JP2020102646A - Light-emitting device - Google Patents

Light-emitting device Download PDF

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JP2020102646A
JP2020102646A JP2020047090A JP2020047090A JP2020102646A JP 2020102646 A JP2020102646 A JP 2020102646A JP 2020047090 A JP2020047090 A JP 2020047090A JP 2020047090 A JP2020047090 A JP 2020047090A JP 2020102646 A JP2020102646 A JP 2020102646A
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light
light emitting
emitting element
emitting device
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JP7011196B2 (en
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将嗣 市川
Masatsugu Ichikawa
将嗣 市川
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Nichia Chemical Industries Ltd
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Abstract

To provide a light emitting device capable of improving the extraction efficiency of light emitted from a light emitting element, achieving miniaturization, increasing light emission efficiency, and providing light emission characteristics with suppressed uneven color and uneven brightness.SOLUTION: A light-emitting device includes a covering member including a light-reflecting material, a light-transmitting member having a light-emitting side surface and a light-incident side surface that faces the surface of the covering member and is disposed in the surface, and a light emitting element and a wavelength conversion member that is coupled to the incident area side of the light emitting element and is excited by the light emitting element in a light source portion partially embedded in the covering member and coupled to an incident area surrounded by an outer reflection area on the light incident side surface of the light-transmitting member.SELECTED DRAWING: Figure 1

Description

本発明は、発光装置に関し、特に発光素子からの光の取り出し効率を増大させるための光透過部材および被覆部材を備える発光装置に関する。 The present invention relates to a light emitting device, and more particularly to a light emitting device including a light transmitting member and a covering member for increasing the efficiency of extracting light from a light emitting element.

近年、光源として発光ダイオード(Light Emitting Diode:LED)やレーザダイオード(Laser Diode:LD)等の半導体発光素子を搭載した発光装置は、各種の照明や表示装置に利用されている。特に、これら半導体発光素子は消費電力が低く長寿命であるため、蛍光灯に代替可能な次世代照明の光源として注目を集めており、さらなる発光出力および発光効率の向上が求められている。 In recent years, a light emitting device equipped with a semiconductor light emitting element such as a light emitting diode (LED) or a laser diode (LD) as a light source has been used for various illuminations and display devices. In particular, since these semiconductor light emitting devices have low power consumption and long life, they are attracting attention as a light source for next-generation lighting that can replace fluorescent lights, and further improvement in light emission output and light emission efficiency is required.

例えば、特許文献1で提案されている発光装置は、LEDである発光素子チップが、実装基板であるパッケージに設けられた収納凹所の底部にフリップチップ実装されている。また、発光素子チップの出射面には、平凸レンズの形状を有した光取出増大部材の入射面が光結合されている。光取出増大部材は、発光素子チップのサファイア基板と空気との中間の屈折率を有している。そして、光取出増大部材の出射面は球面であって、出射面上のすべての位置において、当該位置の法線を中心線とし臨界角を中心線と母線とのなす角度とする円錐内に発光素子チップの出射面が含まれるように形成されている。この構成によれば、光取出増大部材の出射面において実質的に全反射を生じないから、多重反射による光の減衰や消滅を生じさせずに光取出増大部材から光を取り出すことができ、結果的に光の利用効率が高くできるとされている。 For example, in the light emitting device proposed in Patent Document 1, a light emitting element chip, which is an LED, is flip-chip mounted on the bottom of a storage recess provided in a package, which is a mounting substrate. Further, the incident surface of a light extraction increasing member having the shape of a plano-convex lens is optically coupled to the emission surface of the light emitting element chip. The light extraction increasing member has a refractive index intermediate between that of the sapphire substrate of the light emitting element chip and air. The emission surface of the light extraction increasing member is a spherical surface, and at all positions on the emission surface, light is emitted in a cone whose normal line is the center line and whose critical angle is the angle formed by the center line and the generatrix. It is formed so as to include the emission surface of the element chip. According to this configuration, since total reflection is not substantially generated on the emission surface of the light extraction increasing member, light can be extracted from the light extraction increasing member without causing attenuation or extinction of light due to multiple reflection. It is said that the utilization efficiency of light can be improved.

特開2006−351809号公報JP, 2006-351809, A 特開2007−019096号公報JP, 2007-019096, A 特開2006−037097号公報JP, 2006-037097, A 特開2006−352061号公報JP, 2006-352061, A 特開2002−305328号公報JP-A-2002-305328 特開平10−151794号公報JP, 10-151794, A

しかしながら、上記特許文献1に記載された発光装置において、発光素子チップからその側方へ出射される光は、封止樹脂を透過して、その内部を伝搬することでこの封止樹脂やパッケージにより吸収・減衰される。また、封止樹脂からも光取出増大部材の入射面に光結合するため、入射面における発光領域は実質的に大きくなり、光取出増大部材の出射面において反射される光成分が増加する。これらのことから、発光素子チップから出射される光を十分に外部に取り出すことができず、また光の取り出し効率を維持したまま装置の更なる小型化を図ることが難しい。 However, in the light emitting device described in Patent Document 1, the light emitted from the light emitting element chip to the side thereof passes through the sealing resin and propagates inside the sealing resin and the package. Absorbed and attenuated. Further, since the sealing resin also optically couples to the incident surface of the light extraction increasing member, the light emitting region on the incident surface becomes substantially large, and the light component reflected on the emission surface of the light extraction increasing member increases. For these reasons, it is difficult to sufficiently extract the light emitted from the light emitting element chip to the outside, and it is difficult to further reduce the size of the device while maintaining the light extraction efficiency.

また、従来は光源としてLED光を想定し、その取り出し効率を高める構造であり、取り出されたLED光を、別途設けた蛍光体などにより波長変換させる構造となっている。そのため、発光装置の出射光としての波長変換光、それに付加されたLED光、について、分離されたLED光源部と波長変換部との間での光散乱、吸収などにより、その光取り出し効率が低下する構造となっていたり、その出射光の指向性が低下する構造となっていたり、色むら、輝度むらが大きくなる構造となっていたり、装置の出射光の発光特性が不十分なものとなっている場合がある。さらにこのような光源と変換部の分離構造では、装置全体の小型化が難しい側面もある。 Further, conventionally, a structure is assumed in which LED light is assumed as a light source, and the extraction efficiency thereof is increased, and the extracted LED light is wavelength-converted by a separately provided phosphor or the like. Therefore, the wavelength conversion light as the emitted light of the light emitting device and the LED light added to the wavelength conversion light are reduced in light extraction efficiency due to light scattering and absorption between the separated LED light source section and the wavelength conversion section. The structure is such that the directivity of the emitted light is reduced, the color unevenness and the brightness unevenness are increased, or the emission characteristics of the emitted light of the device are insufficient. There is a case. Further, with such a separation structure of the light source and the conversion unit, it is difficult to downsize the entire device.

本発明は、上記課題に鑑みてなされたものであり、その目的は、発光素子から出射される光の取り出し効率を向上させること、小型化できること、発光効率を高くすること、色むら、輝度むらを抑えた発光特性とすること、が可能な発光装置を提供することである。 The present invention has been made in view of the above problems, and an object thereof is to improve the extraction efficiency of light emitted from a light emitting element, to be able to downsize, to increase the emission efficiency, color unevenness, and brightness unevenness. It is an object of the present invention to provide a light-emitting device that has a light-emitting characteristic that suppresses

