JP2007129273A - Method for manufacturing led display apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a LED display apparatus, which enables manufacturing process to be simplified by reducing more of the number of components than ever before, and uses a high thermal conductivity three-dimensional substrate with an excellent heat dissipation property. <P>SOLUTION: A high thermally conductive three dimensional substrate is manufactured, where a concave 10 for mounting an electronic component is provided in an insulating layer 9 by means of a convex 4 of a mold plate 5 by: forming a circuit pattern 6 on the surface of the mold plate 5 on which the convex 4 is provided; superposing a metal substrate 8 on the surface through a resign sheet 7 containing a filler; heating and pressurizing them to stack and unify the insulating layer 9 made of the resin sheet 7 on the metal substrate 8; transferring the circuit pattern 6 on the insulating layer 9; and subsequently releasing the mold plate 5 from the insulating layer 9. Then, LED 2 is mounted in the concave 10 of the high thermally conductive three dimensional substrate while electrically connecting LED 2 and the circuit pattern 6, thereafter transparent sealant 18 is poured in the concave 10, while being molded into a lens shape. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for manufacturing an LED display device equipped with a light emitting diode (LED).

  Conventionally, the LED display device 3 is manufactured as follows. That is, for example, after a glass cloth base epoxy resin copper-clad laminate is manufactured in advance and used as the LED mounting substrate 1, the copper foil on the surface is etched to form the circuit pattern 6. The LED 2 is mounted on the surface of the LED mounting substrate 1 as shown in FIG. 6A, and the LED 2 and the LED mounting substrate 1 are electrically connected by a bonding wire 13 such as a gold wire. Next, as shown in FIG. 6B, a frame 16 surrounding the periphery of the LED 2 is bonded to the LED mounting substrate 1 to form a recess 17 so that the LED 2 is located inside. Then, by pouring the transparent sealing agent 18 into the recessed portion 17 and filling the recessed portion 17 with the transparent sealing agent 18, the LED display device 3 as shown in FIG. 6C can be manufactured. is there. In order to reflect light emitted from the LED 2 to the opening side of the recessed portion 17, the wall surface in the recessed portion 17 is inclined toward the opening side.

  Here, in the LED display device 3 shown in FIG. 6C, there is one LED 2 mounted on the LED mounting substrate 1, but in recent years, the LED 2 mounted on the LED mounting substrate 1. The number of people tends to increase. Therefore, recently, the LEDs 2 are densely packed on the LED mounting substrate 1, and heat generated from the LEDs 2 cannot be ignored, and this heat causes a problem that the performance of the LEDs 2 is deteriorated.

  For such problems, for example, the glass cloth base epoxy resin copper-clad laminate used as the LED mounting substrate 1 is changed to a high thermal conductivity type, or the LED 2 is directly attached to the metal substrate 8. The heat | fever emitted from LED2 is considered to escape outside by doing, and the application regarding this is made | formed.

  However, even if a high thermal conductivity type substrate is used as the LED mounting substrate 1, the process for manufacturing the LED display device 3 is basically the same as described above, and on the contrary, the cost increases. In the method of directly attaching the LED 2 to the metal substrate 8, it is necessary to go through a special process, which increases the man-hours as a whole, and has a problem that the cost becomes very high. It was.

  The present invention has been made in view of the above points, and it is possible to simplify the manufacturing process by reducing the number of parts as compared with the related art, and an LED display device using a highly thermally conductive three-dimensional substrate excellent in heat dissipation. The object is to provide a manufacturing method.

  In the manufacturing method of the LED display device according to claim 1 of the present invention, the circuit pattern 6 is formed on the surface of the mold plate 5 provided with the convex portions 4, and the resin sheet 7 containing the filler is provided on this surface. The metal substrate 8 is superposed and heated and pressed to laminate and integrate the insulating layer 9 made of the resin sheet 7 on the metal substrate 8, and the circuit pattern 6 is transferred to the insulating layer 9. 5 is peeled from the insulating layer 9 to produce a highly heat-conductive three-dimensional substrate provided with a recess 10 for mounting an electronic component on the insulating layer 9 by the protrusion 4 of the mold plate 5. The LED 2 is mounted in the concave portion 10 of the substrate, the LED 2 and the circuit pattern 6 are electrically connected, and then the transparent sealing agent 18 is poured into the concave portion 10 and formed into a lens shape. It is intended to.

