the epoxy resin layer 123a is heated to a temperature (for example, 170 DEG C) And the epoxy resin layer 123a is fixed to the heat conductive plate 21 by heating and curing.
Thereafter, the sheet-like adhesive agent 133 is superimposed on the epoxy resin layer 123a so that the epoxy resin layer 133a is in contact with the epoxy resin layer 123a and is pressed by a columnar rubber roller 140 at a predetermined pressure The adhesive agent 133 is heated to a first predetermined temperature (for example, 110 ° C to 120 ° C) which is lower than the curing temperature of the epoxy resin layer 133a so that the adhesive agent 133 is adhered to the epoxy resin layer 123a, Go to and get good. Then, the sheet-like adhesive 133 is cut to an appropriate length.
Thereafter, in the laminated structure of the epoxy resin layer 123a and the epoxy resin layer 133a, in each region corresponding to the through hole 23b of the insulating layer 23, as shown in Fig. 32A, For example, the through hole 134 is formed by the laser device 150. The means for forming the through hole 134 is not limited to the laser device 150, and for example, a drill or the like may be used.
Thereafter, as shown in Fig. 32B, the plastic film 133b is peeled from the epoxy resin layer 133a.
Thereafter, as shown in Fig. 32C, the lead frame 120 is mounted on the epoxy resin layer 133a and an appropriate load is applied. Thereafter, an epoxy resin layer 133a is formed in a drying furnace The lead frame 120 and the epoxy resin layer 133a are temporarily fixed to each other by curing at a temperature (for example, 150 DEG C) above the curing temperature. Thereby, the first insulating layer 23 is formed.
Thereafter, the wiring pattern 22 is cut off from the supporting piece 122 of the lead frame 120, and a part of the lead frame 120 other than the wiring pattern 22 is removed as shown in Fig. 32D .
Thereafter, the base substrate 24 and the wiring pattern 22 are bonded to the second insulating layer 25 in such a manner that the heat transfer plate 21 and the wiring pattern 22 are bonded to each other with the first insulating layer 23 interposed therebetween. The mounting board 2 of Fig. 28 can be obtained.
The solid light emitting element 3 is bonded to the one surface side of the mounting substrate 2 and then the first electrode 31 and the second electrode of each solid light emitting element 3 32 may be electrically connected to the first pattern 22a and the second pattern 22b through the wires 26, respectively. Thereafter, the sealing portion 36 and the color conversion portion 37 may be provided on one side of the mounting substrate 2 as required.
The light emitting unit 1 described above is provided with the wiring pattern 22 formed by using the heat transfer plate 21 and the lead frame 120 so that the solid light emitting element 3 is mounted on the metal base printed wiring board It is possible to achieve a high output of light output at a low cost as compared with the case where the light emitting diode is mounted and used. Further, by using the light-emitting unit 1 having the function of the reflection plate as the heat transfer plate 21, it is possible to reduce the light loss in the heat transfer plate 21, and it becomes possible to achieve high output of light output . Therefore, the light-emitting unit 1 of the present embodiment can be reduced in power consumption. Here, the light-emitting unit 1 is constituted such that the first metal plate of the heat transfer plate 21 is an aluminum plate, and an aluminum film of higher purity than the aluminum plate is laminated on the side of the aluminum plate opposite to the side of the first insulating layer 23, It is possible to achieve a high output of light output by using the reflector film formed of two kinds of dielectric films having different refractive indices. Particularly, in the case where the LED chip is used as the solid light-emitting element 3, the light-emitting unit 1 can efficiently dissipate heat generated from the LED chip, thereby achieving high output of light output, In addition, it is possible to improve the utilization efficiency of the light emitted from the LED chip. When the light-emitting unit 1 is provided with the color conversion section 37 (see Fig. 27 and the like), light emitted from the phosphor as the wavelength conversion material of the color conversion section 37 to the heat transfer plate 21 side , It is possible to reflect light scattered from the LED chip to the heat transfer plate 21 side by the phosphor, so that it is possible to improve the utilization efficiency of light.
In the above-described light emitting unit 1, since the mounting substrate 2 is elongated and almost all of the wiring patterns 22 are bonded to the first insulating layer 23, for example, There is a fear that the heat transfer plate 21 is bent or the wiring pattern 22 is peeled off from the first insulating layer 23 due to a temperature change during production or use due to the difference in coefficient of linear expansion with respect to the second metal plate. The inventors of the present invention have found that each of the connecting pieces 22c and 22d and the connecting pieces 22e described above has a bent shape in order to alleviate the stress acting on the wiring pattern 22, but the base substrate 24 and the second insulating layer The length of the first pattern 22a and the length of the second pattern 22b of the heat transfer plate 21 and the length of the second pattern 22b in the prototype product It was found that warping may occur in the heat transfer plate 21 due to the difference in the expansion ratio.
On the other hand, in the light emitting unit 1 of the present embodiment, the above-described base substrate 24 is provided. Since the base substrate 24 is formed of the third metal plate in the light emitting unit 1 of the present embodiment, the base substrate 24 and the wiring pattern 22 are electrically insulated from each other. And the second insulation layer 25 is interposed between the wiring pattern 22 and the wiring pattern 22.
The light emitting unit 1 of the present embodiment includes the mounting substrate 2 and the plurality of solid light emitting elements 3 arranged on the one surface side of the mounting substrate 2 as described above. The light emitting unit 1 is configured such that the mounting substrate 2 is formed by a heat transfer plate 21 formed by a first metal plate and each solid light emitting element 3 is mounted on the one surface side and a second metal plate A wiring pattern 22 formed on the other surface side of the heat transfer plate 21 and electrically connected to the solid light emitting element 3 and an insulation layer 23 interposed between the heat transfer plate 21 and the wiring pattern 22, . Thus, the light emitting unit 1 can efficiently heat the heat generated by each solid light emitting element 3 in the lateral direction by the heat transfer plate 21, thereby enabling heat to be radiated. Further, in the thickness direction of the heat transfer plate 21 It is possible to conduct heat and radiate heat. Therefore, the light emitting unit 1 can improve heat dissipation, and the temperature rise of each solid light emitting element 3 can be suppressed, and the light output can be made higher.
In the light emitting unit 1 of the present embodiment, since the first insulating layer 23 contains a filler having a higher thermal conductivity than the thermosetting resin in the thermosetting resin, the heat generated in the solid light emitting element 3 can be more efficiently It is possible to radiate heat to the outside.
In the light-emitting unit 1 of the present embodiment, the solid-state light-emitting element 3 is an LED chip, and the heat generated by the LED chip can be transferred to the lateral direction by the heat-transfer plate 21 to dissipate heat with good efficiency.
In the light emitting unit 1 of the present embodiment, the first metal plate as the foundation of the heat transfer plate 21 is an aluminum plate, and on the opposite side of the aluminum plate from the first insulating layer 23 side, Reflection films made of two kinds of dielectric films having different refractive indexes are laminated on the aluminum film and the light incident on the one surface of the heat transfer plate 21 can be reflected with good efficiency by radiating from the LED chip .