本発明に係る発光装置は、下記(1)〜(13)の構成により、上記目的を達成することができる。
(1) 光反射性材料を含有する被覆部材と、発光側の表面と、前記被覆部材の表面に対向し、該表面内に配置された光入射側の表面とを有する光透過部材と、前記光透過部材の光入射側表面において、外側の反射領域に囲まれた入射領域に結合し、前記被覆部材に一部が埋め込まれた光源部に、発光素子と、該発光素子の前記入射領域側に結合され、該発光素子に励起される波長変換部材と、を備える発光装置。
(2) 前記光透過部材は、前記発光側が凸曲面で、前記光入射側の少なくとも反射領域が略平坦な表面であり、前記入射領域の断面幅は、前記光入射側表面の半分以下である上記(1)に記載の発光装置。
(3) 光反射性材料を含有する被覆部材と、凸曲面の発光側の表面と、前記被覆部材の表面に対向し、該表面内に配置された光入射側の表面とを有する光透過部材と、前記光透過部材の光入射側表面において、略平坦な表面の反射領域に囲まれた内側の入射領域に結合し、前記被覆部材に一部が埋め込まれた光源部が設けられて、該光源部内に設けられた発光素子と、を備え、前記入射領域の断面幅は、前記光入射側表面の半分以下である発光装置。
(4) 前記発光装置は、前記光源部に、前記発光素子の前記入射領域側に結合され、前記発光素子に励起される波長変換部材をさらに備える上記(3)に記載の発光装置。
(5) 前記波長変換部材は、互いに対向する第1及び第2の主面を有する板状体であって、前記第2の主面に複数の前記発光素子が接合されており、前記入射領域に前記第1の主面が接合されている上記(1),(2),(4)のいずれか1つに記載の発光装置。
(6) 前記反射領域は、前記被覆部材の表面と離間された前記光透過部材表面に設けられる上記(1)乃至(5)のいずれか1つに記載の発光装置。
(7) 前記発光装置は、前記光透過部材の光入射側の表面と前記被覆部材の表面とを接着させる透光性接着材を有し、前記入射領域及び反射領域は、前記透光性接着剤との界面に設けられる上記(1)乃至(6)のいずれか1つに記載の発光装置。
(8) 前記光透過部材は、前記光源部上及び前記被覆部材表面に設けられ、前記反射領域は、前記光透過部材と前記被覆部材との界面である上記(1)乃至(5)のいずれか1つに記載の発光装置。
(9) 前記入射領域は、前記反射領域より前記発光側に突出している上記(8)に記載の発光装置。
(10) 前記光透過部材の発光側の表面形状は、球面形状である上記(1)乃至(9)のいずれか1つに記載の発光装置。
(11) 前記発光装置は、前記発光素子が実装される実装基板を有し、前記発光素子は、前記入射領域側の表面に対向する実装面側で、前記実装基板と電気的に接続される上記
(1)乃至(10)のいずれか1つに記載の発光装置。
(12) 前記発光装置の光源部は、前記発光素子の入射領域側表面に結合して、発光素子により励起される波長変換部材を有し、前記被覆部材は、前記入射領域から、前記光源部の側面を覆って、前記実装基板の表面上にまで延在して設けられている上記(11)に記載の発光装置。
(13) 前記被覆部材が、前記発光素子及び前記波長変換部材の側面にそれぞれ接して設けられる上記(12)に記載の発光装置。
The light emitting device according to the present invention can achieve the above object by the following configurations (1) to (13).
(1) A light transmitting member having a covering member containing a light reflecting material, a light emitting side surface, and a light incident side surface facing the surface of the covering member and disposed in the surface, On the light incident side surface of the light transmissive member, the light emitting element and the incident area side of the light emitting element are coupled to the incident area surrounded by the outer reflective area and partly embedded in the covering member. And a wavelength conversion member that is excited by the light emitting element.
(2) In the light transmitting member, the light emitting side is a convex curved surface, and at least the reflecting region on the light incident side is a substantially flat surface, and the cross sectional width of the incident region is half or less of the light incident side surface. The light emitting device according to (1) above.
(3) Light-transmitting member having a covering member containing a light-reflecting material, a light-emitting side surface of a convex curved surface, and a light-incident side surface facing the surface of the covering member and arranged in the surface. And a light source unit, which is coupled to an inner incident region surrounded by a reflection region of a substantially flat surface on the light incident side surface of the light transmitting member and is partially embedded in the covering member, And a light emitting element provided in the light source unit, wherein a cross-sectional width of the incident region is half or less of a surface of the light incident side.
(4) The light emitting device according to (3), further including a wavelength conversion member that is coupled to the light source unit on the incident region side of the light emitting element and is excited by the light emitting element.
(5) The wavelength conversion member is a plate-shaped body having first and second main surfaces facing each other, and a plurality of the light emitting elements are joined to the second main surface, and the incident area is provided. The light emitting device according to any one of (1), (2), and (4) above, wherein the first main surface is bonded to the.
(6) The light emitting device according to any one of (1) to (5), wherein the reflective region is provided on a surface of the light transmitting member that is separated from a surface of the covering member.
(7) The light emitting device includes a translucent adhesive that adheres a surface of the light transmissive member on a light incident side to a surface of the covering member, and the incident region and the reflective region include the translucent adhesive. The light emitting device according to any one of (1) to (6) above, which is provided at an interface with the agent.
(8) Any of the above (1) to (5), wherein the light transmitting member is provided on the light source section and on the surface of the covering member, and the reflection region is an interface between the light transmitting member and the covering member. The light-emitting device according to any one of the above.
(9) The light-emitting device according to the above (8), wherein the incident area projects toward the light-emitting side from the reflective area.
(10) The light emitting device according to any one of (1) to (9), wherein a surface shape of the light transmitting member on the light emitting side is a spherical shape.
(11) The light emitting device has a mounting substrate on which the light emitting element is mounted, and the light emitting element is electrically connected to the mounting substrate on a mounting surface side facing a surface on the incident region side. The light-emitting device according to any one of (1) to (10) above.
(12) The light source unit of the light emitting device includes a wavelength conversion member that is coupled to a surface of the light emitting element on the incident region side and is excited by the light emitting device, and the covering member is provided from the incident region to the light source unit. The light emitting device according to (11), which is provided so as to cover the side surface of the mounting substrate and extend to the surface of the mounting substrate.
(13) The light emitting device according to (12), wherein the covering member is provided in contact with side surfaces of the light emitting element and the wavelength conversion member, respectively.

本発明は、光反射性の被覆部材により、光源部の発光素子、それに結合する波長変換部を被覆して、発光素子の光源、又はその複合的な光源からの出射光を一方向に取り出し、すなわち、光源を1つの発光面として、発光装置の光出射の窓部を一面の特定の領域とし、上記窓部を内包する光透過部材を接合させて被覆部材に覆われることにより、光源からの光の取り出し効率を格段に向上させ、色と輝度むらを抑えた発光特性を得ることができる。特に、光透過部材の一部領域において窓部に結合させ、他の領域において光透過部材の内面で反射される光成分が、被覆部材で反射されることで、光を効率良く取り出すことができ、すなわち、部材中を伝搬する光成分が多い光透過部材であっても取り出し効率を高くできるため、比較的大きな面積、容積を占める光透過部材を小さくして、装置を小型化した場合にも特性の低下を抑えることができる。また、上記複合的な光源としているため、その光源部を小さくでき、これも装置の小型化に寄与する。 The present invention, the light-reflecting coating member, the light-emitting element of the light source section, the wavelength conversion section coupled to it is coated, the light source of the light-emitting element, or the emitted light from the composite light source is extracted in one direction, That is, the light source is used as one light emitting surface, the light emitting window portion of the light emitting device is used as one specific area, and the light transmitting member that encloses the window portion is joined to be covered with the covering member. It is possible to significantly improve the light extraction efficiency and obtain light emission characteristics with suppressed color and luminance unevenness. In particular, since the light component that is coupled to the window portion in a part of the light transmitting member and reflected by the inner surface of the light transmitting member in the other region is reflected by the covering member, the light can be extracted efficiently. That is, even if a light transmitting member having a large amount of light components propagating through the member can be taken out with high efficiency, the light transmitting member occupying a relatively large area and volume can be made small, and the device can be downsized. It is possible to suppress deterioration of characteristics. Further, since the above-mentioned composite light source is used, the light source section can be made small, which also contributes to downsizing of the device.

本発明の一実施の形態に係る発光装置の概略断面図(a)と、その概略上面図(b)である。FIG. 1 is a schematic cross-sectional view (a) of a light emitting device according to an embodiment of the present invention and a schematic top view (b) thereof. 本発明の一実施の形態に係り、図1の発光装置の光源部周辺を説明する概略断面図である。FIG. 2 is a schematic cross-sectional view illustrating the periphery of the light source unit of the light emitting device of FIG. 1 according to the embodiment of the present invention. 本発明に係る各計算モデルの発光装置を示す概略断面図(A)〜(D)である。It is schematic sectional drawing (A)-(D) which shows the light-emitting device of each calculation model which concerns on this invention. 本発明の各計算モデルにおける光透過部材の径と入射領域の径の比と光取り出し効率の関係を示すグラフである。6 is a graph showing the relationship between the ratio of the diameter of the light transmitting member and the diameter of the incident region and the light extraction efficiency in each calculation model of the present invention. 本発明の一実施の形態に係る発光素子の概略断面図である。It is a schematic sectional drawing of the light emitting element which concerns on one embodiment of this invention. 本発明の一実施の形態に係る発光装置の製造方法を示す模式断面図(A)〜(D)である。FIG. 5 is schematic cross-sectional views (A) to (D) showing a method for manufacturing a light emitting device according to an embodiment of the present invention. 本発明の一実施の形態に係る発光装置の概略断面図(a)と、その光源部周辺を説明する概略断面図(b)である。1A is a schematic cross-sectional view of a light emitting device according to an embodiment of the present invention, and FIG. 2B is a schematic cross-sectional view illustrating the periphery of a light source unit thereof. 本発明の一実施の形態に係る発光装置の光源部周辺を説明する概略断面図である。It is a schematic sectional drawing explaining the light source part periphery of the light-emitting device which concerns on one embodiment of this invention. 本発明の一実施の形態に係る各発光装置の概略断面図(a)〜(c)である。It is a schematic sectional drawing (a)-(c) of each light-emitting device which concerns on one embodiment of this invention. 本発明の一実施の形態に係る発光装置の概略断面図である。It is a schematic sectional drawing of the light-emitting device which concerns on one embodiment of this invention. 本発明に係る発光装置における光透過部材と発光効率の関係を示すグラフである。6 is a graph showing a relationship between a light transmitting member and light emission efficiency in the light emitting device according to the present invention.