  According to a second aspect of the present invention, in the first aspect, as the mold plate 5, the protruding portion 11 whose tip is in contact with the metal substrate 8 is provided at a position other than the convex portion 4 on the surface on the side where the convex portion 4 is provided. What is provided is used.

  The invention according to claim 3 is characterized in that, in claim 1 or 2, the mold plate 5 is one in which a material having a releasing property and heat resistance is attached to the tip of the convex portion 4. is there.

  The invention according to a fourth aspect is characterized in that, in any one of the first to third aspects, as the mold plate 5, an end of the convex portion 4 having a rounded shape is used.

  According to a fifth aspect of the present invention, in any one of the first to fourth aspects, the mold plate 5 is formed of a stainless steel material.

  The invention according to claim 6 is characterized in that, in any one of claims 1 to 5, the color of the insulating layer obtained by molding and curing the resin sheet 7 is white.

  The invention according to claim 7 is the invention according to any one of claims 1 to 6, wherein the metal substrate 8 is aluminum, copper, iron, or a clad material or alloy containing two or three kinds of these metals. It is characterized by this.

  The invention according to claim 8 is the method according to any one of claims 1 to 7, wherein the filler is at least one selected from silica, alumina, aluminum nitride, boron nitride, magnesium oxide, and titanium oxide. It is a feature.

  The invention according to claim 9 is the coupling according to any one of claims 1 to 8, wherein the filler content in the resin sheet 7 is 70 to 95% by mass with respect to the total amount of the resin sheet 7, and the filler is a coupling. And at least one selected from an agent and a dispersant, which is surface-treated.

  The invention according to a tenth aspect is characterized in that, in any one of the first to ninth aspects, the metal substrate 8 is provided with a heat radiating fin 12 formed on the side opposite to the side overlapping the resin sheet 7. Is.

  According to the manufacturing method of the LED display device according to claim 1 of the present invention, the manufacturing process is simplified by forming the concave portion by the convex portion of the mold plate in the process of manufacturing the high thermal conductive solid substrate. In addition, the number of parts can be reduced compared to the prior art in that it is not necessary to use a frame for forming the recess, and the cost required for manufacturing a high thermal conductive three-dimensional substrate can be greatly reduced. is there. Moreover, by forming an insulating layer using a resin sheet containing a filler, it is possible to efficiently release the heat generated from the LED to the outside, and to obtain a highly thermally conductive three-dimensional substrate excellent in heat dissipation. In addition, since the LED can be directly mounted on a metal substrate, it is possible to obtain higher heat dissipation. As described above, the LED display device is obtained by a simple process at a low cost, and is very excellent in heat dissipation.

  According to the second aspect of the present invention, the surface of the metal substrate is exposed on the bottom surface of the recess, or the height between the protrusion and the protrusion is simply brought into contact with the surface of the metal substrate. It is possible to leave only one layer of resin or scrape the metal substrate by the difference, to obtain high heat dissipation, to improve insulation reliability, and to improve light emission luminance.

  According to the invention which concerns on Claim 3, the front-end | tip of a convex part can be contact | abutted without the clearance gap to the surface of a metal substrate, and the penetration | invasion of the molten resin to this location can be prevented.

  According to the invention which concerns on Claim 4, the surface of a metal substrate can be scraped off by the front-end | tip of a convex part, the concave curved surface which has non-oxidized and metallic luster can be obtained, and also the reflectance can be improved.

  According to the invention of claim 5, it is possible to adjust the adhesion of the plating to the mold plate, and the circuit pattern can be easily transferred to the resin sheet side by molding, and the surface of the insulating layer and the surface of the circuit pattern can be transferred. The circuit pattern can be embedded so as to be flush with each other.

  According to the invention which concerns on Claim 6, the reflective efficiency with respect to the light emission from LED can be improved.

  According to the invention which concerns on Claim 7, heat dissipation can be obtained more highly than the thing of another material.

