JP2011176017A - Light emitting device and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To maintain quality and to improve product yield, without causing increase in the manufacturing man-hours, for a light-emitting device (an LED package) which uses a slit substrate. <P>SOLUTION: Projection structures are provided so as to surround a slit on both sides of the slit on the rear face side of the substrate mounted with LED elements. At manufacturing, the substrate is gripped by a vacuum chuck and sealed with translucent resin through compression molding, a space formed by the slit and projections is thereby filled with the translucent resin, and leakage of the translucent resin to the outside from the projections is prevented. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to an issuing device equipped with a light emitting diode (LED element), and more particularly to a light emitting device using a slit substrate.

  In a light emitting device (LED package) using an LED element, the LED element is mounted on a substrate on which a pair of electrodes are formed, and the LED element and the wire are sealed with a light-transmitting resin after wire bonding. The back side of the substrate is plated with metal to form external connection terminals for a pair of electrodes. The external connection terminals are joined to an insulating wiring board such as a lead frame by soldering.

  In order to electrically separate the pair of electrodes formed on the substrate, a slit is formed in the substrate. When sealing with a translucent resin, if the translucent resin flows into the external connection terminal on the back side of the substrate through this slit, poor bonding is likely to occur. For this reason, a contrivance is made so that the translucent resin does not wrap around the external connection terminals on the back surface of the substrate during manufacture. For example, there is one in which a polyimide film is attached to the back surface of a substrate provided with a slit and the slit is sealed (for example, see Patent Document 1). In addition, there is a method in which a protective film is applied before resin sealing, and the protective film is peeled off after molding (for example, see Patent Document 2).

Japanese Patent No. 3992301 Japanese Patent No. 4257807

  The method disclosed in Patent Document 1 requires a step of attaching a polyimide film. In addition, the polyimide film has a lower reflectance and a higher light absorption rate than metals such as Ag and Al and white resins. Therefore, compared with the case where these metals and white resin are used for the substrate, the extraction efficiency of the emitted light is reduced by 5% or more. Further, since the absorbed light is converted into heat, the forward drop voltage (Vf) is reduced and the luminous flux is reduced, and thermal degradation during lighting for a long time is promoted.

  In the case of the method disclosed in Patent Document 2, it takes a double labor to put a protective film and to peel it off. Further, after the protective film is peeled off, the stress acting on the protective film is released, so that the substrate is warped. Due to this warpage, the translucent resin and the metal substrate may be peeled off at the interface, or a load may be applied to the wire and disconnection may occur.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a technique for maintaining the quality and improving the product yield without increasing the number of manufacturing steps in the light emitting device using the slit substrate. .

  In the present invention, protrusion structures are provided on both sides of the slit on the back side of the substrate on which the LED element is mounted so as to surround the slit. At the time of manufacture, the substrate is held by a vacuum chuck and sealed with a light-transmitting resin by compression molding, so that the space formed by the slit and the protrusion is filled with the light-transmitting resin and the outside of the protrusion is extended. Prevent leakage of translucent resin.

  Specifically, a metal substrate having a slit, one or more light emitting elements mounted on the substrate, and a resin molded body that forms a lens portion on the light emitting element and seals the light emitting element and the slit A light emitting device comprising: protrusions on both sides of the slit on the back surface side of the substrate on which the light emitting element is disposed, in parallel with the slit. To do.

  One or more slits arranged in a predetermined direction; a first protrusion formed so as to surround the slit; and a second protrusion formed on the same surface as the first protrusion so as to border the entire substrate; A substrate preparing step of preparing a metal substrate comprising: a light emitting element mounting step of mounting and electrically connecting one or more light emitting elements on a surface of the substrate opposite to the surface on which the protrusion is formed; A resin sealing step of sealing the light emitting element and the slit with a translucent resin, and a subdividing step of subdividing the substrate after sealing in a predetermined direction by dicing. The stopping step provides a method for manufacturing a light emitting device, wherein a surface of the substrate on which the first protrusion is formed is fixed to an upper mold by a vacuum chuck, and a seal is formed by compression molding.