In the light emitting unit 1 of this embodiment, the heat transfer plate 21 has a long shape and the solid light emitting elements 3 are arranged along the longitudinal direction of the heat transfer plate 21, And the long base substrate 24 is disposed on the side opposite to the side of the heat transfer plate 21 in the wiring pattern 22. Therefore, even when the mounting substrate 2 is made long , It becomes possible to suppress the warping of the heat transfer plate 21 and to suppress the warping of the whole light emitting unit 1. [ Thereby, the light-emitting unit 1 can be reduced in cost by improving the yield at the time of manufacturing, and at the same time, it is possible to improve the reliability as a product.
The light emitting unit 1 is formed by a third metal plate made of the same material as that of the first metal plate and a first insulating layer 23 is formed between the base substrate 24 and the wiring pattern 22 The second insulating layer 25 made of the same material as the first insulating layer 25 is interposed, so that the worm of the heat transfer plate 21 can be further suppressed. The dimension of the base substrate 24 in the longitudinal direction is preferably the same as the dimension of the heat transfer plate 21 in the longitudinal direction.
In the light emitting unit 1 of the present embodiment, the solid light emitting element 3 is an LED chip, and the first electrode 31 and the second electrode 32 are provided on one side in the thickness direction, Each of the first electrode 31 and the second electrode 32 is electrically connected to the wiring pattern 22 via the wire 26. The through hole 21b for allowing each wire 26 to pass therethrough is formed on the heat transfer plate 21, The LED chip can be die-bonded to the heat conductive plate 21, heat generated in the LED chip can be easily transferred in the lateral direction of the heat conductive plate 21, and heat radiation can be improved.
When the LED chip is used as the solid light-emitting device 3, the sub-mount member that alleviates the stress acting on the LED chip due to the difference in coefficient of linear expansion between the solid light-emitting device 3 and the heat- The heat transfer plate 21 may be die-bonded. Here, the sub-mount member is preferably formed in a plane size larger than the chip size of the LED chip. When the LED chip is a GaN-based blue LED chip and the first metal plate is an aluminum plate, for example, AlN, a composite SiC, Si, CuW, or the like can be used as the material of the sub-mount member. In the sub-mount member, a reflective film for reflecting light emitted from the LED chip is formed around a bonding site (that is, a portion overlapping the LED chip) on the surface of the side where the LED chip is bonded . When the LED chip is provided with electrodes on both sides in the thickness direction, the first electrode (31) or the second electrode (32) disposed on the sub-mount member side of the LED chip is electrically And the first pattern 22a or the second pattern 22b may be electrically connected to the conductor pattern via the wires 26. [
36 shows an example of a lighting device 7 provided with a light-emitting unit 1. Fig. The lighting apparatus 7 is a lighting apparatus and includes a main body 71 for holding the light emitting unit 1 and the light emitting unit 1.
The mechanism body 71 is formed in a long shape (rectangular plate shape in this embodiment) having a larger planar size than the light emitting unit 1 and has a wiring pattern 22 on the other surface side of the heat transfer plate 21 in the light emitting unit 1 And the base board 24 are formed along the longitudinal direction of the instrument body 71. The concave portion 71a is formed in the longitudinal direction of the instrument body 71,
The illuminating device 7 is held in the instrument body 71 by a mounting tool 8 composed of a plurality of resin screws. Here, in the light emitting unit 1, the semicircular cut portions 21c (see A in Fig. 25) are spaced apart from each other in the longitudinal direction of the heat transfer plate 21 at both side edges in the width direction of the heat transfer plate 21, Respectively. Therefore, if the cutting portion 21c of the heat transfer plate 21 of the light emitting unit 1 is formed into a semicircular shape having a radius smaller than the circular head portion of the screw constituting the mounting tool 8, The light emitting unit 1 can be sandwiched and held between the light emitting unit 1 and the light emitting unit 71. 62 and 63, a fixing screw S1 for fixing the printed board 110 to the instrument body 103 is provided at both ends and a central portion in the longitudinal direction of the printed board 110 As compared with the light emitting diodes 4A to 4L in the lighting apparatus L employing the structure in which the screw holes 110b to be screwed therethrough are provided so as to penetrate the solid light emitting elements 3 and the respective joining portions 35 It becomes possible to reduce the stress.
The light emitting unit 1 is connected to a power source unit (not shown) through two electric wires 73 connected to the wiring pattern 22 by soldering or the like and supplies power from the power source unit to the light emitting unit 1 It is possible to cause each of the solid light-emitting elements 3 to emit light. 36 shows only one electric line 73 connected to the first terminal pattern 22f connected to the first pattern 22a at one end side in the longitudinal direction of the heat transfer plate 21, , One electric wire 73 is connected to a second terminal pattern (not shown) connected to the second pattern 22b. The first terminal pattern 22f and the second terminal pattern are formed by a part of the wiring pattern 22 formed by the lead frame 120 described above.
The light emitting unit 1 can suppress the warpage of the heat transfer plate 21 and the arrangement pitch of the solid light emitting elements 3 can be shortened to suppress the appearance of each solid light emitting element 3 as a point light source Becomes possible, and it becomes possible to make it appear as a linear light source.
In the illuminating device 7 of the present embodiment described above, by providing the light emitting unit 1 described above, heat dissipation can be improved, and high output of light output can be achieved.
Hereinafter, the light emitting unit 1 of this embodiment will be described with reference to Figs. 37 and 38. Fig.
The basic structure of the light emitting unit 1 of this embodiment is substantially the same as that of the third embodiment and the point that the base substrate 24 in the mounting substrate 2 has the same shape as the heat transfer plate 21 is different. The same components as those in the third embodiment are denoted by the same reference numerals, and a description thereof will be omitted.
A through hole 24b is formed in a portion of the base plate 24 corresponding to the through hole 21b of the heat transfer plate 21 and a cut portion 24c is formed at a portion corresponding to the cut portion 21c of the heat transfer plate 21. [ Is formed. The second insulating layer 25 has the same shape as the first insulating layer 23 and a through hole 25b is formed in a portion corresponding to the through hole 23b of the first insulating layer 23 .
In the light emitting unit 1 of this embodiment, it is possible to improve the heat dissipation performance as in the light emitting unit 1 of the third embodiment, and also to increase the light output power. Also in the light emitting unit 1 of the present embodiment, it is possible to suppress warping of the elongated heat transfer plate 21.
In the light emitting unit 1 of this embodiment, the base substrate 24 formed of the same material as the heat transfer plate 21 has the same shape as that of the heat transfer plate 21 to further suppress the warping of the light emitting unit 1 . In addition, the light emitting unit 1 of the present embodiment can achieve commonization of parts between the heat transfer plate 21 and the base substrate 24, and it is possible to reduce the cost.
The light emitting unit 1 of the present embodiment may be used in place of the light emitting unit 1 of the lighting apparatus 7 described in the third embodiment.