  According to the invention which concerns on Claim 8, while being able to raise thermal conductivity rather than another filler, the particle size design at the time of carrying out high filling in resin becomes easy.

  According to the ninth aspect of the present invention, the filler in the resin sheet can be uniformly dispersed by surface-treating the filler with the above-described coupling agent or dispersant, and the filler content in the resin sheet can be increased. By increasing the height as described above, it is possible to obtain a highly heat-conductive three-dimensional substrate that is less likely to warp or twist.

  According to the invention which concerns on Claim 10, the highly heat-conductive solid board | substrate which improved the heat dissipation further while simplifying a manufacturing process can be obtained.

  Embodiments of the present invention will be described below.

  FIG. 1 shows an example of a process for manufacturing an LED mounting substrate 1 which is a kind of a highly heat-conductive three-dimensional substrate according to the present invention. In manufacturing the LED mounting substrate 1, the mold plate 5, the resin sheet 7, and the metal substrate 8 are required, and these will be described first below. In addition, although LED2 is demonstrated as a specific example of an electronic component as mentioned above, this invention is not limited to the board | substrate 1 for LED mounting, or its manufacturing method. That is, according to the present invention, a three-dimensional board on which electronic components other than the LED 2 can be mounted can also be manufactured.

  In the present invention, the material of the mold plate 5 is not particularly limited, and a material having a convex portion 4 on the surface is used. In forming the convex portion 4, for example, the mold plate 5 This can be done by etching the surface. And this convex part 4 is the same as LED2, or is formed larger than LED2, and can form the convex part 4 with a level | step difference by forming the step part 14 like FIG. Moreover, the number of the convex parts 4 provided in the mold plate 5 is not particularly limited.

  Further, as the mold plate 5, as shown in FIG. 1, the mold plate 5 is provided on the same side as the side on which the convex portion 4 is provided and provided with the protruding portion 11 at a place other than the convex portion 4. be able to. The protrusion 11 is formed so that the tip thereof is in contact with the surface of a metal substrate 8 to be described later, and can be formed integrally with the mold plate 5. Moreover, it can provide so that the circumference | surroundings of the convex part 4 may be enclosed like FIG. Furthermore, the height of the protrusion 11 with respect to the surface of the mold plate 5 is not particularly limited, and the protrusion 11 is formed as a mold so as to have the same height as the protrusion 4 or a different height. Although it can be provided on the plate 5, when a plurality of protrusions 11 are provided on the mold plate 5, the heights of all the protrusions 11 are made uniform.

  Next, the resin sheet 7 is not particularly limited as long as the resin sheet 7 contains a filler. Specifically, for example, 63.8 parts by mass of thermosetting resin, 80 to 95 parts by mass of filler, 5 parts by mass of curing agent, 0.2 part by mass of curing accelerator, and 30 parts by mass of solvent are contained. After applying the thermosetting resin composition to 5 to 20 parts by mass of a PET film or the like, the resin sheet 7 can be produced by drying by heating until a semi-cured state (B stage) is obtained. Since the resin sheet 7 contains a filler, it can obtain high heat dissipation, and can be melted by reheating at the time of molding and easily processed into a target shape. And since it is produced without using a glass base material etc., resin can infiltrate also into the clearance gap of a very complicated structure.

  Moreover, it is desirable to adjust the color (color tone) of the insulating layer 9 obtained by molding and curing the resin sheet 7 highly filled with the filler so that the light emitted from the LED 2 is easily reflected. Moreover, when imparting flame retardancy to the resin sheet 7, it is preferable to use a brominated or phosphorus-modified one of the above thermosetting resin. This is because the use of the additive-type flame retardant may cause a decrease in heat resistance and mechanical strength of the insulating layer 9 made of the resin sheet 7 in the manufactured LED mounting substrate 1.

The filler is not particularly limited, but silica (SiO ₂ ), alumina (Al ₂ O ₃ ), aluminum nitride (AlN), boron nitride (BN), magnesium oxide (MgO), titanium oxide (TiO 2) _It is preferable to use at least one selected from ₂ ). This is because the inorganic filler as described above has better thermal conductivity than the other fillers, and has a degree of freedom in particle size distribution, facilitating the particle size design when highly filling the resin.