  According to the present invention, in a light emitting device using a slit substrate, the quality is maintained and the product yield is improved without increasing the number of manufacturing steps.

(A) is explanatory drawing for demonstrating schematic structure of the line light source of 1st embodiment. Further, (b) is a top view of the line light source, (c) is a sectional view taken along the line A-A 'of (b), and (d) is an enlarged view of (c). (A)-(h) is explanatory drawing for demonstrating the manufacturing process of the line light source of 1st embodiment. (A) is explanatory drawing for demonstrating the back surface of the metal plate of 1st embodiment, (b) is the AA 'sectional drawing, (c) and (d) are (b). FIG. It is explanatory drawing for demonstrating the mode of mounting to the external substrate of the line light source of 1st embodiment. (A) is explanatory drawing for demonstrating the line light source of the modification of 1st embodiment, (b)-(d) is explanatory drawing for demonstrating the structure of the metal plate. It is explanatory drawing for demonstrating the mode of mounting to the external substrate of the line light source of the modification of 1st embodiment. (A) is explanatory drawing for demonstrating the line light source of 2nd embodiment, (b)-(d) is explanatory drawing for demonstrating the structure of the metal plate. It is explanatory drawing for demonstrating the mode of mounting to the external substrate of the line light source of 2nd embodiment. (A)-(c) is explanatory drawing for demonstrating the horizontal maintenance characteristic of the line light source of 2nd embodiment. (A) is explanatory drawing for demonstrating the line light source of the modification of 2nd embodiment, (b)-(d) is explanatory drawing for demonstrating the structure of the metal plate. It is explanatory drawing for demonstrating the mode of mounting to the external substrate of the line light source of the modification of 2nd embodiment. (A) is explanatory drawing for demonstrating the line light source of 3rd embodiment, (b)-(d) is explanatory drawing for demonstrating the structure of the metal plate. It is explanatory drawing for demonstrating the mode of mounting to the external substrate of the line light source of 3rd embodiment. (A)-(c) is explanatory drawing for demonstrating the other example of the cavity of each embodiment.

<< First Embodiment >>
Hereinafter, a first embodiment to which the present invention is applied will be described. Hereinafter, in all the drawings for explaining the embodiments of the present invention, those having the same function are denoted by the same reference numerals, and repeated explanation thereof is omitted.

  FIG. 1A is an explanatory diagram for explaining a schematic configuration of a line light source 10 which is an example of a light emitting device of the present embodiment. FIG. 1B is a top view of the line light source 10, and FIG. 1C is a cross-sectional view taken along the line A-A 'of FIG. FIG.1 (d) is an enlarged view of FIG.1 (c).

  The line light source 10 according to the present embodiment is linearly arranged in the longitudinal direction on a substrate 11 on which one surface is Ni-plated 12 and a surface of the substrate 11 opposite to the surface on which the Ni plating 12 is applied. A plurality of LED elements 14 to be formed, a wire 15 for electrically connecting the LED element 14 to an electrode formed on the substrate 11, and a cavity formed by sealing the LED element 14 and the wire 15 with a translucent resin 16. The plating is not limited to Ni, and any plating suitable for solder bonding such as tin may be used.

  A pair of electrodes is formed on the substrate 11, and a slit 13 is formed to electrically separate these electrodes. In addition, on the back side of the substrate 11 and on both sides of the slit 13, projection groups 17 (17 a and 17 b) are formed in parallel to the slit 13. The translucent resin forming the cavity 16 is also filled between the slit 13 and the projections 17a and 17b.

  The surface of the substrate 11 on which the Ni plating 12 is applied is configured as an external connection terminal.

  Next, the manufacturing process of the line light source 10 of this embodiment is demonstrated. FIG. 2 is a diagram for explaining a manufacturing process of the line light source 10 of the present embodiment.

  First, as shown in FIGS. 2A and 2B, a metal plate 110 that becomes the substrate 11 after subdivision is prepared (substrate preparation step).