以下、発明の実施の形態について適宜図面を参照して説明する。ただし、以下に説明する発光素子・装置は、本発明の技術思想を具体化するためのものであって、本発明を以下のものに特定しない。特に、以下に記載されている構成部品の寸法、材質、形状、その相対的配置等は特定的な記載がない限りは、本発明の範囲をそれのみに限定する趣旨ではなく、単なる説明例にすぎない。なお、各図面が示す部材の大きさや位置関係等は、説明を明確にするため誇張していることがある。さらに、本発明を構成する各要素は、複数の要素を同一の部材で構成して一の部材で複数の要素を兼用する態様としてもよいし、逆に一の部材の機能を複数の部材で分担して実現することもできる。また、以下に記載されている各実施の形態についても同様に、特に排除する記載が無い限りは各構成等を適宜組み合わせて適用できる。 Hereinafter, embodiments of the present invention will be described with reference to the drawings as appropriate. However, the light emitting elements and devices described below are for embodying the technical idea of the present invention, and the present invention is not limited to the following. In particular, unless otherwise specified, the dimensions, materials, shapes, relative positions, etc. of the components described below are not intended to limit the scope of the present invention thereto, but are merely illustrative examples. Only. The sizes and positional relationships of members shown in each drawing may be exaggerated for clarity of explanation. Further, each element constituting the present invention may be configured such that a plurality of elements are configured by the same member and one member also serves as a plurality of elements, or conversely, the function of one member is performed by a plurality of members. It can be shared and realized. Further, similarly to each of the embodiments described below, the respective configurations and the like can be appropriately combined and applied unless otherwise specified.

(実施の形態1)
図1、2は、本発明の実施の形態1に係る発光装置100の概略図であり、図1(a)は概略上面図の図1(b)のA−Aにおける概略断面図であり、図2は光源部周辺の概略断面図である。図1,2に示す例の発光装置100は、主として、発光素子10と、光透過部材20と、被覆部材30と、波長変換部材40と、実装基板50と、から構成される。基板50は、枠体55と、複数個(図中では2個)の発光素子10がフリップチップ実装された配線51を備えている。この波長変換部材40は、板状で互いに対向する第1および第2の面を有し、その第2の面が各発光素子10の裏面に接合されている。そして、光反射材料35を含有する被覆部材30が枠体55の内側に充填され、光源部の発光素子10と波長変換部材40は、第1の面を露出面として、被覆部材30に被覆されている。被覆部材30は、側面と第2の面の一部、さらに発光素子10の側面と、を連続して被覆する。これにより、発光素子10及び/又は波長変換部材40から出射された光は、光反射性の被覆部材30により発光側に反射、導光されて、波長変換部材40の第1の面から取り出され、この第1の面を主要な光取り出しの窓部すなわち発光面とする面発光型の光源となる。第1の面の形状、大きさでそれを光源とでき、この光源の上に、光源に対する光学素子として光透過部材20がその光入射側の一部領域の光入射領域80に接合されている。
(Embodiment 1)
1 and 2 are schematic diagrams of a light emitting device 100 according to Embodiment 1 of the present invention, and FIG. 1A is a schematic cross-sectional view taken along the line AA in FIG. FIG. 2 is a schematic cross-sectional view around the light source unit. The light emitting device 100 of the example shown in FIGS. 1 and 2 mainly includes a light emitting element 10, a light transmitting member 20, a covering member 30, a wavelength converting member 40, and a mounting substrate 50. The substrate 50 includes a frame body 55 and a wiring 51 on which a plurality (two in the drawing) of the light emitting elements 10 are flip-chip mounted. The wavelength conversion member 40 is plate-shaped and has first and second surfaces facing each other, and the second surface is bonded to the back surface of each light emitting element 10. Then, the covering member 30 containing the light reflecting material 35 is filled inside the frame body 55, and the light emitting element 10 and the wavelength conversion member 40 of the light source unit are covered by the covering member 30 with the first surface as an exposed surface. ing. The covering member 30 continuously covers the side surface, a part of the second surface, and the side surface of the light emitting element 10. Thereby, the light emitted from the light emitting element 10 and/or the wavelength conversion member 40 is reflected and guided to the light emission side by the light reflective coating member 30, and is extracted from the first surface of the wavelength conversion member 40. The surface emitting light source uses the first surface as a main light extraction window, that is, a light emitting surface. With the shape and size of the first surface, it can be used as a light source, and the light transmitting member 20 as an optical element for the light source is bonded to the light incident area 80 of a partial area on the light incident side on the light source. ..

図2は、実施の形態1に係る発光装置の光源部周辺を説明するための概略断面図である。図2に示すように、光透過部材20は、その光入射側の表面において、波長変換部材40の第1の面を内包し、その外側を囲む被覆部材30の一部に設けられており、その光入射側の表面に対向して、発光装置の発光面となる発光側の表面21を有する。この光入射側の表面は、波長変換部材40の第1の面と対向し、発光素子10及び/又は波長変換部材40からの光が入射される入射領域80と、その外側の被覆部材30表面に対向する反射領域90と、を有する。この入射領域80は、波長変換部材40の第1の面からの光の取り出し効率を増大させ、また、図1及び図2に示すように、反射領域90で光透過部材20の光を反射する。ここで、図示するように、光透過部材20は半球状レンズで、その中心は図3Aに示すように光源部表面で入射領域の略中心となっており、すなわち凸曲面の発光面21を備えた光学素子となっている。このとき、波長変換部材40の第1の面に垂直な断面において、光源部、入射領域80の径(断面幅)Lは、光透過部材20の曲率半径r(=R/2)の半分以下、L≦(R/2)/2、となっていることが好ましい。入射領域80から入射した光の一部は発光側の表面21から外部に放出され、残りの光成分は発光側の表面21の内面で光入射側へ反射されて戻り光となる。この戻り光は、直接、又は光透過部材20の内面での多重反射を繰り返しながらその多くが、反射領域90に到達する。反射領域90に入射された戻り光は、光反射性の被覆部材30の表面で反射されることにより、光透過部材20の発光側の表面21への入射角が変えられ外部への透過が促進される。ここで、後述するように、被覆部材が光反射性材料を備えた透光性の部材であると、その表面における乱反射効果が高められ、また光の損失が少なく、好ましい。 FIG. 2 is a schematic cross-sectional view for explaining the vicinity of the light source unit of the light emitting device according to the first embodiment. As shown in FIG. 2, the light transmitting member 20 is provided on a part of the covering member 30 that encloses the first surface of the wavelength conversion member 40 on the surface on the light incident side and surrounds the outer surface thereof. A light emitting side surface 21 which is a light emitting surface of the light emitting device is provided so as to face the light incident side surface. The surface on the light incident side faces the first surface of the wavelength conversion member 40, the incident region 80 on which the light from the light emitting element 10 and/or the wavelength conversion member 40 is incident, and the surface of the covering member 30 outside thereof. And a reflection region 90 facing the. The incident area 80 increases the light extraction efficiency from the first surface of the wavelength conversion member 40, and, as shown in FIGS. 1 and 2, reflects the light of the light transmission member 20 in the reflection area 90. .. Here, as shown in the figure, the light transmitting member 20 is a hemispherical lens, the center of which is substantially the center of the incident area on the surface of the light source unit, that is, a light emitting surface 21 having a convex curved surface is provided. It is an optical element. At this time, in the cross section perpendicular to the first surface of the wavelength conversion member 40, the diameter (cross section width) L of the light source section and the incident region 80 is half or less of the radius of curvature r (=R/2) of the light transmission member 20. , L≦(R/2)/2. A part of the light incident from the incident area 80 is emitted to the outside from the light emitting side surface 21, and the remaining light components are reflected to the light incident side on the inner surface of the light emitting side surface 21 and become return light. Most of this return light reaches the reflection region 90 either directly or while repeating multiple reflections on the inner surface of the light transmitting member 20. The return light that has entered the reflection region 90 is reflected by the surface of the light-reflective coating member 30 to change the angle of incidence on the light-emission-side surface 21 of the light-transmissive member 20 and promote its transmission to the outside. To be done. Here, as described later, it is preferable that the covering member is a translucent member including a light-reflecting material because the diffuse reflection effect on the surface thereof is enhanced and the light loss is small.