  Further, when the filler is surface-treated with a coupling agent or a dispersant, the dispersibility of the filler in the resin is improved, and the flow characteristics of the resin melted by reheating at the time of molding are improved. In particular, when at least one selected from the group consisting of a silane coupling agent, a titanate coupling agent, a phosphate ester dispersant, and an ether amine dispersant is used as the above coupling agent or dispersant, Properties and flow characteristics can be obtained.

  Moreover, it is preferable that the content rate of the filler in the resin sheet 7 is 70-95 mass% with respect to the resin sheet 7 whole quantity. Since the cured product of the resin sheet 7 highly filled with the filler has a thermal expansion coefficient as low as 20 ppm / ° C. or less, such a cured product is formed as an insulating layer 9 on the surface of the metal substrate 8 to be described later. In other words, even if the LED mounting substrate 1 or the LED display device 3 is subjected to a rapid temperature change, warping or twisting is less likely to occur. However, if the filler content is less than 70% by mass, the above-mentioned warpage may occur. Conversely, if it exceeds 95% by mass, voids such as voids are generated in the insulating layer 9 and the reliability is lowered. There is a risk.

  Further, the curing agent, the curing accelerator, and the solvent are not particularly limited, but when a low boiling point solvent such as methyl ethyl ketone or acetone is used as the solvent, the resin sheet 7 dried in a semi-cured state is used. The surface shape is favorable and preferable. On the other hand, when a high boiling point solvent is used, there is a high possibility that the solvent will not volatilize sufficiently during drying and remain in the resin sheet 7, which may reduce the electrical insulation and mechanical strength of the cured product.

  Next, the metal substrate 8 is not particularly limited, but it is possible to use any one of aluminum, copper, iron, or a clad material or alloy containing two or three of these metals. preferable. When such a metal substrate 8 is used, it is possible to obtain higher heat dissipation than other materials and to sufficiently fulfill the role of a heat sink. Further, the metal substrate 8 also needs a role as a reinforcing plate, and it is necessary to select the material and thickness of the metal substrate 8 so as not to generate warp or the like on the LED mounting substrate 1 to be manufactured. The material of the metal substrate 8 can also be selected according to the purpose, such as aluminum if priority is given to the formation, or iron if strength is given priority. On the other hand, the thickness of the metal substrate 8 is not particularly limited, but is preferably 0.5 to 5 mm. If the thickness of the metal substrate 8 is increased, the strength can be increased by that amount. However, since the heat generated from the LED is usually released, the LED display device 3 is finally integrated with the chassis or the like by a fixing tool such as a screw. Since the required strength is ensured by this, the thickness of the metal substrate 8 does not need to be particularly thick. Therefore, in such a case, the material cost of the metal substrate 8 can be saved.

  Thus, by using the mold plate 5, the resin sheet 7, and the metal substrate 8 described above, the LED mounting substrate 1 can be manufactured as follows. That is, after the surface of the mold plate 5 is first roughened by chemical polishing or the like, the circuit pattern 6 is formed on the surface on which the convex portions 4 are provided by copper plating or the like. At this time, if the mold plate 5 is formed of SUS301 series stainless steel, the adhesion of plating or the like may be lacking, and the formation of the circuit pattern 6 may be difficult. Adhesion can be increased. By performing such processing, the circuit pattern 6 due to plating does not peel off when the mold plate 5 is handled, and the circuit pattern 6 is embedded in the resin sheet 7 when transferred to the resin sheet 7 side. Therefore, the adhesion strength is improved, and the circuit pattern 6 can be easily peeled from the mold plate 5. Note that the circuit pattern 6 may be formed on a three-dimensional surface such as the convex portion 4, and in the mold plate 5 shown in FIG. 1, the circuit extends from the stepped portion 14 of the convex portion 4 to a portion other than the convex portion 4. Pattern 6 is formed.