In the light emitting unit 1 of this embodiment, when the solid light emitting element 3 is mounted on the side opposite to the side of the second insulating layer 25 in the base substrate 24, the thickness direction of the mounting substrate 2 It is possible to emit light to both of the one surface side and the other surface side of the light emitting unit and can be used as a double-sided light emitting unit. Here, in the light emitting unit 1 of the present embodiment, the base substrate 24 also functions as a heat transfer plate, and heat generated in the solid light emitting element 3 or the like on the one surface side of the mounting substrate 2 is transferred to the heat transfer plate 21 Heat generated in the solid light emitting element 3 or the like on the other side of the mounting substrate 2 is transferred to the base substrate 24 in a good efficiency in the lateral direction and dissipated. When the light emitting unit 1 is configured as a double-sided light emitting unit, the base substrate 24 has the function of a heat transfer plate and the function of a reflection plate identical to those of the heat transfer plate 21.
Hereinafter, the light emitting unit 1 of this embodiment will be described with reference to FIG.
The basic structure of the light emitting unit 1 of the present embodiment is substantially the same as that of the third embodiment, except that the base substrate 24 is made of a resin substrate in which a filler having a higher thermal conductivity than that of the resin is mixed. The same components as those in the third embodiment are denoted by the same reference numerals, and a description thereof will be omitted.
The resin of the resin substrate preferably has a small difference in coefficient of linear expansion from the first metal plate as a base of the heat transfer plate 21. For example, when the material of the first metal plate is aluminum and the material of the second metal plate is copper, An ester resin, an unsaturated polyester resin or the like is preferably used. As the filler, for example, magnesium oxide, boron nitride, aluminum hydroxide, glass fiber and the like are preferably used. The filling rate of the filler is preferably about 60 vol% to about 75 vol%, so that the thermal conductivity of the resin substrate can be set to about 4 W / m · K to 10 W / m · K.
For example, the resin substrate may have a thermal conductivity of 5 W / m · K and a coefficient of linear expansion of 18 to 22 ppm when the vinyl ester resin is used as the resin and magnesium oxide is used as the filler, Or more. As described above, the thermal conductivity of aluminum is about 23 ppm and the thermal conductivity of copper is about 17 ppm.
Since the resin substrate is used as the base substrate 24 in the light emitting unit 1 of the present embodiment, the base substrate 24 is made of the same material as the first metal plate, like the light emitting unit 1 of Fig. It is possible to reduce the cost as compared with the case where the second insulating layer 25 is interposed between the wiring pattern 22 and the base substrate 24. [
In the light emitting unit 1 of the present embodiment, the base substrate 24 and the wiring pattern 22 can be simultaneously formed at the time of manufacturing, and the manufacturing cost can be reduced and the cost can be reduced.
Fig. 40 shows an example of a lighting device 7 provided with a light-emitting unit 1. Fig. This illuminating device 7 is a lighting device and includes a mechanism body 71 for holding the light emitting unit 1 and the light emitting unit 1.
In the light emitting unit 1, the width dimension of the base substrate 24 is set larger than the width dimension of the heat transfer plate 21. [ Therefore, even when the instrument body 71 has metal conductivity, the creepage distance between the heat transfer plate 21 and the wiring pattern 22 and the instrument body 71 can be set to be It becomes possible to lengthen it, and it becomes possible to secure a predetermined creepage distance. In the lighting device 7 of the present embodiment, when the instrument body 71 is made of metal, heat generated in the light emitting unit 1 can be dissipated with higher efficiency. When the instrument body 71 does not have conductivity, the width dimension of the base substrate 24 does not necessarily have to be larger than the width dimension of the heat transfer plate 21.
The lighting apparatus 7 of the present embodiment is provided with a plurality of mounting tools 8 for mounting the light emitting unit 1 to the instrument body 71. The mounting tool 8 is made of a synthetic resin and has a base portion 81 abutting against the side surface along the longitudinal direction of the instrument body 71 and the base substrate 24, And a holding portion 82 for holding the light emitting unit 1 with the instrument body 71. The mounting tool 8 in Fig. 40 is formed with an insertion hole 83 for inserting a screw (not shown) for fixing the mounting tool 8 to the instrument body 71. In the lighting device 7 of the present embodiment, since the holding portion 82 of the mounting tool 8 is disposed so as to overlap with the side portion in the width direction of the heat transfer plate 21, warpage of the heat transfer plate 21 can be suppressed .
The mounting tool 8 is not limited to being fixed to the instrument body 71 by means of a screw but is to be inserted into the mounting hole 9 of the instrument body 71 as shown in Fig. . 41, a T-shaped slide piece 84 protrudes from one surface of the base 81 on the base 81 in the mounting tool 8 shown in Fig. On the other hand, the mounting hole 9 of the instrument body 71 is formed with a wider portion 91 into which the slide piece 84 can be inserted and a narrower portion 92 with a narrower opening width than the wider portion 91, And is formed in a T shape. The mounting tool 8 is configured such that the slide piece 84 is inserted into the wide portion 91 of the mounting hole 9 and slid toward the narrow portion 92, The light emitting unit 1 can be mounted on the instrument body 71 without using screws.
The light emitting unit 1 of the present embodiment has the first protruding piece 24d protruding from one end surface in the longitudinal direction of the base substrate 24 and thinner than the other portion, And a second protruding piece 24e is provided. Here, one surface of the first projecting piece 24d in the thickness direction is flush with the one surface of the base substrate 24. The second projecting piece 24e has one surface in the thickness direction on the same plane as the other surface of the base substrate 24. The base substrate 24 is designed such that the total dimension of the thickness dimension of the first projecting pieces 24d and the thickness dimension of the second projecting pieces 24e is equal to the thickness dimension of the base substrate 24. [
The first projecting pieces 24d of the base substrate 24 in the light emitting unit 1 of one of the adjacent light emitting units 1 are arranged so as to be aligned with one another, And the second projecting pieces 24e of the base substrate 24 in the other light emitting unit 1 can be superimposed and arranged as shown in Figs. 42A and 42B. As compared with the case where the end faces of the base board 24 on which the first projecting pieces 24d and the second projecting pieces 24e are not provided are arranged to face each other in the lighting device 7 of the present embodiment, ) Or the wiring pattern 22 and the instrument body 71 can be made longer. The adjacent light emitting units 1 may be electrically connected to each other by the wiring patterns 22, for example, by electric wires (not shown) or connectors (not shown) for feeding wirings. As a result, in the lighting device 7 having the plurality of light emitting units 1, power is supplied from one power supply unit to the series circuit of the light emitting units 1, The element 3 can be made to emit light.
In the third to fifth embodiments, the wire 26 is bonded to the wiring pattern 22 disposed on the other surface side of the heat transfer plate 21. However, as shown in FIG. 43, The through hole 23b of the first insulating layer 23 and the protruding portion 22h inserted into the through hole 21b of the heat transfer plate 21 are provided and the wire 26 is bonded to the tip end face of the protruding portion 22h .