また、上述のように、発光素子10、又は、発光素子10と波長変換部材40からなる光源部からの光透過部材20への光入射は、光反射性の被覆部材30にその光源部の一部が埋め込まれることよって入射領域80にほぼ限定されているため、光は反射領域90から光透過部材20へ直接的に殆ど入射されず、この発光領域を光透過部材20に対して点光源に近づけることができる。これにより、凸曲面を備えた光学素子の光透過部材の発光側の表面21での光反射を低減して、ひいては高い光取り出し効率を維持したまま装置全体を小型化、薄型化することが可能となる。このように、本発明の発光装置は、光透過部材20の光入射側の表面に、光透過部材20内に高効率に光源部を結合させる入射領域80と、その光透過部材内の光成分を発光側の表面21方向に反射させる反射領域90と、を有し、その異なる作用により、光透過部材20の発光側の表面21の多様な形状に対応して、光の取り出し効率を格段に向上させることができる。 In addition, as described above, the light incident from the light emitting element 10 or the light source portion including the light emitting element 10 and the wavelength converting member 40 to the light transmitting member 20 causes the light reflecting coating member 30 to be exposed to one of the light source portions. Since the portion is embedded, the light is almost not directly incident on the light transmissive member 20 from the reflective region 90 because it is almost limited to the incident region 80. You can get closer. As a result, it is possible to reduce the light reflection on the surface 21 on the light emitting side of the light transmitting member of the optical element having the convex curved surface, and thus to downsize and thin the entire device while maintaining high light extraction efficiency. Becomes As described above, in the light emitting device of the present invention, on the surface of the light transmitting member 20 on the light incident side, the incident region 80 for highly efficiently coupling the light source unit in the light transmitting member 20 and the light component in the light transmitting member. And a reflection region 90 that reflects the light toward the surface 21 on the light emitting side, and the different action allows the light extraction efficiency to be remarkably corresponding to various shapes of the surface 21 on the light emitting side of the light transmitting member 20. Can be improved.

特に、本実施の形態1においては、光透過部材20の光入射側の表面は、光源部、すなわち波長変換部材40の第1の面と、その外側の被覆部材30の表面と、に各々直接接合され、すなわち入射領域80は第1の面との界面に、反射領域90は被覆部材30の表面との界面に、それぞれ設けられている。したがって、この反射領域90に到達する戻り光を、光反射性の被覆部材30の表面で反射若しくは散乱せしめ、発光側の表面21を透過させ装置外部に取り出すことができる。特に、後述するように、被覆部材が光反射性材料を含有する透光性の部材、例えば透光性樹脂である場合には、被覆部材表面で、光透過部材との界面反射ができ、さらに内部に入射した光は、光反射性材料により反射、散乱されるため、反射領域90の効果を高められ、発光特性に優れた発光装置となる。このような実施の形態1の発光装置100は、後述するように上記面発光型の光源部を作製した後、その上に光透過部材20を各種成形技術により直接接合させて成形することにより作製することができ、後述する他の実施の形態の発光装置に比して、最も量産性に優れる形態である。 In particular, in the first embodiment, the light incident side surface of the light transmitting member 20 is directly connected to the light source section, that is, the first surface of the wavelength conversion member 40 and the surface of the covering member 30 outside thereof. That is, they are joined, that is, the incident region 80 is provided at the interface with the first surface, and the reflective region 90 is provided at the interface with the surface of the covering member 30, respectively. Therefore, the return light that reaches the reflection region 90 can be reflected or scattered by the surface of the light-reflective coating member 30, transmitted through the light-emitting side surface 21, and taken out of the device. In particular, as will be described later, when the covering member is a translucent member containing a light-reflecting material, for example, a translucent resin, interface coating with the light transmissive member is possible on the surface of the covering member, and The light that has entered the inside is reflected and scattered by the light-reflecting material, so that the effect of the reflection region 90 is enhanced and the light emitting device has excellent light emitting characteristics. The light emitting device 100 according to the first embodiment is manufactured by manufacturing the surface emitting light source unit as described later and then directly bonding the light transmitting member 20 thereon by various molding techniques to form the light emitting member 20. This is the form that is most suitable for mass production as compared with the light emitting devices of other embodiments described later.

また、入射領域80は、図示するように、反射領域90より発光側に突出していることが好ましい。これにより、被覆部材30の表面により遮光されず、さらに図示するように、反射領域90を突出した入射領域80に向けて反射領域から傾斜した傾斜面、すなわち外側に反射する傾斜面とすれば、その反射領域90による光透過部材20側方への光放出、すなわち発光装置からの高角度成分を増大させ、広い配向性が得られる。 Further, as shown in the figure, the incident area 80 preferably protrudes to the light emitting side from the reflective area 90. As a result, if the surface of the covering member 30 is not shielded from light, and as shown in the drawing, the reflection area 90 is an inclined surface inclined from the reflection area toward the projecting incident area 80, that is, an inclined surface reflecting to the outside, Light emission to the side of the light transmitting member 20 by the reflection region 90, that is, a high angle component from the light emitting device is increased, and a wide orientation is obtained.

(光学素子と光源)
本発明における光透過部材20、すなわち光学素子の径W、凸曲面の曲率半径rと、入射領域80の径Lとの関係について、以下にこれを詳述する。図3は、ここで検討する理論計算モデルの各発光装置の構造を示す概略断面図である。図3(A)に示す発光装置110は、一辺の長さLの正方形で厚さ100μmの直方体(板状)の光源部16を備える。また、光源部は、その上面のみを露出して、その側面及び底面を被覆部材31により被覆し、被覆部材31の反射率は100%とする。そして、図中の黒丸で示す光源部の上面の中心を曲率中心とする直径Rの半球状の光透過部材20aが、同一面の光源部及び被覆部材表面上に設けられている。光透過部材の直径R及び径Wは4mm(曲率半径2mm)とし、屈折率は1.537とする。この発光装置110は、上述の実施の形態1の発光装置100を想定している。また、図3(B)に示す発光装置120は、光透過部材20bと被覆部材32の表面との間に空隙86が設けられて、この両表面が互いに離間されているほかは、上述の発光装置110と同様である。より詳細には、光源部16より外側の光透過部材20bの平坦な表面(反射領域)に対向して、光源部の上面より下方に傾斜した傾斜面94があり、空隙86の空気の屈折率は1.000とする。この発光装置120は、後述する実施の形態2の発光装置200を想定している。
(Optical element and light source)
The relationship between the diameter W of the light transmitting member 20, that is, the optical element, the radius of curvature r of the convex curved surface, and the diameter L of the incident region 80 in the present invention will be described in detail below. FIG. 3 is a schematic cross-sectional view showing the structure of each light emitting device of the theoretical calculation model studied here. The light-emitting device 110 illustrated in FIG. 3A includes a light source portion 16 that is a rectangular parallelepiped (plate-like) having a square shape with one side length L and a thickness of 100 μm. Further, the light source section exposes only its upper surface and covers the side surface and the bottom surface thereof with the covering member 31, and the covering member 31 has a reflectance of 100%. Then, a hemispherical light transmitting member 20a having a diameter R whose center of curvature is the center of the upper surface of the light source portion indicated by a black circle in the figure is provided on the same surface of the light source portion and the covering member. The diameter R and the diameter W of the light transmitting member are 4 mm (the radius of curvature is 2 mm), and the refractive index is 1.537. This light emitting device 110 is assumed to be the light emitting device 100 of the above-described first embodiment. Further, in the light emitting device 120 shown in FIG. 3B, a gap 86 is provided between the light transmitting member 20b and the surface of the covering member 32, and both surfaces are separated from each other. Similar to device 110. More specifically, there is an inclined surface 94 that is inclined downward from the upper surface of the light source section, facing the flat surface (reflection area) of the light transmitting member 20b outside the light source section 16, and the refractive index of the air in the void 86. Is 1.000. This light emitting device 120 is assumed to be a light emitting device 200 according to a second embodiment described later.