Next, as shown in FIG. 1A, a metal substrate 8 is overlaid on a surface of the mold plate 5 on which the circuit pattern 6 is formed via a resin sheet 7 containing a filler, and this is heated and pressurized. . Then, the resin sheet 7 is softened and melted, and the molten resin is filled in a gap formed between the mold plate 5 and the metal substrate 8. At this time, the convex portion 4 provided on the mold plate 5 easily pushes away the molten resin and reaches the surface of the metal substrate 8, and the tip of the convex portion 4 comes into contact with the surface of the metal substrate 8. Accordingly, there is no room for the molten resin to enter the portion concealed by the tip of the convex portion 4, and the surface of the metal substrate 8 at this portion can be kept clean without being stained with the resin. At this time, if a mold plate 5 having a rubber sheet (not shown) attached to the tip of the convex portion 4 is used, even if there are minute irregularities on the surface of the metal substrate 8, the elasticity of the rubber sheet The tip of the convex part 4 can be brought into contact with the surface of the metal substrate 8 without any gap, and intrusion of the molten resin into this part can be prevented. Further, as the above rubber sheet, it is a matter of course to use a sheet having heat resistance enough to withstand reheating at the time of molding. The mold plate 5 can be easily peeled off. Furthermore, the tip of the convex portion 4 is usually formed on a smooth surface, but if the tip of the convex portion 4 is rounded to form a convex curved surface, a mold plate is formed. When 5 is pressed against the metal substrate 8, the surface of the metal substrate 8 is scraped off by the tip of the convex portion 4, and a concave curved surface having a non-oxidized and metallic luster can be obtained. In addition, although it does not specifically limit as said heating-and-pressurization conditions, For example, the pressure of 0.49-19.6 MPa (5-200 kg / cm < ² >), 100-250 degreeC (150-200 degreeC) Can be set to about 1 hour.

  Here, when the protrusion 11 is provided on the mold plate 5, the tip of the protrusion 11 is brought into contact with the surface of the metal substrate 8. As shown in FIGS. 1 and 2, if the protrusion 11 and the protrusion 4 are the same height, if the tip of the protrusion 11 is brought into contact with the surface of the metal substrate 8, the tip of the protrusion 4 inevitably also It contacts the surface of the metal substrate 8. However, as described above, the height of the protruding portion 11 can be different from the height of the protruding portion 4. For example, when the protruding portion 11 is higher than the protruding portion 4 as shown in FIG. 3B, even if the tip of the projection 11 is brought into contact with the surface of the metal substrate 8, the tip of the projection 4 does not reach the surface of the metal substrate 8, and the tip of the projection 4 A space where the resin can enter between the metal substrate 8 is secured. On the other hand, when the protrusion 11 is lower than the protrusion 4 as shown in FIG. 4, when the tip of the protrusion 11 is brought into contact with the surface of the metal substrate 8 as shown in FIG. The tip of the protrusion 4 scrapes off the surface of the metal substrate 8 to form a recess 15, and the tip of the protrusion 4 fits into the recess 15. In short, the tip of the protrusion 11 is not brought apart from the surface of the metal substrate 8, and the tip of the protrusion 11 is not abraded away from the surface of the metal substrate 8. If so, the surface of the metal substrate 8 is exposed on the bottom surface of the concave portion 10 according to the height of the convex portion 4, or the resin is peeled by the height difference between the protruding portion 11 and the convex portion 4. The metal substrate 8 can be left or scraped off.

  Then, once melted resin is cured and fixed to the metal substrate 8, the insulating layer 9 made of the resin sheet 7 is laminated and integrated on the surface of the metal substrate 8. At this time, the circuit pattern 6 previously formed on the mold plate 5 is transferred to the insulating layer 9. Note that if the heating and pressurization is performed under vacuum, voids are less likely to enter and remain in the insulating layer 9, and the reliability of the LED display device 3 can be improved. In order to ensure connection reliability, the circuit pattern 6 is preferably subjected to Ni plating, gold plating, or the like.

  Thereafter, the mold plate 5 is peeled off from the insulating layer 9. Then, as shown in FIG. 1C, the concave portion 10 is formed at the portion of the insulating layer 9 occupied by the convex portion 4 of the mold plate 5, and the LED mounting substrate 1 can be obtained. In addition, when using LED2 as an electronic component, the direction which inclined the wall surface in the recessed part 10 toward the opening of the recessed part 10 can reflect more light emission from LED2 to the opening side of the recessed part 10. preferable.