  FIG. 3 is an explanatory diagram for explaining the metal plate 110 of the present embodiment. (A) is explanatory drawing for demonstrating the back surface side of the metal plate 110, (b) is the AA 'sectional drawing, (c), (d) is the partially expanded view of (b). is there.

  The metal plate 110 is a metal plate-like member, and is preferably made of a material that has high thermal conductivity and high reflectance and is easy to process. For example, a Cu plate material is preferably used. As the metal plate 110, a normal pure Al plate material (A1050) or a Cu plate material or the like may be a metal plate material plated with Ag plating or the like.

  The size of the metal plate 110 is, for example, 150 mm in the longitudinal direction and 70 mm in the short direction. This is a substrate size suitable for a generally used molding apparatus. The thickness of the metal plate 110 is preferably about 0.3 to 1.0 mm in terms of press working and handling.

  Ni plating 12 is applied to the surface layer of one surface of the metal plate 110 so that solder can be easily joined. Hereinafter, the side of the metal plate 110 on which the Ni plating 12 is applied is referred to as the back surface, and the opposite surface is referred to as the front surface. In addition, since the surface layer should just be a Ni surface on the back surface of the metal plate 110, you may form a Ni surface by lamination | stacking.

  After the Ni plating 12 is formed, slits 13 and protrusion groups 17 are formed on the metal plate 110 by pressing or the like.

  The width of the slit 13 is equal to or greater than the thickness of the metal plate 110 due to the limit of press working. For example, when the 0.5 mm thick metal plate 110 is used, the minimum width of the slit 13 is 0.5 mm. In addition, you may produce the slit 13 by an etching, cutting, etc.

  In the example of FIG. 3A, the slit 13 is formed in the longitudinal direction of the metal plate 110. In this case, after segmentation by dicing, the LED elements 14 of the line light source 10 are electrically in parallel.

  The protrusion group 17 is formed on the back surface of the metal plate 110. The projection group 17 includes projections 17 c provided on both sides of the slit 13 so as to surround the slit 13 in parallel with the slit 13 and projections 17 d that border the entire metal plate 110. The protrusion 17c becomes the protrusions 17a and 17b after subdividing. The protrusion group 17 has a role of bringing the metal plate 110 into close contact with the mold in a resin sealing process described later. Further, the protrusions 17c (17a and 17b) surrounding the slit 13 also have a role of preventing the translucent resin from leaking from the slit 13 to the back surface of the metal plate 110.

  A side cross-sectional shape of the projection group 17 is a dome shape. The side cross-sectional shape may be a rectangle, an upward convex mountain, or a downward convex mountain. The protrusion group 17 has a thickness (height) of, for example, 0.2 mm. In addition, if the height of the protrusion group 17 can ensure 0.1 mm or more, when performing compression molding in the resin sealing process mentioned later, sufficient adhesiveness is shown. However, when the protrusions 17 are formed by press working, the height is equal to or less than the thickness of the metal plate 110.

  In addition, the groove | channel 19 shown in FIG.3 (d) is a groove | channel produced when a press is strong when forming the projection group 17 by press work. The protrusion group 17 may be produced by etching or cutting.

  The metal plate 110 is formed with, for example, a V-shaped dicing auxiliary groove 18 so as to be subdivided into the substrate 11 by breaking during dicing. The dicing auxiliary groove 18 is formed by pressing.

  When the above metal plate 110 is prepared, the LED element 14 is then mounted on the surface side of the metal plate 110 as shown in FIGS. 2C and 2D (LED mounting step).

  For the LED element 14, a sapphire substrate whose back surface is a lateral conduction face-up double wire element, a longitudinal conduction MB element, or the like is used.

  The LED element 14 is fixed to the metal plate 110 with, for example, a white die attach material (silicone adhesive). Instead of the white die attach material, a high thermal conductivity die attach material (silicone adhesive) containing a filler such as silver may be used. Further, the mounting surface may be subjected to partial Au plating and solder eutectic bonding.