また、図3(C)に示す発光装置130は、光源部16が被覆部材33表面上に設けられているほかは、上記発光装置110と同様であり、光源部は光透過部材20c内に埋め込まれて、底面を除いて被覆されており、図中の黒丸で示すように曲率中心は光源部16の底面の中心に位置する。さらに、図3(D)に示す発光装置140は、光透過部材が設けられる表面が、被覆部材34とその外側に反射率の低い基材35を備えること、並びに光透過部材20dを変更したこと以外は、発光装置110と同様である。詳細には、被覆部材34は他の装置同様に100%の反射率とし、上面視において一辺が2.7mmの正方形であり、基材35は90%の反射率とし、被覆部材34の外側で光透過部材の全領域を構成している。光透過部材20dは、光源部上面の中心から直下へ2mm離れた位置に曲率中心を有する曲率半径3mmの球面であり、径Wは約4.472mmである。したがって、この発光装置140は、光透過部材の光入射側の表面において、入射領域の外側の被覆部材34による反射率100%の領域と、さらにその外側の基材35に反射率90%の領域と、を有しており、光源側の表面は半球面の扁形面となっている。 A light emitting device 130 shown in FIG. 3C is similar to the above light emitting device 110 except that the light source section 16 is provided on the surface of the covering member 33, and the light source section is embedded in the light transmitting member 20c. Therefore, the center of curvature is located at the center of the bottom surface of the light source unit 16 as indicated by the black circle in the figure. Further, in the light emitting device 140 shown in FIG. 3D, the surface on which the light transmitting member is provided includes the covering member 34 and the base material 35 having a low reflectance outside the covering member 34, and the light transmitting member 20d is changed. Other than that, the light emitting device 110 is the same as the light emitting device 110. In detail, the covering member 34 has a reflectance of 100% like other devices, is a square having a side of 2.7 mm in a top view, and the base material 35 has a reflectance of 90%. It constitutes the entire region of the light transmitting member. The light transmitting member 20d is a spherical surface having a radius of curvature of 3 mm and having a center of curvature at a position 2 mm away from the center of the upper surface of the light source unit, and has a diameter W of about 4.472 mm. Therefore, in the light emitting device 140, on the light incident side surface of the light transmitting member, a region having a reflectance of 100% by the covering member 34 outside the incident region and a region having a reflectance of 90% on the base material 35 further outside thereof. And, and the surface on the light source side is a hemispherical flat surface.

上述の各発光装置110、120、130、140を元に、光透過部材の曲率半径r(R/2)又は径(断面幅)Wと、入射領域の径(断面幅)Lの比(L/R,L/W)と、光取り出し効率との関係を、各モデルについて理論計算により解析する。図4はその解析結果であり、モデルA〜Cは上記装置110〜130、モデルADは上記装置110の被覆部材31を装置140の被覆部材34及び基材35に置き換えたモデル、モデルDDとDD−Wは上記装置140とそれをL/W比にしたもの、モデルDAとDA−Wは上記装置140で被覆部材34と基材35を装置110の被覆部材31に置き換えたモデルとそれをL/W比にしたもの、をそれぞれ示し、光源部16の径Lを変化させている。図4に示すように、モデルA〜CとAD、DD−W、DA−Wの発光装置において、L/R比(モデルDD−WとDA−Wは、L/W比)が0.5より大きくなると、光の取り出し効率が低下し始め、特にモデルA〜C、ADではそれが顕著となる。これは、0.5以下の範囲では、半球面、凸曲面の光透過部材の発光側の表面に対して、光源部が点光源に近い光取り出し効率にできることを示している。また、モデルA〜Cを比較すると、モデルAとBは、比較例のモデルCに比して、L/Rが大きい領域においても光取り出し効率の低下量が大幅に抑制され、光源部16の一部を光反射性の被覆部材により被覆する構造は、高い発光効率を維持したまま装置を小型化する上で優位性があることが分かる。また、比較例のモデルADでは光源が小さい領域でも、モデルA〜Cより効率が低く、またL/Rが0.5以上で急激に低下するため、モデルA〜Cに比して、光源部を十分に小さく、然るに光透過部材を十分に大きくしなければならず、高効率化には装置の大型化が必要であることを示している。 Based on the above-described light emitting devices 110, 120, 130, 140, the ratio (L) of the radius of curvature r (R/2) or diameter (cross section width) W of the light transmitting member to the diameter (cross section width) L of the incident region. /R, L/W) and the light extraction efficiency are analyzed by theoretical calculation for each model. FIG. 4 shows the analysis results. Models A to C are the devices 110 to 130, and model AD is a model in which the covering member 31 of the device 110 is replaced with the covering member 34 and the base material 35 of the device 140, models DD and DD. -W is the device 140 and its L/W ratio, and models DA and DA-W are models in which the covering member 34 and the base material 35 of the device 140 are replaced by the covering member 31 of the device 110 and the model L and L. /W ratio, and the diameter L of the light source unit 16 is changed. As shown in FIG. 4, in the models A to C and the AD, DD-W, and DA-W light emitting devices, the L/R ratio (the models DD-W and DA-W are L/W ratio) is 0.5. When it becomes larger, the light extraction efficiency starts to decrease, which becomes remarkable especially in the models A to C and AD. This shows that in the range of 0.5 or less, the light extraction efficiency of the light source unit is close to that of a point light source with respect to the light emitting side surface of the light transmitting member having a hemispherical surface or a convex curved surface. Further, comparing the models A to C, the models A and B have a large reduction in the light extraction efficiency even in the region where L/R is large, as compared with the model C of the comparative example, and the models of the light source unit 16 are suppressed. It can be seen that the structure in which a part is covered with the light-reflecting covering member has an advantage in downsizing the device while maintaining high luminous efficiency. Further, in the model AD of the comparative example, the efficiency is lower than the models A to C even in the region where the light source is small, and the L/R sharply decreases at 0.5 or more. It is necessary to make the size sufficiently small and the size of the light transmitting member large enough, and it is necessary to increase the size of the device for high efficiency.

さらに、発光装置140の光透過部材20dを用いたモデルDA,DDの光取り出し効率は、他の発光装置110〜130の光透過部材20a〜cを用いたモデルA〜C,ADに比して、その初期値、最大値が大幅に低くなっている。光取り出し効率の観点において、光透過部材の発光側の表面の形状は半球面であることが最も好ましい反面、装置が大型化する。他方、半球面の扁形の部材20dの発光装置140(モデルDA,DD)では、光透過部材20d内面での光反射成分が多くなり、効率が低下するが、装置の小型化、薄型化に優れる。このモデルDA,DDを比較しても、比較例のモデルDD(装置140)に比して、モデルDAの効率が優れる傾向にあり、本発明が小型化、薄型化においても高効率の装置を実現できることが分かる。また、発光装置140のように、光透過部材20の光入射側の表面の外縁に反射率の低い領域35を有するモデルAD、DDは比較例であり、このような領域は例えば基板50、配線51などの被覆部材より低い装置内の部材が露出される構造を想定している。そのため、このモデルでは装置の小型化、光源部の大面積化により、内面での光反射が増大し、この環状で外縁を構成する低反射率領域に到達する光量が増し、さらに光取り出し効率が低下することとなる。本発明の光透過部材が半球面からの扁形であったり、扁平した、曲率が変わった凸曲面であったり、また図9(b)、(c)のように種々の光学レンズ形状であったりして、光透過部材の内面反射が多くなる構造でも、高い発光効率を有し、そして高効率を維持して装置を小型化、薄型化することができる。 Furthermore, the light extraction efficiency of the models DA and DD using the light transmitting member 20d of the light emitting device 140 is higher than that of the models A to C and AD using the light transmitting members 20a to 20c of the other light emitting devices 110 to 130. , Its initial value and maximum value are significantly lower. From the viewpoint of light extraction efficiency, it is most preferable that the surface of the light transmitting member on the light emitting side is a hemispherical surface, but the size of the device becomes large. On the other hand, in the light emitting device 140 (models DA and DD) of the semi-spherical flat member 20d, the light reflection component on the inner surface of the light transmitting member 20d increases and the efficiency decreases, but the device is excellent in downsizing and thinning. .. Even if the models DA and DD are compared, the efficiency of the model DA tends to be superior to that of the model DD (device 140) of the comparative example, and the present invention provides a highly efficient device even in miniaturization and thinning. I see that it can be realized. Further, like the light emitting device 140, the models AD and DD having the regions 35 having a low reflectance on the outer edge of the surface of the light transmitting member 20 on the light incident side are comparative examples, and such regions are, for example, the substrate 50 and wiring. It is assumed that a member in the apparatus lower than the covering member such as 51 is exposed. Therefore, in this model, due to the downsizing of the device and the large area of the light source part, the light reflection on the inner surface increases, the amount of light reaching the low reflectance region forming the outer edge of this ring increases, and the light extraction efficiency is further improved. Will be reduced. The light transmitting member of the present invention has a flat shape from a hemispherical surface, a flat convex surface with a different curvature, or various optical lens shapes as shown in FIGS. 9B and 9C. Even with the structure in which the inner surface reflection of the light transmitting member is large, the device has high luminous efficiency, and the device can be miniaturized and thinned while maintaining high efficiency.