  In manufacturing the LED display device 3 using the LED mounting substrate 1, the LED 2 is mounted on the bottom surface of the recess 10, and the LED 2 and the circuit pattern 6 formed on the LED mounting substrate 1 are made of gold wire. 1 can be performed by pouring the transparent sealing agent 18 into the concave portion 10 and filling the concave portion 10 with the transparent sealing agent 18. Such an LED display device 3 can be manufactured. At this time, the surface of the transparent sealing agent 18 is preferably formed in a lens shape.

  Here, as shown in FIG. 1 and FIG. 2, if the LED mounting substrate 1 is manufactured using the mold plate 5 having the same protrusion 11 and protrusion 4, the bottom surface of the recess 10 is formed. The metal substrate 8 can be used. Therefore, the LED 2 can be directly attached to the metal substrate 8 having high thermal conductivity, and the LED display device 3 excellent in heat dissipation can be manufactured, and the bottom surface of the recess 10 formed by the metal substrate 8 can be formed. By using it as a reflecting plate and reflecting all of the light emission energy from the LED 2 toward the opening side of the recess 10, it is possible to improve the light emission luminance by 30 to 50% compared to the conventional one.

  Further, as shown in FIG. 3, if the LED mounting substrate 1 is manufactured using the mold plate 5 having the protrusions 11 higher than the protrusions 4, the entire inner surface of the recess 10 is formed of the insulating layer 9. can do. Therefore, since the LED is not directly attached to the metal substrate 8, that is, it is insulated from the base metal, if the insulation is necessary in designing the electronic device, the LED display device 3 is manufactured using the LED mounting substrate 1. do it.

  Further, as shown in FIG. 4, if the LED mounting substrate 1 is manufactured by using the mold plate 5 having the protrusions 11 lower than the protrusions 4, only the bottom surface of the recesses 10 is formed by the recesses 15. Alternatively, a part of the inner peripheral surface of the recess 10 can also be formed of the metal substrate 8. Therefore, the LED 2 can be directly attached to the metal substrate 8 having high thermal conductivity, and the LED display device 3 having excellent heat dissipation can be manufactured. By using a part of the bottom surface and the inner peripheral surface as a reflecting plate, the effect of improving the light emission luminance can be further enhanced.

  Further, as shown in FIG. 5, it is preferable to manufacture the LED mounting substrate 1 by using the metal substrate 8 having the radiation fins 12 formed on the side opposite to the side overlapping the resin sheet 7. Usually, since the heat radiation fin 12 is used by being screwed to the metal substrate 8 via a heat conductive grease or a heat conductive sheet, there is a gap between the heat radiation fin 12 and the metal substrate 8, and the heat generated by the heat radiation fin 12. The dissipative effect could not be enhanced as expected, and there was a problem that the cost increased due to an increase in the number of parts and man-hours. However, if the heat dissipating fins 12 are integrally formed on the metal substrate 8 as described above, the LED mounting substrate 1 and the LED display device 3 with further improved heat dissipation can be obtained while simplifying the manufacturing process. Is.

  As described above, in the past, after manufacturing a glass cloth base epoxy resin copper-clad laminate, etc., the recessed portion 17 for filling the transparent sealing agent 18 had to be formed. In the invention, in the process of manufacturing the LED mounting substrate 1, the concave portion 10 corresponding to the concave portion 17 can be formed by the convex portion 4 of the mold plate 5. Can be simplified. Moreover, in the prior art, the frame 16 must be used separately when forming the recessed portion 17, whereas in the present invention, it is not necessary to use an equivalent to the frame 16. The number of parts can be further reduced. Therefore, the cost required for manufacturing the LED mounting substrate 1 and the LED display device 3 can be greatly reduced by simplifying the manufacturing process and reducing the number of components.