  For example, 75 LED elements 14 having a size of 0.5 mm × 0.29 mm are arranged in a vertical direction at intervals of 2 mm on a metal plate 110 having a longitudinal direction of 150 mm and a short side direction of 70 mm. In addition, 35 pieces are arranged at intervals of 2 mm in the horizontal direction.

  An Au wire is used as the wire 15 used for electrical connection between the LED elements 14. The cathode electrode and the anode electrode of the LED element 14 are bonded to a pair of electrodes provided on the metal plate 110 by the wire 15.

  When the mounting of the LED element 14 is finished, next, as shown in FIGS. 2E and 2F, the LED element 14, the wire 15 and the slit 13 are sealed with a translucent resin (resin sealing step). . Here, by forming the cavity 16 with a translucent resin, sealing and lens molding are realized in one step. The lens shape is, for example, a dome-shaped semicircle.

  The translucent resin used in this resin sealing step is a silicone resin in which phosphors are dispersed. A fluorescent material that emits fluorescence of a predetermined wavelength using the light of the LED element 14 as excitation light is used.

  It is desirable that the cavity 16 is formed by translucent resin by compression molding. The compression molding procedure is as follows. The back surface of the metal plate 110 is attached to the upper mold with a vacuum unit and a crumbler. Next, after a sheet for releasing the translucent resin is adsorbed to the lower mold, the translucent resin is applied to the lower mold having the cavity shape formed by the dispenser unit. Then, after the LED element 14 mounted on the metal plate 110 is immersed in a resin that has been evacuated by vacuuming and cured, the upper and lower molds are removed (for example, Japanese Patent Laid-Open Nos. 2003-133351 and 2007). No. 189116). In addition, the lower mold and the metal plate 110 are adsorbed by a rubber ring, but it is preferable that the dicing groove is at a processing level that is filled with rubber when adsorbed so that the resin does not enter. By using such compression molding, resin sealing can be performed efficiently and uniformly.

  At this time, the translucent resin is also filled between the slits 13. Furthermore, since the metal plate 110 of the present embodiment is in close contact with the upper mold by the projections 17a and 17b on both sides of the slit 13, as shown in FIG. The space 20 formed by the above is also filled with a translucent resin by the height of the protrusions 17a and 17b. On the other hand, the translucent resin filling the space 20 does not leak out of the protrusions 17a and 17b. In addition, the translucent resin with which the space 20 is filled physically connects the electrodes of the substrate 11 after dicing. Further, since the translucent resin is insulative, the electrodes are electrically insulated.

  At the time of compression molding, the upper mold that is in contact with the back side of the metal plate 110 is subjected to Teflon (registered trademark) processing so that the resin around the slit 13 on the back side of the mold and the metal plate 110 is easily peeled after molding. It is preferable. The resin around the slit 13 on the back side of the mold and the metal plate 110 may be easily peeled off. For example, a Teflon (registered trademark) sheet is sandwiched between the metal plate 110 and the mold in contact with the back side of the metal plate 110. May be.

  Note that the molding of the cavity 16 with the translucent resin is not limited to compression molding, and may be injection molding as long as it can be uniformly molded in the surface direction of the substrate 11.

  After sealing with a translucent resin, as shown in FIGS. 2G and 2H, it is subdivided by dicing (subdividing step). In the present embodiment, cutting is performed in a direction parallel to the slit 13. In the present embodiment, as described above, the dicing auxiliary grooves 18 are formed by pressing in the metal plate 110 in the substrate preparation process so that the metal plate 110 can be divided by breaking. In the subdividing step, the metal plate 110 is divided along the dicing auxiliary grooves 18 and subdivided.

  The subdivided line light source 10 is mounted on the external substrate 31 as shown in FIG. The mounting is performed by joining the external connection terminal (Ni plating 12) on the back surface of the substrate 11 and the wiring pattern 34 of the external substrate 31 with solder 32.