次に、本発明の発光装置の各構成部材および構造について、以下に詳述する。 Next, each component and structure of the light emitting device of the present invention will be described in detail below.

(発光素子)
発光素子10は公知のもの、具体的には半導体発光素子を利用でき、特にGaN系半導体であれば、蛍光物質を効率良く励起できる短波長の可視光や紫外光が発光可能であるため好ましい。具体的な発光ピーク波長は240nm以上560nm以下、好ましくは380nm以上470nm以下である。なお、このほか、ZnSe系、InGaAs系、AlInGaP系半導体の発光素子でもよい。
(Light emitting element)
As the light emitting element 10, a known light emitting element, specifically, a semiconductor light emitting element can be used, and in particular, a GaN-based semiconductor is preferable because it can emit visible light or ultraviolet light having a short wavelength that can efficiently excite a fluorescent substance. The specific emission peak wavelength is 240 nm or more and 560 nm or less, preferably 380 nm or more and 470 nm or less. In addition to this, a ZnSe-based, InGaAs-based, or AlInGaP-based semiconductor light emitting element may be used.

(発光素子構造)
半導体層による発光素子構造11は、図5に例示するように少なくとも第1導電型(n型)層2と第2導電型(p型)層3とにより構成され、更にその間に活性層3を有する構造が好ましい。また、電極構造は、一方の主面側に第1導電型、第2導電型の両電極6,7が設けられる同一面側電極構造が好ましいが、半導体層の各主面に対向して電極が各々設けられる対向電極構造でも良い。発光素子10の実装形態も、例えば上記同一面側電極構造では、電極形成面を実装面として、それに対向する基板1側を主な出射面とするフリップチップ実装が、その出射面と光透過部材20との光学的な接続上好ましい。この他、電極形成面側を主な出射面として、その上に透光性部材、波長変換部材を結合する実装、フェイスアップ実装、また配線構造を備えた透光性部材、波長変換部材にフリップチップ実装、上記対向電極構造で光透過部材と実装基板に接続すること、ができ、好ましくは発光素子と透光性部材、波長変換部材に配線、電極を備えない実施例の実装が良い。なお、半導体層11の成長基板1は、発光素子構造を構成しない場合には除去してもよく、成長基板が除去された半導体層に、支持基板、例えば導電性基板または別の透光性の部材・基板を接着した構造とすることもできる。この支持基板に透光性部材、波長変換部材20を用いることもでき、その他、ガラス、樹脂などの光透過性の部材により半導体層が接着・被覆されて、支持された構造の素子でもよい。成長基板の除去は、例えば支持体、装置又はサブマウントに実装又は保持して、剥離、研磨、若しくはLLO(Laser Lift Off)で実施できる。また、発光素子10は光反射構造を有することができ、具体的には、半導体層11の互いに対向する2つの主面の内、光取り出し側(出射面側)と対向する他方の主面を光反射側(図1における下側)とし、この光反射側の半導体層内や電極などに光反射構造を設けることができる。光反射構造の例として、半導体層内に多層膜反射層が設ける構造、あるいは半導体層の上にAg、Al等の光反射性の高い金属膜や誘電体多層膜を有する電極、反射層を設けた構造がある。
(Light emitting device structure)
As shown in FIG. 5, the light emitting device structure 11 made of a semiconductor layer is composed of at least a first conductivity type (n-type) layer 2 and a second conductivity type (p-type) layer 3, and an active layer 3 between them. The structure having is preferred. Further, the electrode structure is preferably the same-surface-side electrode structure in which the electrodes 6 and 7 of the first conductivity type and the second conductivity type are provided on one principal surface side, but the electrode structure is opposed to each principal surface of the semiconductor layer. It may be a counter electrode structure in which each is provided. Also in the mounting form of the light emitting element 10, for example, in the above-mentioned same-side electrode structure, flip-chip mounting in which the electrode forming surface is the mounting surface and the substrate 1 side facing the electrode forming surface is the main emitting surface is the emitting surface and the light transmitting member. It is preferable in terms of optical connection with 20. In addition, the electrode forming surface side is used as a main emitting surface, and a translucent member, a wavelength conversion member is mounted thereon, face-up mounting, a translucent member having a wiring structure, and a flip to the wavelength conversion member. It is possible to perform chip mounting and connect to the light transmitting member and the mounting substrate with the above-mentioned counter electrode structure, and it is preferable to mount the embodiment in which the light emitting element and the light transmitting member and the wavelength converting member are not provided with wiring and electrodes. The growth substrate 1 of the semiconductor layer 11 may be removed when the light emitting device structure is not formed, and the support substrate, for example, a conductive substrate or another transparent substrate may be added to the semiconductor layer from which the growth substrate has been removed. It is also possible to adopt a structure in which members and substrates are bonded. A transparent member and a wavelength conversion member 20 may be used for this support substrate, or an element having a structure in which a semiconductor layer is adhered/covered by a transparent member such as glass or resin may be used. The growth substrate can be removed by, for example, mounting or holding it on a support, a device, or a submount, and peeling, polishing, or LLO (Laser Lift Off). The light emitting element 10 may have a light reflecting structure. Specifically, of the two main surfaces of the semiconductor layer 11 that face each other, the other main surface that faces the light extraction side (emission surface side) is The light-reflecting side (the lower side in FIG. 1) can be provided, and a light-reflecting structure can be provided in the semiconductor layer on the light-reflecting side or in the electrode. As an example of the light reflection structure, a structure in which a multilayer film reflection layer is provided in the semiconductor layer, or an electrode having a metal film having high light reflectivity such as Ag and Al or a dielectric multilayer film and a reflection layer are provided on the semiconductor layer. There is a different structure.

(窒化物半導体発光素子)
発光素子10の一例として、図5の窒化物半導体の発光素子10では、成長基板1であるC面サファイア基板の上に、第1の窒化物半導体層2であるn型半導体層、活性層3である発光層、第2の窒化物半導体層4であるp型半導体層が順にエピタキシャル成長されている。そして、n型層2の一部が露出されて第1の電極7であるn型パッド電極を形成し、p型層4のほぼ全面にITO等の透光性導電層5、第2の電極6であるp型パッド電極が形成されている。さらに、保護膜8をn型、p型パッド電極6,7の表面を露出し、半導体層を被覆して設けられる。なお、n型パッド電極7は、p型同様に透光性導電層を介して形成してもよい。成長基板1は、C面サファイアの他、R面、及びA面、スピネル
(MgAl24)のような絶縁性基板、また炭化珪素(6H、4H、3C)、Si、ZnS、ZnO、GaAs、GaNやAlN等の半導体の導電性基板がある。窒化物半導体の例としては、一般式がInxAlyGa1-x-yN(0≦x、0≦y、x+y≦1)の他、BやP、Asを混晶してもよい。また、n型、p型半導体層2,4は、単層、多層を特に限定されず、活性層3は単一(SQW)又は多重量子井戸構造(MQW)が好ましい。青色発光の素子構造11の例としては、サファイア基板上に、バッファ層などの窒化物半導体の下地層、例えば低温成長薄膜GaNとGaN層、を介して、n型半導体層として、例えばSiドープGaNのn型コンタクト層とGaN/InGaNのn型多層膜層が積層され、続いてInGaN/GaNのMQWの活性層、更にp型半導体層として、例えばMgドープのInGaN/AlGaNのp型多層膜層とMgドープGaNのp型コンタクト層が積層された構造がある。
(Nitride semiconductor light emitting device)
As an example of the light emitting element 10, in the nitride semiconductor light emitting element 10 of FIG. 5, an n-type semiconductor layer that is the first nitride semiconductor layer 2 and an active layer 3 are provided on the C-plane sapphire substrate that is the growth substrate 1. And the p-type semiconductor layer which is the second nitride semiconductor layer 4 are sequentially epitaxially grown. Then, a part of the n-type layer 2 is exposed to form an n-type pad electrode which is the first electrode 7, and the translucent conductive layer 5 such as ITO and the second electrode are formed on almost the entire surface of the p-type layer 4. A p-type pad electrode of No. 6 is formed. Further, a protective film 8 is provided by exposing the surfaces of the n-type and p-type pad electrodes 6, 7 and covering the semiconductor layer. The n-type pad electrode 7 may be formed via a translucent conductive layer like the p-type. The growth substrate 1 is, in addition to C-plane sapphire, R-plane and A-plane, an insulating substrate such as spinel (MgAl 2 O 4 ), silicon carbide (6H, 4H, 3C), Si, ZnS, ZnO, GaAs. , GaN, AlN, and other semiconductor conductive substrates. Examples of the nitride semiconductor, the general formula In x Al y Ga 1-xy N (0 ≦ x, 0 ≦ y, x + y ≦ 1) of the other, B and P, it may be mixed with As. The n-type and p-type semiconductor layers 2 and 4 are not particularly limited to a single layer or a multilayer, and the active layer 3 preferably has a single (SQW) or multiple quantum well structure (MQW). As an example of the blue-light-emitting device structure 11, an n-type semiconductor layer such as Si-doped GaN is formed on a sapphire substrate via a nitride semiconductor underlayer such as a buffer layer, for example, a low-temperature grown thin film GaN and a GaN layer. N-type contact layer and a GaN/InGaN n-type multilayer film layer are laminated, then an InGaN/GaN MQW active layer and a p-type semiconductor layer, for example, Mg-doped InGaN/AlGaN p-type multilayer film layer. And a p-type contact layer of Mg-doped GaN are laminated.