In the light emitting units 1 of Examples 3 to 5, the through holes 21b are formed on both sides of the mounting region of the solid light emitting element 3 in the width direction of the heat transfer plate 21. [ In other words, the solid light-emitting element 3 is mounted on the portion between the two through-holes 21b aligned in the width direction of the heat transfer plate 21. [ However, the present invention is not limited thereto. For example, as shown in Fig. 44, among the two sets of through holes 21b arranged in the width direction of the heat transfer plate 21, The solid light-emitting element 3 may be disposed between the two sets.
The basic structure of the light emitting unit 1 of this embodiment is substantially the same as that of the third embodiment, and the shape and the like of the mounting substrate 2 are different. The same components as those in the third embodiment are denoted by the same reference numerals, and a description thereof will be omitted.
The light emitting unit 1 of the third embodiment can be used as a light source of the lighting device 7 (see FIG. 36) formed of a lighting device such as a base light, Emitting unit 1 of the present invention can be used as a light source of an illumination device (not shown) comprising a lighting device such as a down light.
The wiring pattern 22 in the light emitting unit 1 of the present embodiment is also formed using a lead frame (not shown). The light emitting unit 1 can supply electric power from the power source unit by connecting electric wires to the first terminal patterns 22f and the second terminal patterns 22g by solder or the like.
In the light emitting unit 1 of this embodiment, it is possible to improve the heat dissipation performance as in the light emitting unit 1 of the third embodiment, and also to increase the light output power.
Hereinafter, a light emitting unit (hereinafter, referred to as a both-side light emitting unit) 1 of this embodiment will be described with reference to Figs. 46 to 52. Fig.
The double-sided light-emitting unit 1 includes a pair of heat transfer plates 21 and 24 arranged to be spaced apart in the thickness direction and a pair of heat transfer plates 21 and 24 which are mounted on one surface of the heat transfer plates 21 and 24 opposite to each other, And elements 3 and 3 are provided. The double-sided light emitting unit 1 includes a wiring pattern 22 disposed between the heat transfer plates 21 and 24 and electrically connected to the solid state light emitting elements 3 and 3, And a pair of insulating layers (23, 25) interposed between the wiring patterns (22). Here, each of the heat transfer plates 21 and 24 is formed by a first metal plate, and the wiring pattern 22 is formed by a second metal plate. In this embodiment, the mounting substrate 2 on which all the solid state light emitting elements 3 are mounted is formed of a pair of the heat transfer plates 21 and 24, the pair of insulating layers 23 and 25, and the wiring pattern 22, .
Hereinafter, each component of the double-sided light emitting unit 1 will be described in detail.
Each of the heat transfer plates 21 and 24 is formed in a long shape (in this case, an elongated rectangular plate shape). Each of the heat transfer plates 21 and 24 has a plurality of solid light emitting elements 3 arranged along the longitudinal direction of each of the heat transfer plates 21 and 24 on the one surface side.
As a material of the first metal plate serving as a base of each of the heat transfer plates 21 and 24, a metal having a high thermal conductivity such as aluminum or copper is preferable. However, the material of the first metal plate is not limited to these, and may be stainless steel, steel, or the like.
It is preferable that each of the heat transfer plates 21 and 24 has a function as a reflection plate, and aluminum is more preferably used as the material of the first metal plate. Each of the heat transfer plates 21 and 24 is formed by stacking an aluminum film having a higher purity than the aluminum plate on the side opposite to the side of the insulating layers 23 and 25 in the aluminum plate, It is preferable that a retroreflective film composed of two different kinds of dielectric films are laminated. Here, as the two kinds of dielectric films, for example, it is preferable to adopt a SiO 2 film and a TiO 2 film. By using such heat transferring plates 21 and 24, it becomes possible to make the reflectance with respect to visible light 95% or more. As such heat transfer plates 21 and 24, for example, MIRO2 and MIRO (registered trademark) of Alanod Co., Ltd. and the like can be used. As the above-mentioned aluminum plate, an anodized surface may be used. The thickness of each of the heat transfer plates 21 and 24 may be appropriately set within a range of, for example, about 0.2 to 3 mm.
The solid light emitting element 3 mounted on each of the heat transfer plates 21 and 24 has a first electrode (anode electrode) 31 and a second electrode (cathode electrode) (not shown) on one surface side in the thickness direction 32, and the other surface side in the thickness direction is bonded to the heat transfer plates 21, 24 through the bonding portion 35. [ Each of the first electrode 31 and the second electrode 32 of the solid light emitting device 3 is electrically connected to the wiring pattern 22 through a wire (bonding wire) 26. Here, the heat transfer plates 21 and 24 are formed with through holes 21b and 24b through which the wires 26 pass, respectively. The through holes 21b and 24b are formed on both sides of the mounting region of the solid light emitting element 3 in the width direction of the heat transfer plates 21 and 24. The through holes 21b and 24b have a circular opening shape. The inner diameters of the through holes 21b and 24b are set to 0.5 mm, but this value is merely an example and is not particularly limited. The shape of the through holes 21b, 24b is not limited to a circular shape, and may be, for example, a rectangular shape, an elliptical shape, or the like. In the case where the solid light emitting element 3 is an LED chip, the bonding portion 35 may be formed by a die bond material.
The LED chip is a GaN-based blue LED chip that emits blue light, and a sapphire substrate is used as the substrate. However, the substrate of the LED chip is not limited to the sapphire substrate but may be a GaN substrate, a SiC substrate, a Si substrate, or the like. The structure of the LED chip is not particularly limited.
49, when the LED chip is used as the solid light-emitting element 3, the double-sided light-emitting unit 1 is provided with the solid-state light-emitting element 3 on one side of the heat- (3) and a sealing portion (36) sealing the wire (26). In Fig. 49, a silicone resin which is the first translucent material is used as the material of the sealing portion 36. Fig. The first translucent material is not limited to a silicone resin, and for example, an epoxy resin, an acrylic resin, glass, or the like may be used.
When the LED chip is used as the solid light-emitting element 3, the double-sided light-emitting unit 1 is required to have a wavelength conversion material that radiates light of a different color from the light emitted from the LED chip And a color conversion unit 37 as shown in FIG. As such a color conversion section 37, for example, a phosphor that is excited by light emitted from the LED chip and emits light of a color different from the emission color of the LED chip is used as a wavelength conversion material, It is preferable to include a light-transmitting material.
When the blue LED chip is used as the LED chip and the yellow phosphor is used as the phosphor of the color conversion unit 37, for example, the double-side light-emitting unit 1 can obtain white light. That is, in the double-sided light emitting unit 1, the blue light emitted from the LED chip and the light emitted from the yellow phosphor are radiated through the surface of the color conversion portion 37, so that white light can be obtained. A silicone resin is used as the second translucent material used as the material of the color conversion portion 37. However, the present invention is not limited to this. For example, acrylic resin, glass, , A combined organic-inorganic hybrid material, or the like may be employed. The phosphor used as the material of the color conversion portion 37 is not limited to the yellow phosphor. For example, by using the yellow phosphor and the red phosphor or by using the red phosphor and the green phosphor, the color rendering property can be enhanced . The phosphor used as the material of the color conversion portion 37 is not limited to one kind of yellow phosphor and two kinds of yellow phosphors having different emission peak wavelengths may be used.