  The external substrate 31 is obtained by forming a wiring pattern 34 on the surface of the substrate covered with the resist 33 and uses a substrate having a reflective structure in order to reflect light leaking from the slit 13. As the substrate having a reflective structure, a white resin, a substrate coated with a resist, or the like is suitable. By using a substrate having a reflective structure as the external substrate 31, the light extraction efficiency from the surface side of the substrate 11 is improved.

  As described above, according to the present embodiment, since the substrate 11 (metal plate 110) has the above-described projection group 17, the external connection terminal on the back surface side of the substrate 11 (metal plate 110) from the slit 13 at the time of manufacture. Resin leaks can be prevented. That is, in the resin sealing step with the translucent resin 16, the translucent resin 16 is filled between the slits 13 and the space 20 of the substrate 11 (metal plate 110), but the substrate 11 (metal plate 110). It does not leak outside the protrusions 17a and 17b on the back surface.

  Therefore, according to this embodiment, it is not necessary to block the slit 13 using a film or the like in order to prevent the translucent resin from adhering to the external connection terminal during manufacturing. Accordingly, there is no deterioration in quality due to the film, and a film sticking and peeling process becomes unnecessary. Since these steps can be reduced, the manufacturing cost can also be reduced. Moreover, since there is no curvature of the board | substrate 11 which generate | occur | produces at the process of film peeling, the disconnection of a wire can be prevented and a product yield improves.

  In addition, a translucent resin region having a predetermined width can be secured on the joint surface with the external substrate 31 by the translucent resin filled in the space 20. Since the translucent resin used in the present embodiment is an insulating material, an insulating region having a predetermined width can be secured between solders that connect both electrodes of the substrate 11 to external electrodes, and conduction between the two electrodes can be suppressed. .

  Moreover, according to this embodiment, since sealing of LED element 14 grade | etc., And formation of a lens are performed in 1 process, manufacturing cost can be held down rather than performing these separately.

  Further, since the dicing auxiliary grooves 18 are provided in the preparation process of the metal plate 110, the metal plate 110 can be divided by breaking. Therefore, the time for dicing can be reduced, and damage to the translucent resin due to cutting waste generated when cutting with a dicing blade can be suppressed. Therefore, the manufacturing time can be shortened and the product yield is improved.

  In addition, in the said embodiment, although the side surface cross-sectional shape of protrusion 17a and 17b is made into dome shape, side surface cross-sectional shape is not restricted to this. For example, as shown in FIG. 5, the shape which divided the dome shape into two in the left-right direction may be sufficient.

  FIGS. 5B to 5D are explanatory views for explaining the metal plate 110 having the protrusions 17a and 17b having the shape shown in FIG. (B) is explanatory drawing for demonstrating the back surface side of the metal plate 110, (c) is the A-A 'sectional drawing, (d) is the partially expanded view of (c).

  The material and size of the metal plate 110 of this modification are the same as those in the above embodiment. Moreover, the slit 13 and the auxiliary groove | channel 18 for dicing are formed similarly to the said embodiment.

  The formation method of the protrusion group 17 is the same as that of the said embodiment. However, the shape of the mold used for press working is different. In the above embodiment, the protrusions 17c that become the protrusions 17a and 17b after forming the slit 13 are formed on both sides of the slit 13, but in this modification, one protrusion 17c is formed on the slit 13, and the slit 13 is divided into two protrusions 17a and 17b.

  The line light source 10 of this modification after subdivision is mounted on the external substrate 31 as shown in FIG.

<< Second Embodiment >>
Next, a second embodiment to which the present invention is applied will be described. As shown in FIG. 7A, the line light source 10-2 of this embodiment has protrusions 17e and 17f not only on both sides of the slit 13 but also on both ends of the substrate 11 after dicing.

  The manufacturing process of the line light source 10-2 of this embodiment is basically the same as that of the first embodiment. However, since the configuration of the projection group 17 is different, the projection group 17 is formed using a mold different from that of the first embodiment in the substrate preparation step.