  In addition, in the present invention, since the insulating layer 9 is formed using the resin sheet 7 containing the filler, it is possible to efficiently release the heat generated from the LED 2 to the outside, and the LED has excellent heat dissipation. The mounting substrate 1 and the LED display device 3 can be obtained. In addition, when a circuit board manufactured by a glass epoxy laminate is used in the past, the insulating layer of the glass epoxy laminate absorbs the light from the LED 2, so that the surface is coated with a white coating, etc. Although a process was required, since the color of the insulating layer 9 itself can be made white by using this resin sheet 7, it is very useful for improving luminance. In addition, in the past, the LED mounting substrate 1 and the frame 16 must be strictly adhered to each other, and if even a slight gap occurs, the emission energy from the LED 2 may leak from this gap. In the present invention, the resin sheet 7 becomes a molten resin at the time of heating and pressurizing and flows into a small gap and fills the gap with the resin, so that the gap as described above does not occur and the reduction of the light emission energy is prevented. In this way, high luminance can be obtained. At this time, since the LED 2 can be directly mounted on the metal substrate 8, it is possible to obtain higher heat dissipation, as well as higher light emission luminance due to increased reflection efficiency. It will be.

An example of embodiment of this invention is shown and (a) thru | or (d) are all sectional drawings. Another example of the above is shown, and (a) to (d) are all sectional views. Still another example of the above is shown, and (a) to (d) are sectional views. Still another example of the above is shown, and (a) to (d) are sectional views. Still another example of the above is shown, and (a) to (d) are sectional views. A conventional example is shown, and (a) to (c) are all cross-sectional views.

Explanation of symbols

1 LED mounting board 2 LED
DESCRIPTION OF SYMBOLS 3 LED display device 4 Convex part 5 Mold plate 6 Circuit pattern 7 Resin sheet 8 Metal substrate 9 Insulating layer 10 Concave part 11 Protrusion part 12 Radiation fin

Claims (10)

  A circuit pattern is formed on the surface of a mold plate provided with projections, a metal substrate is superimposed on this surface via a resin sheet containing a filler, and this is heated and pressed to form a resin sheet on the metal substrate. The insulating layer is laminated and integrated, and the circuit pattern is transferred to the insulating layer, and then the mold plate is peeled from the insulating layer, whereby the electronic component is mounted on the insulating layer by the convex portion of the mold plate. A highly heat-conductive three-dimensional board provided with a recess is manufactured, an LED is mounted in the recess of the high-heat-conducting three-dimensional board, the LED and the circuit pattern are electrically connected, and then a transparent sealant is poured into the recess and Is formed in a lens shape. A method for manufacturing an LED display device.   2. The LED according to claim 1, wherein a mold plate is used in which a protrusion having a tip abutting against a metal substrate is provided at a portion other than the protrusion on the surface on the side where the protrusion is provided. Manufacturing method of display device.   The method for manufacturing an LED display device according to claim 1 or 2, wherein a mold plate is used in which a material having releasability and heat resistance is attached to the tip of the convex portion.   The method for manufacturing an LED display device according to any one of claims 1 to 3, wherein a mold plate having a rounded end is used at the tip of the convex portion.   The method for manufacturing an LED display device according to claim 1, wherein the mold plate is made of a stainless steel material.   The method for manufacturing an LED display device according to any one of claims 1 to 5, wherein the color of the insulating layer obtained by molding and curing the resin sheet is white.   The LED display device according to any one of claims 1 to 6, wherein the metal substrate is aluminum, copper, or iron, or a clad material or an alloy containing two or three of these metals. Manufacturing method.   The LED display device according to any one of claims 1 to 7, wherein the filler is at least one selected from silica, alumina, aluminum nitride, boron nitride, magnesium oxide, and titanium oxide. Production method.   The filler content in the resin sheet is 70 to 95% by mass with respect to the total amount of the resin sheet, and the filler is surface-treated with at least one kind selected from a coupling agent and a dispersant. The manufacturing method of the LED display device of any one of Claims 1 thru | or 8 characterized by these.   The method for manufacturing an LED display device according to any one of claims 1 to 9, wherein a metal substrate is used in which heat dissipating fins are formed on a side opposite to a side overlapped with a resin sheet.

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