In the case where white light can be emitted by a single LED chip or when a phosphor is dispersed in the sealing portion 36 or when the color of light desired to be obtained by the double-side light emitting unit 1 is the same as that of the LED chip, It is possible to adopt a structure in which the conversion section 37 is not provided.
The double-sided light-emitting unit 1 is preferably arranged not only in the heat generated in the LED chip, but also in the color conversion unit 37, The heat generated by the heat transfer plates 21 and 24 can be dissipated through the heat transfer plates 21 and 24 so that the light output can be made higher. In the example shown in FIG. 49, the color conversion unit 37 is formed into a semi-cylindrical shape And is provided between the heat conductive plates 21 and 24 on the one surface side of the heat conductive plates 21 and 24 so as to surround the LED chip and the sealing portion 36. More specifically, ) Is disposed so as to form a gas layer (for example, an air layer) 38 between the sealing portions 36 on the one surface side of the heat transfer plate 21. The double- , The color conversion section 37 is formed into a hemispherical shape, and the color conversion section 37 converts the color conversion section 37 into a solid- The double-sided light emitting unit 1 may be configured such that the color conversion unit 37 is formed into a dome-shaped shape, The LED chip and the wire 26 which are the solid light-emitting element 3 may be sealed by the sealing member 37. The double-sided light-emitting unit 1 may be configured such that the color- The LED chip and the wire 26 as the solid light emitting element 3 may be sealed by the color conversion portion 37. The color conversion portion 37 as shown in Figs. (For example, a silicone resin, an epoxy resin, or the like) is used for the end surfaces of the heat transfer plates 21 and 24 (peripheral edges of the openings) on the heat transfer plates 21 and 24 The color conversion portion 37 as shown in Fig. 53 can be formed by, for example, a molding method. Such as the color conversion unit 37 it is, for example, can be formed by a coating method using a dispenser or a screen printing method.
The wiring pattern 22 is formed by a second metal plate having a coefficient of linear expansion different from that of the heat transfer plates 21 and 24 as described above. Here, the second metal plate uses a lead frame 120 (refer to C in Fig. 52) formed by punching a metal hoop material by pressing.
The material of the second metal plate is preferably a copper having a relatively high thermal conductivity among metals (the copper thermal conductivity is about 398 W / m · K), but is not limited to copper and may be phosphor bronze or the like, 42 alloy or the like). The thickness of the second metal plate is preferably set to, for example, about 100 m to 1500 m.
The lead frame 120 is formed such that the wiring pattern 22 is supported on the inner side of the outer frame portion 121 through the support piece 122 (see D in FIG. 52). The wiring patterns 22 are formed such that the first pattern 22a to which the first electrode 31 of the solid state light emitting element 3 is connected and the second pattern 22b to which the second electrode 32 is connected form the heat transfer plate 21 And 24, respectively. The wiring pattern 22 has a predetermined number (for example, 16) of the first pattern 22a and the second pattern 22b, and the first pattern 22a and the second pattern 22b 22b are arranged side by side in the longitudinal direction of the heat transfer plates 21, 24 (see FIG. 50). The first pattern 22a and the second pattern 22b are formed in a rectangular shape and arranged so as to coincide with the heat transfer plates 21 and 24 in the longitudinal direction. The first patterns 22a arranged in the longitudinal direction of the heat transfer plates 21 and 24 are divided into two sets and the first patterns 22a forming the sets are arranged on the connecting piece 22c Lt; / RTI > The wiring pattern 22 is divided into two sets of the second patterns 22b of a prescribed number (for example, 16) aligned in the longitudinal direction of the heat transfer plates 21 and 24, And the patterns 22b are connected and electrically connected to each other by a connecting piece 22d. The connecting pieces 22c and 22d are provided with a first linear portion 22ca and 22da arranged along the width direction of the heat transfer plates 21 and 24 and a second linear portion 22c and 22d extending from both ends of the first portions 22ca and 22da in the longitudinal direction, Second portions 22cb, 22db and third portions 22cc, 22dc extending in the opposite directions in the longitudinal direction of the first portion 22c. The connecting piece 22c is formed narrower than the first pattern 22a and the connecting piece 22d is formed narrower than the second pattern 22b. Here, the wiring pattern 22 includes two first patterns 22a forming a set, a connecting piece 22c connecting the two first patterns 22a, two second patterns 22b forming a set, And a connecting piece 22d connecting these two second patterns 22b constitute one unit pattern 22u. In the above-described lead frame 120, a plurality of unit units 22u are arranged along the longitudinal direction of the outer frame portion 121. [ The wiring patterns 22 are formed in such a manner that the unit patterns 22u adjacent to each other in the lengthwise direction of the heat transfer plates 21 and 24 are spaced apart from the first patterns 22a of the unit patterns 22u 22u are connected and electrically connected by the contact piece 22e. The contact piece 22e is narrower than the first pattern 22a and the second pattern 22b.
The wiring patterns 22 are formed by connecting a predetermined number (for example, six) of the solid light emitting elements 3 arranged in parallel in the longitudinal direction of the heat transfer plates 21 and 24 for each unit pattern 22u in parallel to form a parallel circuit And a parallel circuit formed for each adjacent unit pattern 22u can be connected in series. Therefore, power can be supplied to all the solid light-emitting elements 3 by supplying power between the first pattern 22a at one end in the longitudinal direction of the heat transfer plates 21 and 24 and the second pattern 22b at the other end.
The insulating layers 23 and 25 are made of an epoxy resin layer (thermosetting resin) having a property of containing a filler made of a filler such as silica or alumina and having a low viscosity and high fluidity at the time of heating, (For example, an adhesive sheet TSA manufactured by Toray Industries, Inc.) having a thermosetting adhesive layer (PET film) laminated thereon. As the filler, an insulating material having a higher thermal conductivity than an epoxy resin as a thermosetting resin may be used. Here, the epoxy resin layer of the sheet-like adhesive has electrical insulating properties, high thermal conductivity, high fluidity at the time of heating, and high adhesiveness to uneven surfaces. Therefore, it is possible to prevent the occurrence of gaps between the insulating layers 23 and 25 and the heat transfer plates 21 and 24 and the wiring pattern 22, thereby improving the adhesion reliability and improving the thermal resistance due to insufficient adhesion And occurrence of unevenness can be suppressed. Therefore, compared with the case of sandwiching a rubber sheet type heat radiation sheet or the like such as SOCON (registered trademark) between the heat conductive plates 21 and 24 and the wiring pattern 22, It is possible to reduce the thermal resistance and reduce the unevenness of the thermal resistance so that the heat dissipation is improved and the temperature rise of the junction temperature of each solid light emitting element 3 can be suppressed, And high output power of the light output can be achieved. The thickness of the above-described epoxy resin layer is set to be 100 占 퐉, but this value is merely an example and is not particularly limited. For example, it may be suitably set within a range of about 50 占 퐉 to 150 占 퐉. The thermal conductivity of the above-described epoxy resin layer is preferably 4 W / m · K or more. The plastic film of the sheet-like adhesive is peeled from the epoxy resin layer before the wiring pattern 22 and the heat transfer plates 21 and 24 are superimposed. That is, after one surface of the epoxy resin layer opposite to the plastic film side is fixed to the object, the plastic film is peeled off.