  FIGS. 7B to 7D are explanatory views for explaining the metal plate 110-2 that becomes the substrate 11-2 of the line light source 10-2 of the present embodiment. (B) is explanatory drawing for demonstrating the back surface side of the metal plate 110-2, (c) is the A-A 'sectional drawing, (d) is the partially expanded view of (c).

  The material and size of the metal plate 110-2 of this embodiment are the same as those of the first embodiment. Further, similarly to the first embodiment, the metal plate 110-2 is provided with Ni plating 12 on the back surface side, and a slit 13 and a dicing auxiliary groove 18 are formed.

  Also in the present embodiment, as in the first embodiment, the projection group 17 is formed on the back surface of the substrate 11-2 by press working or the like. However, in the present embodiment, in addition to the protrusions 17c (17a, 17b) provided on both sides of the slit 13 and the protrusion 17d that borders the entire metal plate 110-2, it corresponds to the auxiliary dicing groove 18 formed on the surface side. Projections 17e and 17f are formed on both sides of the position on the back surface side.

  The positions of the protrusions 17d and 17e may be on the protrusions 17a and 17b side from the position on the back side corresponding to the dicing auxiliary groove 18.

  Also in this embodiment, the projection group 17 may be formed by etching and cutting, as in the first embodiment.

  The subsequent LED mounting process, resin sealing process, and subdivision process are the same as in the first embodiment.

  The segmented line light source 10-2 is mounted on the external substrate 31, as shown in FIG. Also in the present embodiment, as in the first embodiment, the external connection terminal of the line light source 10-2 is connected to the wiring pattern 34 of the external substrate 31 by solder bonding.

  According to this embodiment, since it has the projection group 17, there exists an effect similar to 1st embodiment.

  Further, according to the present embodiment, the protrusions 17e and 17f are further provided at both ends of the subdivided substrate 11-2. When the line light source 10 is mounted on the external substrate 31, the LED element 14 is easily maintained level because it is joined to the external substrate 31 with a plurality of protrusions.

  For example, as shown in FIG. 9 (a), when there are protrusions only on both sides of the slit 13 of the substrate 11, when applied so that the thickness of the solder is constant, the level is maintained, but the coating is applied. If the thickness of the solder is not constant, the substrate is tilted and the optical axis of the line light source 10 is tilted as shown in FIG. On the other hand, when the projections 17e and 17f are further provided at both ends of the substrate 11-2 as in the present embodiment, the level can be maintained regardless of the thickness of the solder as shown in FIG. 9C.

  Therefore, according to this embodiment, even when the solder 32 is not uniformly applied at the time of mounting, the level of the line light source 10-2 can be maintained, and the occurrence of problems due to the deviation of the optical axis of the LED element 14 can be prevented. Can do. As a result, the occurrence of product defects due to the amount of solder 32 applied decreases, and the product yield improves.

  For example, when the projection group 17 is formed by press working, the height accuracy obtained is about ± 0.05 to 0.1 mm. In addition, the accuracy in manufacturing by etching is about ± 0.05 mm. Therefore, according to the present embodiment, it is possible to realize such high-accuracy leveling regardless of the joining method at the time of mounting. Conventionally, solder bonding can be used even in a mounting scene where high leveling accuracy is required where solder bonding is not used, and the manufacturing cost can be reduced.

  Any one of the protrusions 17e and 17f to be added may be used as long as the stability due to the uneven solder application amount is not impaired as described above.

  Also in this embodiment, the side cross-sectional shapes of the protrusions 17a and 17b and the protrusions 17d and 17e are not limited to the dome shape. For example, as in the modification of the first embodiment, one protrusion may be divided by the slit 13 and a cut surface by dicing to form two protrusions. FIG. 10A is an explanatory diagram for explaining the line light source 10-2 in this case, and FIGS. 10B to 10D are line light sources having protrusions having the shape shown in FIG. It is explanatory drawing for demonstrating the board | substrate 11-2 of 10-2. (B) is explanatory drawing for demonstrating the back surface side of the board | substrate 11-2, (c) is the A-A 'sectional drawing, (d) is the partially expanded view of (c). The line light source 10-2 of the present modified example after subdivision is mounted on the external substrate 31 as shown in FIG.