(波長変換部材)
図1の発光装置100は、光源部に発光素子10からの光により励起され、該入射光の少なくとも一部を波長変換可能な波長変換部材40を備える。光源部は発光素子、又はそれに接合する透光性部材を加えた構造で構成されてもよく、好ましくはその透光性部材に波長変換部材を用いる。本明細書では単に波長変換部材と記載している場合でも、波長変換機能に依らないときには透光性部材に置き換えて適用できる。これにより、光源部において発光素子10から出射された一次光が波長変換部材40で励起することで、発光素子10の発光波長とは異なった波長を持つ二次光が得られ、一次光と、波長変換された二次光の混色により、所望の色相を有する出射光を実現できる複合光源となる。この他、一次光で励起された二次光もしくはその副次的な光についてほぼその光だけを透過させる形態、例えば紫外線発光LEDの変換光(単色、混色光)、を発光する光源部、それを備えた発光装置であってもよい。
(Wavelength conversion member)
The light emitting device 100 of FIG. 1 includes a wavelength conversion member 40, which is excited by light from the light emitting element 10 in the light source unit and is capable of wavelength conversion of at least a part of the incident light. The light source unit may have a structure in which a light emitting element or a translucent member joined to the light emitting element is added, and a wavelength conversion member is preferably used for the translucent member. Even when described simply as a wavelength conversion member in the present specification, it can be applied by being replaced with a translucent member when it does not depend on the wavelength conversion function. Thereby, the primary light emitted from the light emitting element 10 in the light source section is excited by the wavelength conversion member 40, whereby secondary light having a wavelength different from the emission wavelength of the light emitting element 10 is obtained, and the primary light and By mixing the wavelength-converted secondary light, a composite light source that can realize emitted light having a desired hue is obtained. In addition, a light source unit that emits a secondary light excited by the primary light or a form that transmits substantially only the secondary light, for example, converted light of an ultraviolet light emitting LED (monochromatic or mixed color light), It may be a light emitting device provided with.

また、図1の波長変換部材40は、第1の面側からの平面視において発光素子10を内包するように構成される。言い換えると、図1に示すように、波長変換部材40の側面が、発光素子10の側面よりも外側に突出している。これにより、発光素子10からの出射光を、発光素子10の上面より幅広な受光面でもって直接的に結合されるため光束の損失が少ない。なお、発光素子10の側面に対する波長変換部材40の側面の突出量は、発光素子10の寸法に比して、例えば3%以上30%以下であり、具体的には5%以上15%以下である。例として、下記実施例2の発光装置においては波長変換部材40の終端に約50μmの幅で突出している。 Further, the wavelength conversion member 40 of FIG. 1 is configured to include the light emitting element 10 in a plan view from the first surface side. In other words, as shown in FIG. 1, the side surface of the wavelength conversion member 40 projects outside the side surface of the light emitting element 10. Thereby, the light emitted from the light emitting element 10 is directly coupled by the light receiving surface wider than the upper surface of the light emitting element 10, so that the loss of the light flux is small. The protrusion amount of the side surface of the wavelength conversion member 40 with respect to the side surface of the light emitting element 10 is, for example, 3% or more and 30% or less, specifically, 5% or more and 15% or less, as compared with the size of the light emitting element 10. is there. As an example, in the light emitting device of Example 2 below, the wavelength conversion member 40 is projected at the terminal end with a width of about 50 μm.

波長変換部材40の形状は特に限定されないが、実施の形態1では板状体であり、面状の発光素子10の出射面との結合効率が良く、互いに略平行になるよう容易に位置合わせでき好ましい。加えて、その厚みを略一定とすることで、混色の割合を安定させ、光源部表面の入射領域80において色ムラを抑止できる。また、1つの波長変換部材40に複数の発光素子10を接合しやすく、また光源部の出射表面の輝度や色度の分布は、発光素子の配置に依存するが、それを抑えることができる。なお、波長変換部材40の厚みは、発光効率や色度調整において、10μm以上500μm以下であることが好ましく、さらには50μm以上300μm以下であることがより好ましい。また、1つの透光性部材、波長変換部材40に接合される発光素子10の搭載個数は特に限定されず、複数にすれば、光束量を多くでき光源部の放出光の輝度を高められて好ましい。複数とする場合の配置は、一列状に配置、等間隔に格子位置に配置などが挙げられる。 The shape of the wavelength conversion member 40 is not particularly limited, but it is a plate-like body in the first embodiment, has a good coupling efficiency with the emission surface of the planar light emitting element 10, and can be easily aligned so as to be substantially parallel to each other. preferable. In addition, by making the thickness substantially constant, it is possible to stabilize the ratio of color mixing and suppress color unevenness in the incident area 80 on the surface of the light source unit. In addition, it is easy to join a plurality of light emitting elements 10 to one wavelength conversion member 40, and the distribution of brightness and chromaticity on the emission surface of the light source section depends on the arrangement of the light emitting elements, but this can be suppressed. The thickness of the wavelength conversion member 40 is preferably 10 μm or more and 500 μm or less, more preferably 50 μm or more and 300 μm or less in terms of light emission efficiency and chromaticity adjustment. Further, the number of the light emitting elements 10 bonded to one light transmissive member or the wavelength conversion member 40 is not particularly limited, and if a plurality of light emitting elements 10 are mounted, the luminous flux amount can be increased and the brightness of the light emitted from the light source unit can be increased. preferable. Examples of the arrangement in the case of a plurality include arrangement in a line, arrangement at equal intervals in a lattice position, and the like.

ここで、光源部に用いられる、また波長変換部材40の母材となる、透光性部材の材料としては、下記被覆部材30と同様の材料を用いることができ、例えば、樹脂、ガラス、無機物を用いることができる。また下記蛍光体の成形体、結晶体などでもよい。具体的には、波長変換部材40としては、波長変換部材を備えたガラス板、あるいは蛍光体結晶若しくはその相を有する単結晶体、多結晶体、アモルファス体、セラミック体などが挙げられる。この他、蛍光体結晶粒子と適宜付加される透光性の部材との焼結体、凝集体、多孔質体、更にそれらに光透過部材、例えば透光性樹脂を混入、含浸したもの、あるいは蛍光体粒子を含有する光透過部材、例えば透光性樹脂の成形体等から構成される。 Here, as the material of the translucent member used for the light source section and serving as the base material of the wavelength conversion member 40, the same material as the covering member 30 described below can be used, and examples thereof include resin, glass, and inorganic materials. Can be used. Further, a molded body or a crystal body of the following phosphor may be used. Specifically, examples of the wavelength conversion member 40 include a glass plate provided with the wavelength conversion member, or a single crystal body, a polycrystal body, an amorphous body, a ceramic body having a phosphor crystal or a phase thereof. In addition, a sintered body, an aggregate, and a porous body of phosphor crystal particles and a translucent member that is appropriately added, and a light transmissive member such as a translucent resin mixed and impregnated therein, or It is composed of a light transmitting member containing phosphor particles, for example, a molded body of a light transmitting resin.