Here, at the time of forming the insulating layers 23 and 25, the heat transfer plates 21 and 24 and the lead frame 120 having the epoxy resin layer and the wiring pattern 22 may be appropriately pressed in a superposed state.
The outer size of the insulating layers 23 and 25 may be suitably set in accordance with the outer size of the lead frame 120. Here, the insulating layers 23 and 25 have electrical insulation and thermal conductivity, and have a function of electrically insulating the heat transfer plates 21 and 24 from the wiring patterns 22, and a function of thermally coupling them.
The insulating layers 23 and 25 are formed with through holes 23b and 25b communicating with the through holes 21b and 24b of the heat transfer plates 21 and 24, respectively. The wire 26 is passed through the through holes 21b and 24b of the heat transfer plates 21 and 24 and the through holes 23b and 25b of the insulating layers 23 and 25 at the time of manufacturing the double- And can be bonded to the wiring pattern 22. The first pattern 31 and the second electrode 32 of the solid state light emitting element 3 and the first pattern 22a and the second pattern 22b are connected to each other by wire The material of the sealing portion 36 (see FIG. 49) is filled in the through holes 21b, 24b and the through holes 23b, 25b by a dispenser or the like, 26 are not brought into contact with the first metal plate, and then the sealing portion 36 is formed.
The wiring pattern 22 is formed of a metal material having higher oxidation resistance and corrosion resistance than the second metal plate and has a surface treatment layer (not shown) having a high adhesion with the insulating layers 23 and 25 desirable. When the material of the second metal plate is Cu, it is preferable to form, for example, a Ni film, a lamination film of an Ni film and an Au film, a Ni film, a lamination film of a Pd film and an Au film, Do. The surface treatment layer may be formed by plating, for example.
However, depending on the size of the heat capacity of the heat transfer plates 21 and 24, if the heating temperature of the epoxy resin layer is increased to about 170 ° C and hardened, the fixing performance between the heat transfer plates 21 and 24 and the wiring patterns 22 may deteriorate If the heating temperature is lowered to about 150 ° C., the electric insulation between the heat conductive plates 21 and 24 and the wiring pattern 22 may be deteriorated. That is, the fixing performance and the electric insulation have a trade-off relationship. Thus, in the present embodiment, as described later, the epoxy resin layers 123a and 133a (C of FIG. 51 and B of FIG. 52) of the sheet-like adhesives 123 and 133 (see FIG. 51B and FIG. 52A) And the other epoxy resin layer 133a is cured at 150 DEG C to secure the fixing performance and thermoelectric properties of the epoxy resin layer 133a by superimposing the epoxy resin layer 123a on the other epoxy resin layer 123a at 170 DEG C to secure electrical insulation and thermal conductivity, To secure the city. The other epoxy resin layer 133a and the lead frame 120 are overlapped with each other so that the other epoxy resin layer 133a and the lead frame 120 are stacked, The resin layer 133a may be cured at 150 deg. Thus, when manufacturing the double-sided light emitting unit 1 of the present embodiment, it is possible to satisfy both the fixing performance and the electric insulation requirement, regardless of the heat capacity of the heat transfer plates 21 and 24.
Hereinafter, a method of joining the heat transfer plate 21 and the wiring pattern 22 will be briefly described with reference to Figs. 51 and 52. Fig.
51B, a sheet-like adhesive 123 is superimposed on the other surface of the heat transfer plate 21 so that the epoxy resin layer 123a is in contact with the heat transfer plate 21, (For example, 110 占 폚 to 120 占 폚) which is lower than the curing temperature of the epoxy resin layer 123a while being pressed at a predetermined pressure (for example, 0.5 MPa) 123 are attached to the heat transfer plate 21. Then, the sheet-like adhesive 123 is cut to an appropriate length.
Thereafter, the heat transfer plate 21 on which the sheet-like adhesive 123 is fixed is naturally cooled. Subsequently, as shown in Fig. 51C, the plastic film 123b is peeled off from the epoxy resin layer 123a.
Thereafter, the heat transfer plate 21 in which the epoxy resin layer 123a is fixedly attached is placed in a drying furnace (not shown), and the epoxy resin layer 123a is heated to a temperature (for example, 170 DEG C) And the epoxy resin layer 123a is fixed to the heat conductive plate 21 by heating and curing.
Thereafter, in each of the regions corresponding to the through holes 23b of the insulating layer 23 in the laminated structure of the epoxy resin layer 123a and the epoxy resin layer 133a, as shown in Fig. 52A, For example, the through hole 134 is formed by the laser device 150. The means for forming the through hole 134 is not limited to the laser device 150, and for example, a drill or the like may be used.
52C, the lead frame 120 is mounted on the epoxy resin layer 133a and an appropriate load is applied. Then, an epoxy resin layer 133a is formed in a drying furnace (not shown) The lead frame 120 and the epoxy resin layer 133a are temporarily fixed to each other by hardening the lead frame 120 and the epoxy resin layer 133a at a temperature equal to or higher than the hardening temperature (for example, 150 DEG C). Thereby, the insulating layer 23 is formed.
Thereafter, the wiring pattern 22 is cut off at the support piece 122 of the lead frame 120, and as shown in Fig. 52D, a portion other than the wiring pattern 22 in the lead frame 120 is peeled off I will.
The heat transfer plate 24 and the wiring pattern 22 are bonded to each other via the insulating layer 25 in the same manner as in the case where the heat transfer plate 21 and the wiring pattern 22 are bonded via the insulating layer 23, The mounting board 2 can be obtained.
The solid light emitting element 3 is bonded to the one surface side of the heat transfer plates 21 and 24 and then the first electrode 31 and the second electrode 31 of each solid light emitting element 3 are bonded, The electrodes 32 may be electrically connected to the first pattern 22a and the second pattern 22b through the wires 26. [ Thereafter, the sealing portion 36 and the color conversion portion 37 may be provided on one side of the heat transfer plates 21 and 24, if necessary.