<Third embodiment>
Next, a third embodiment to which the present invention is applied will be described. The line light source 10-3 of this embodiment basically has the same configuration as that of the first embodiment. However, the lower mold is not used when forming the protrusions 17a and 17b.

  The manufacturing process of the line light source 10-3 of this embodiment is basically the same as that of the first embodiment. However, since the lower mold is not used when forming the protrusions 17a and 17b, the substrate preparation process is different.

  FIG. 12A is an explanatory diagram for explaining the line light source 10-3 of this embodiment, and FIGS. 12B to 12D are explanations for explaining the metal plate 110-3 of this embodiment. FIG. FIG. 12B is an explanatory view for explaining the back side of the metal plate 110-3, FIG. 12C is its AA ′ cross-sectional view, and FIG. 12D is a partially enlarged view of FIG. is there.

  In the present embodiment, when the slit 13 is produced by press working in the substrate preparation step, the metal plate 110-3 is pressed from the front surface to the back surface of the metal plate 110-3 to be the substrate 11-3 of the line light source 10-3. 3 is generated so that the slits 13 are bordered in the direction of the back surface. Then, the generated burr is polished and adjusted to a certain height to form protrusions 17a and 17b.

  The protrusion 17d that borders the entire metal plate 110-3 may be formed by pressing, or may be formed by etching or the like.

  The material and size of the metal plate 110-3 of the present embodiment are the same as those of the first embodiment. Similarly to the first embodiment, the metal plate 110-3 is provided with Ni plating 12 on the back surface side, and slits 13 and dicing auxiliary grooves 18 are formed.

  Moreover, the other manufacturing process of the line light source 10-3 of this embodiment is the same as that of 1st embodiment. The subdivided line light source 10-3 is mounted on the external substrate 31 as shown in FIG.

  As described above, according to the present embodiment, since the projection group 17 is provided, the same effects as those of the first embodiment can be obtained. Moreover, according to this embodiment, since the metal mold | die for forming the processus | protrusion 17a and the processus | protrusion 17b is unnecessary, it can manufacture by that much cheaply. Further, when the protrusion 17d is manufactured by etching, a lower mold is not required at all in the substrate preparation step, and therefore, it can be manufactured at a lower cost.

  In each of the above embodiments, the shape of the cavity 16 formed of the translucent resin that seals the LED element 14 and the like is a dome-like semicircular shape so as to function as a lens. I can't. For example, a cylindrical lens shape may be used as shown in FIG. When the cylindrical lens shape is used, a line light source with higher directivity can be realized as compared with the case where the cylindrical lens shape is formed.

  In the example of FIG. 14A, the length of the cylindrical portion of the cavity 16 is 1 mm and the lens radius is 0.75 mm. When the radius is this level, directivity can be imparted if the length of the cylindrical portion is 1 mm or more.

  Further, as shown in FIGS. 14B and 14C, a translucent resin containing a phosphor (first translucent resin) and a translucent resin not containing a phosphor (second translucent resin). The cavity 16 may be formed by using two types of resins such as a resin, and the LED element may be sealed and the lens may be formed.

  In the example of FIG. 14B, the first translucent resin is used, the LED element 14, the wire 15 and the slit 13 are sealed, and the second translucent resin is used, and the first translucent resin is used. And a lens is formed. The shape of the lens is, for example, a cylindrical lens shape having a cylindrical portion length of 1 mm and a lens radius of 0.75 mm, as shown in FIG. Similarly, in this example, if the length of the cylinder is 1 mm or more, directivity can be provided.

  In the example of FIG. 14B, the resin molded body made of the first translucent resin and the resin molded body made of the second translucent resin are molded by compression molding or injection molding, respectively.