As described above, the double-sided light-emitting unit 1 of this embodiment comprises a pair of heat transfer plates 21 and 24 formed by a first metal plate and spaced apart in the thickness direction, and a pair of heat transfer plates 21 and 24 (3, 3) mounted on the one surface side opposite to the opposing surfaces of the solid light emitting elements (3, 3) and the second metal plate and disposed between the two heat transfer plates (21, 24) And a pair of insulating layers 23 and 25 sandwiched between the respective heat transfer plates 21 and 24 and the wiring pattern 22, as shown in Fig. Thus, in the double-sided light emitting unit 1 of the present embodiment, heat generated in each of the solid light emitting elements 3 can be efficiently conducted in the lateral direction by the heat transfer plates 21 and 24 to radiate heat. Therefore, in the double-sided light emitting unit 1 of the present embodiment, it is possible to improve the heat dissipation property, thereby suppressing the temperature rise of each solid light emitting element 3 and achieving high light output.
In the double-side light-emitting unit 1 of this embodiment, the solid-state light-emitting element 3 is an LED chip, heat generated in the LED chip is transferred in the lateral direction by the heat conductive plates 21 and 24, It becomes possible.
In the double-sided light-emitting unit 1 of this embodiment, the first metal plate as a foundation of each of the heat transfer plates 21 and 24 is an aluminum plate, and the side of the aluminum plate opposite to the side of the insulating layers 23 and 25 Reflection film made of two kinds of dielectric films having different refractive indexes are laminated on the aluminum film and the light incident on one surface of the heat transfer plates 21 and 24 is emitted from the LED chip It is possible to reflect with good efficiency. That is, the double-sided light-emitting unit 1 can reduce the light loss in the heat transfer plates 21 and 24 by using the heat transfer plates 21 and 24 having the function as the reflection plate, . Particularly, when the LED chip is used as the solid light-emitting element 3, the double-sided light-emitting unit 1 can efficiently dissipate heat generated in the LED chip, thereby achieving high output of light output In addition, it is possible to improve the utilization efficiency of the light emitted from the LED chip. The double-side light-emitting unit 1 is provided with the color conversion portion 37 (see FIG. 49 and the like) Light or light emitted from the LED chip and scattered toward the heat conductive plates 21 and 24 by the fluorescent material can be reflected, thereby making it possible to improve the utilization efficiency of light.
The double-side light-emitting unit 1 of the present embodiment is provided with the wiring pattern 22 formed by using the heat transfer plates 21 and 24 and the lead frame 120 so that the solid light- A high output of light output can be achieved at a low cost as compared with a case where the printed circuit board is mounted on a printed wiring board.
In the two-sided light emitting unit 1 of the present embodiment, the solid light emitting element 3 is an LED chip, and the first electrode 31 and the second electrode 32 are provided on one side in the thickness direction, The electrode 31 and the second electrode 32 are electrically connected to the wiring pattern 22 through the wire 26 and the through holes 32, The LED chips can be die-bonded to the heat conductive plates 21 and 24 so that heat generated in the LED chips can be easily transferred in the lateral direction of the heat conductive plates 21 and 24, .
When the LED chip is used as the solid light-emitting element 3, the sub-mount member 23 for relieving the stress acting on the LED chip due to the difference in coefficient of linear expansion between the solid light-emitting element 3 and the heat- The heat transfer plates 21 and 24 may be die-bonded. Here, the sub-mount member is preferably formed in a plane size larger than the chip size of the LED chip. When the LED chip is a GaN-based blue LED chip and the first metal plate is an aluminum plate, for example, AlN, a composite SiC, Si, CuW, or the like can be used as the material of the sub-mount member. In the sub-mount member, a reflective film for reflecting light emitted from the LED chip is formed around the bonding site (that is, a portion overlapping the LED chip) on the surface of the side where the LED chip is bonded . When the LED chip is provided with electrodes on both sides in the thickness direction, the first electrode (31) or the second electrode (32) disposed on the sub-mount member side of the LED chip is electrically And the first pattern 22a or the second pattern 22b may be electrically connected to the conductor pattern via the wire 26. [
In the above-described double-sided light emitting unit 1, the through holes 21b are formed on both sides of the mounting region of the solid light emitting element 3 in the width direction of the heat transfer plate 21. [ In other words, the solid light-emitting element 3 is mounted on the portion between the two through-holes 21b aligned in the width direction of the heat transfer plate 21. [ However, the present invention is not limited to these examples. For example, as shown in Fig. 56, among two sets of through holes 21b arranged in the width direction of the heat transfer plate 21, two The solid light-emitting element 3 may be disposed between the two sets. The solid light-emitting element 3 mounted on the heat transfer plate 24 may be arranged in the same manner as in Fig.
The double-side light-emitting unit 1 of this embodiment can be used as a light source of various lighting devices. For example, as an example of the lighting apparatus having the double-sided light emitting unit 1 of the present embodiment, an LED lamp 700 of an straight tube type as shown in Fig. 57 can be constructed. For the general straight tube type LED lamp, for example, "L-shaped pin cap GX16t-5-part straight tube type LED lamp system (general illumination type" (JEL 801)) is standardized by the Japan Light Bulb Industry Association, The intuitive LED lamp 700 shown in Fig. 57 is designed to satisfy the JEL 801 standard.
The intuitive LED lamp 700 shown in Fig. 57 has an introductory tube main body 702 formed of a light-transmitting material (e.g., glass or the like) And the above-described double-sided light-emitting unit 1 (see Fig. 46, etc.) is accommodated in the pipe body 702. Fig.
The first lamp socket of the lighting apparatus and the first lamp socket of the second lamp socket are connected to the vertex 703 provided at one end in the longitudinal direction of the tube main body 702, Two first lamp pins (terminals) 714 for supplying power to the lamp 1 are provided. A second lamp pin (terminal) 715 for grounding, which is held by the second lampholder, is provided on the vertex 704 at the other end in the longitudinal direction of the tube main body 702.
The two first lamp pins 714 protrude from the end face of the vertex 703 (the first vertex reference face) to the side opposite to the side of the tube main body 702. Here, the first lamp pin 714 is electrically connected to the wiring pattern 22 of the double-side light-emitting unit 1 housed in the tube main body 702.
Each of the first lamp pins 714 has a L-shaped portion protruding from the end surface of the mouthpiece 703 and has a pin body 714a protruding along the longitudinal direction of the tube body 702, And a key portion 714b extending from one end of the tube main body 702 along one radial direction. Here, the two key portions 714b extend in directions away from each other. The first lamp pin 714 is formed by bending an elongated conductive plate.
The second lamp pin 715 protrudes from the end face of the vertex 704 (the second vertex reference face) to the side opposite to the pipe body 702 side. The second lamp pin 715 includes a pin body 715a having a T-shaped portion protruding from the end surface of the mouthpiece 704 and protruding along the longitudinal direction of the tube body 702, And a terminal portion 715b of a long circular shape, which is provided at the tip end of the base portion 715a and viewed from the front.
The intuitive LED lamp 700 of this embodiment can improve heat dissipation as compared with the conventional straight tube LED lamp and the lighting apparatus 600 shown in Fig. 66, It becomes possible.
The illumination device provided with the double-sided light emitting unit 1 of the present embodiment is not limited to the above-described straight tube LED lamp 700, and for example, a lighting device having a mechanism body for housing the double- You can go. Here, the semi-circular cutting portions 21c and 24c are spaced apart from each other in the longitudinal direction of the heat transfer plates 21 and 24 at both side edges in the width direction of the heat transfer plates 21 and 24, And are formed at regular intervals. Therefore, the cutting portions 21c and 24c of the heat conductive plates 21 and 24 of the double-sided light emitting unit 1 are formed in a semicircular shape having a smaller radius than the circular head portion of the screw for mounting the double- , The double-sided light emitting unit 1 can be sandwiched between the head portion of the screw and the mechanism body. In this lighting device, it becomes possible to reduce the stresses associated with the respective solid light emitting elements 3 and the respective joint portions 35. [
In the lighting apparatus of the present embodiment described above, since the double-sided light emitting unit 1 is provided, heat dissipation can be improved, and high output of light output can be achieved.
The arrangement of the double-side light-emitting unit 1 in the lighting apparatus is not particularly limited. For example, in the lighting apparatus, a plurality of the double-sided light emitting units 1 may be arranged on a straight line. In this case, the wiring patterns 22 of the adjacent double- It may be electrically connected by an electric wire (not shown) or a connector (not shown) for wiring. As a result, in the lighting apparatus provided with the plurality of double-sided light emitting units 1, power is supplied from one power source unit to the series circuit of the double-sided light emitting unit 1, The element 3 can be made to emit light.
Hereinafter, the double-sided light emitting unit 1 of the present embodiment will be described with reference to Fig. In the present embodiment, the double-sided light emitting unit 1 constitutes a light emitting unit.
The basic structure of the light emitting unit 1 of this embodiment is substantially the same as that of the seventh embodiment, and the shape and the like of the mounting substrate 2 are different. The same constituent elements as those of the seventh embodiment are denoted by the same reference numerals, and description thereof is omitted.
In the double-sided light emitting unit 1 of the present embodiment, the heat transfer plates 21 and 24 are octagonal in shape when viewed in plan, and a plurality of (in the illustrated example, , 12 x 6) solid light-emitting elements 3 are arranged in a two-dimensional array. Here, the shape of the heat transfer plates 21 and 24 is not limited to an octagonal shape, but may be, for example, another polygonal shape, a circular shape, an elliptical shape, or the like.
The wiring pattern 22 in the double-sided light emitting unit 1 of this embodiment is also formed using a lead frame (not shown). The double-sided light-emitting unit 1 is formed by connecting electric wires 63 and 63 (see Fig. 59) to the first terminal pattern 22f and the second terminal pattern 22g of the wiring pattern 22 by soldering or the like Power can be supplied from the power source unit.
In the double-sided light emitting unit 1 of the present embodiment, as in the case of the double-sided light emitting unit 1 of the seventh embodiment, it is possible to improve the heat radiation performance and to increase the light output.
Here, as an example of the illumination apparatus having the double-sided light emission unit 1 described above, the illumination apparatus 40 having the configuration shown in Fig. 59 is exemplified.
The lighting apparatus 40 of the configuration shown in Fig. 59 has a flat first cover member 50 having a housing recess 51 for housing the double-sided light emitting unit 1 on one surface in the thickness direction, And the second cover member 60 housed in the housing concave portion 51 of the housing 50 so as to cover the both-side light emitting unit 1. Spacers (not shown) are provided between the double-side light-emitting unit 1 and the first cover member 50 and the second cover member 60, respectively. The first cover member 50 is formed with a cutting portion 54 through which electric power lines 63 and 63 for feeding power to the double-sided light emitting unit 1 are inserted. A power supply unit (not shown) provided separately from the first terminal pattern 22f of the double-sided light emitting unit 1 and the one end side connected to the second terminal pattern 22g in each of the electric wires 63 and 63 And a second connector 70 detachably connected to a first connector (not shown) for output of the second connector 70 (not shown).
The first cover member 50 and the second cover member 60 may be formed entirely of a translucent material or may be formed of a translucent material only in a region that draws light emitted from the both- . In addition, the shape and the configuration of the lighting apparatus constituting the lighting apparatus are not particularly limited. The lighting device is not limited to the lighting device 40, and may be, for example, a display device or the like.
In the illumination device of the present embodiment described above, the heat dissipation property can be improved and the light output can be made higher by providing the double-sided light emission unit 1 described above.
And a plurality of solid state light emitting elements arranged on one side of the mounting substrate,
Wherein the mounting substrate is formed by a first metal plate and a heat transfer plate and a second metal plate on which the respective solid light emitting elements are mounted on one surface side and is disposed on the other surface side of the heat transfer plate and the solid light emitting elements are electrically connected Wiring pattern, and
And an insulating layer interposed between the heat transfer plate and the wiring pattern,
The solid light emitting device is an LED chip,
Wherein each of the LED chips is provided with a first electrode and a second electrode on one side in the thickness direction and each of the first electrode and the second electrode is electrically connected to the wiring pattern via a wire, Wherein a through hole is formed through each of the wires,
Emitting unit.
The method according to claim 1,
Wherein the insulating layer contains a filler having a higher thermal conductivity than the thermosetting resin in the thermosetting resin.
Wherein the first metal plate is an aluminum plate and an aluminum film having a higher purity than that of the aluminum plate is laminated on the side of the aluminum plate opposite to the side of the insulating layer and the two kinds of dielectric films And a light-emitting layer formed on the light-emitting layer.
And a color conversion section including a phosphor and a translucent material which is excited by light emitted from the LED chip and emits light of a color different from a color of light emitted from the LED chip, .
3. The method according to claim 1 or 2,
Wherein the heat transfer plate has a long shape and the solid light emitting elements are arranged along the longitudinal direction of the heat transfer plate and the difference in coefficient of linear thermal expansion between the second metal plate and the first metal plate is small, And an elongated base substrate disposed on the opposite side.
8. The method of claim 7,
Wherein the base substrate is made of a resin substrate in which a resin is mixed with a filler having a thermal conductivity higher than that of the resin.
The base plate is formed by a third metal plate made of the same material as the first metal plate, the insulating layer is a first insulating layer, and the base plate and the wiring pattern are made of the same material as the first insulating layer Wherein a second insulating layer is interposed.
A lighting device comprising the light-emitting unit according to any one of claims 1 to 3.
A pair of heat transfer plates formed by the first metal plate and spaced apart in the thickness direction,
A solid light emitting element mounted on one surface of the heat transfer plate opposite to the mutually facing surfaces,
A wiring pattern formed by a second metal plate and disposed between the both heat transfer plates and electrically connected to the respective solid light emitting elements, and
A pair of insulating layers interposed between the respective heat transfer plates and the wiring patterns,
/ RTI >
12. The method of claim 11,
14. The method according to claim 11 or 13,
A lighting device comprising the light-emitting unit according to claim 11 or claim 13.
KR20127026385A 2010-04-26 2011-04-26 Leadframe, wiring board, light emitting unit, and illuminating apparatus KR101495580B1 (en)
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