  Moreover, in the example of FIG.14 (c), the 1st translucent resin is used, the resin molding body which seals the surface or surface and side surface of the LED element 14 is formed, and the 2nd translucent resin is used. The resin molded body made of the first translucent resin, the LED element 14, the wire 15 and the slit 13 are sealed, and a lens is formed. The resin molded body made of the first translucent resin is formed by a technique such as potting or printing. Further, the resin molded body made of the second translucent resin is formed into a cylindrical lens shape similar to that shown in FIG. 14A by compression molding or injection molding.

  Thus, by forming the cavity 16 using two types of translucent resins, the directivity can be easily controlled.

  Moreover, in each said embodiment, it cuts out so that the direction parallel to the slit 13 may become the longitudinal direction of the line light source 10 in the subdivision process, and each LED element 14 is used as the line light source 10 connected in parallel, but this cut-out direction is this. Not limited to. For example, you may cut out so that the direction orthogonal to the slit 13 may become a longitudinal direction. In this case, the adjacent LED elements 14 become line light sources connected in series. When cutting out so that the direction orthogonal to the slit 13 is the longitudinal direction, the dicing auxiliary groove 18 is formed in the direction orthogonal to the slit 13 in the substrate preparation step.

  Further, even when the direction orthogonal to the slit 13 is cut out in the longitudinal direction, the protrusions 17e and 17f of the second embodiment are parallel to the slit 13 on the inner side of both side ends parallel to the slit 13. Provided.

  In addition, when each LED element 14 is connected in parallel, even if one LED element is not lit, the other LED elements 14 are lit, which is practical. Whether each of the LED elements 14 is electrically connected in series or in parallel is determined by power supply voltage restrictions, arrangement space restrictions, and the like.

  In each of the above embodiments, a line light source in which a plurality of LED elements 14 are connected in parallel or in series is described as an example, but the present invention is not limited to this. Even if the LED element 14 is one light-emitting device, the above embodiments can be applied. When the number of the LED elements 14 is one, it is preferable that the lens shape is provided so as to be circular when viewed from above.

  10: line light source, 10-2: line light source, 10-3: line light source, 11: substrate, 11-2: substrate, 11-3: substrate, 12: Ni plating, 13: slit, 14: LED element, 15 : Wire, 16: cavity, 17: projection group, 17a: projection, 17b: projection, 17c: projection, 17d: projection, 17f: projection, 18: auxiliary groove, 19: groove, 20: assembly 31: External substrate, 32: Solder, 33: Resist, 34: Wiring pattern, 110: Metal plate, 110-2: Metal plate, 110-3: Metal plate

Claims (5)

A metal substrate having a slit;
One or more light emitting elements mounted on the substrate;
A light-emitting device comprising a resin molded body that seals the light-emitting element and the slit on the light-emitting element,
A light emitting device comprising: a protrusion on both sides of the slit on the back surface side of the substrate on which the light emitting element is disposed, in parallel with the slit. The light-emitting device according to claim 1,
The light emitting device according to claim 1, wherein the substrate further includes a second protrusion parallel to the slit on the inner side of both side end portions parallel to the slit on the back surface side. The light emitting device according to claim 2,
A light-emitting device that is mounted on an external substrate by solder bonding. The light-emitting device according to any one of claims 1 to 3,
A light-emitting device, wherein a space surrounded by the slit and the protrusion is filled with a resin constituting the resin molded body to a height equal to the protrusion. One or more slits arranged in a predetermined direction, a first protrusion formed so as to surround the slit, and a second protrusion formed on the same surface as the first protrusion so as to border the entire substrate. A substrate preparation step of preparing a metal substrate;
A light emitting element mounting step of mounting and electrically connecting one or more light emitting elements on a surface of the substrate opposite to the surface on which the protrusions are formed;
A resin sealing step of sealing the light emitting element and the slit with a translucent resin;
Subdividing the substrate after sealing in a predetermined direction by dicing, and
In the resin sealing step, the surface of the substrate on which the first protrusion is formed is fixed to an upper mold by a vacuum chuck, and the sealing is formed by compression molding.

Images