波長変換部材は、青色発光素子と好適に組み合わせて白色発光とでき、波長変換部材に用いられる代表的な蛍光体としては、ガーネット構造のセリウムで付括されたYAG系蛍光体(イットリウム・アルミニウム・ガーネット)及びLAG系蛍光体(ルテチウム・アルミニウム・ガーネット)が挙げられ、特に、高輝度且つ長時間の使用時においては(Re1-xSmx3(Al1-yGay512:Ce(0≦x<1、0≦y≦1、但し、Reは、Y、Gd、La、Luからなる群より選択される少なくとも一種の元素である。)等が好ましい。またYAG、LAG、BAM、BAM:Mn、(Zn、Cd)Zn:Cu、CCA、SCA、SCESN、SESN、CESN、CASBN及びCaAlSiN3:Euからなる群から選択される少なくとも1種を含む蛍光体が使用できる。波長変換部材は、透光性部材の他に、例えば光透過部材中、光透過部材と発光素子との間、そこに介在する接着材中、発光素子と被覆部材との間、にも設けることもできる。黄〜赤色発光を有する窒化物系蛍光体等を用いて赤味成分を増し、平均演色評価数Raの高い照明や電球色LED等を実現することもできる。具体的には、発光素子の発光波長に合わせてCIEの色度図上の色度点の異なる蛍光体の量を調整し含有させることでその蛍光体間と発光素子で結ばれる色度図上の任意の点を発光させることができる。その他に、近紫外〜可視光を黄色〜赤色域に変換する窒化物蛍光体、酸窒化物蛍光体、珪酸塩蛍光体を用いることができる。例えば、L2SiO4:Eu(Lはアルカリ土類金属)、特に(SrxMae1-x2SiO4:Eu(MaeはCa、Baなどのアルカリ土類金属)などが挙げられる。窒化物系蛍光体、オキシナイトライド(酸窒化物)蛍光体としては、Sr−Ca−Si−N:Eu、Ca−Si−N:Eu、Sr−Si−N:Eu、Sr−Ca−Si−O−N:Eu、Ca−Si−O−N:Eu、Sr−Si−O−N:Euなどがあり、アルカリ土類窒化ケイ素蛍光体としては、一般式LSi222:Eu、一般式LxSiy(2/3x+4/3y):Eu若しくはLxSiyz(2/3x+4/3y-2/3z):Eu(Lは、Sr、Ca、SrとCaのいずれか)で表される。 The wavelength conversion member can be suitably combined with a blue light emitting element to emit white light, and a typical phosphor used for the wavelength conversion member is a YAG phosphor (yttrium.aluminum. garnet) and LAG-based phosphor (lutetium aluminum garnet) can be mentioned, in particular, at the time of high luminance and long-term use (Re 1-x Sm x) 3 (Al 1-y Ga y) 5 O 12 : Ce (0≦x<1, 0≦y≦1, where Re is at least one element selected from the group consisting of Y, Gd, La, and Lu) and the like are preferable. Also, a phosphor containing at least one selected from the group consisting of YAG, LAG, BAM, BAM:Mn, (Zn, Cd)Zn:Cu, CCA, SCA, SCESN, SESN, CESN, CASBN and CaAlSiN 3 :Eu. Can be used. The wavelength conversion member may be provided, for example, in the light transmissive member, between the light transmissive member and the light emitting element, in the adhesive material interposed therebetween, or between the light emitting element and the covering member, in addition to the light transmissive member. Can also It is also possible to increase the reddish component by using a nitride-based phosphor or the like that emits yellow to red light, and realize an illumination having a high average color rendering index Ra, a light bulb color LED, or the like. Specifically, by adjusting and containing the amount of phosphors having different chromaticity points on the CIE chromaticity diagram according to the emission wavelength of the light emitting element, the chromaticity diagram between the phosphors and the chromaticity diagram connected by the light emitting element is shown. Can emit light at any point. In addition, a nitride phosphor, an oxynitride phosphor, or a silicate phosphor that converts near-ultraviolet to visible light into a yellow to red region can be used. For example, L 2 SiO 4 :Eu (L is an alkaline earth metal), particularly (Sr x Mae 1-x ) 2 SiO 4 :Eu (Mae is an alkaline earth metal such as Ca or Ba) can be mentioned. As the nitride-based phosphor and the oxynitride (oxynitride) phosphor, Sr-Ca-Si-N:Eu, Ca-Si-N:Eu, Sr-Si-N:Eu, Sr-Ca-Si. -O-N: Eu, Ca- Si-O-N: Eu, Sr-Si-O-N: include Eu, the alkaline earth silicon nitride phosphor, the general formula LSi 2 O 2 N 2: Eu , L x Si y N (2/3x+4/3y) : Eu or L x Si y O z N (2/3x+4/3y-2/3z) : Eu (L is Sr, Ca, It is represented by either Sr or Ca).

(被覆部材)
被覆部材30は、図1に示すように、光源部の一部と光透過部材の表面を被覆し、具体的には少なくとも発光素子を含む光源部を埋め込むように被覆して、加えて光透過部材の入射側表面まで延在して被覆する。さらに、光源部内の波長変換部材40の一部、具体的にはその側面を被覆し、そこから露出された光源部表面から出射面となり光透過部材へ入射する。被覆部材30の基材としては、樹脂材料であり、さらに透光性がよく、シリコーン樹脂組成物、変性シリコーン樹脂組成物等を使用することが好ましいが、エポキシ樹脂組成物、変性エポキシ樹脂組成物、アクリル樹脂組成物等の透光性を有する絶縁樹脂組成物を用いることができる。また、これらの樹脂を少なくとも一種以上含むハイブリッド樹脂等、耐候性に優れた封止部材も利用でき、このように透光性樹脂であると本発明における所望領域の被覆、その成形に適していが、ガラス、シリカゲル等の耐光性に優れた無機物を用いることもできる。さらに被覆部材30は、耐熱性の高い樹脂成形体とすると、光源部の発光素子や波長変換部材40の発熱に対応でき好ましい。実施の形態1では、被覆部材30を構成する基材となる樹脂にシリコーン樹脂を用いる。シリコーン樹脂は耐熱性、撥水性、電気絶縁性に優れる他、経年劣化しにくい利点を備える。さらにまた、被覆部材30表面を所望の形状、例えば図示する傾斜面、曲面の形状、として、反射領域の機能及び効果を高めて、指向性、色分布を制御し、また集光させることもでき、光透過部材の光学機能と適宜組み合わせることで、装置の発光特性を制御し得る。
(Coating member)
As shown in FIG. 1, the covering member 30 covers a part of the light source unit and the surface of the light transmitting member, specifically, covers the light source unit including at least the light emitting element so as to be embedded, and additionally the light transmitting unit. The member extends and covers the incident side surface of the member. Further, a part of the wavelength conversion member 40 in the light source section, specifically, the side surface thereof is covered, and the surface of the light source section exposed from the light conversion section serves as an emission surface and enters the light transmission member. The base material of the covering member 30 is a resin material, and it is preferable that a silicone resin composition, a modified silicone resin composition, or the like is used since it has a good light-transmitting property, but an epoxy resin composition or a modified epoxy resin composition is used. A transparent insulating resin composition such as an acrylic resin composition can be used. Further, a sealing member having excellent weather resistance, such as a hybrid resin containing at least one of these resins, can be used, and the translucent resin is suitable for coating a desired region in the present invention and molding the same. It is also possible to use an inorganic material having excellent light resistance such as glass, silica gel or the like. Furthermore, it is preferable that the covering member 30 is made of a resin molded body having high heat resistance because it can cope with heat generation of the light emitting element of the light source section and the wavelength conversion member 40. In the first embodiment, a silicone resin is used as the resin forming the base material of the covering member 30. Silicone resin has excellent heat resistance, water repellency, and electrical insulation, and has the advantage that it does not easily deteriorate over time. Furthermore, the surface of the covering member 30 can be formed into a desired shape, for example, the shape of an inclined surface or a curved surface shown in the drawing, to enhance the function and effect of the reflection area, control the directivity and the color distribution, and collect light. By properly combining with the optical function of the light transmitting member, the emission characteristics of the device can be controlled.

また、被覆部材30は、上記基材中に少なくとも1種類の光反射性材料35を含有してなる。光反射性材料を含有することで、被覆部材の反射率が高まり、更に好適には低吸収性の粒子を用いると、光吸収、損失が低減され、光散乱性を備えた被覆部材とでき、具体的には透光性の粒子を用いる。この光反射性材料としては、Ti、Zr、Nb、Al、Siからなる群から選択される1種の酸化物、若しくはAlN、MgFの少なくとも1種であり、具体的にはTiO2、ZrO2、Nb25、Al23、MgF、AlN、SiO2よりなる群から選択される少なくとも1種である。光反射性材料の粒子が、Ti、Zr、Nb、Alからなる群から選択される1種の酸化物であることで、材料の高い反射性及び低吸収性とでき、基材、特に透光性樹脂との屈折率差を高められ、好ましい。また、被覆部材は、上記光反射性材料による成形体でもって構成することもでき、具体的には上記粒子を凝集した凝集体、焼結体、などの多孔質材料とすることもでき、その他に、ゾル・ゲル法による成形体でもよく、上記光反射性材料と多孔質内の空気との屈折率差を大きくし、光反射性を高められ、また無機材料で構成できるため、好ましい。一方、上記樹脂などの母材を備えた被覆部材の方が、所望の形状への成形及びその被覆領域の制御性で、また封止性能、気密性能を高められ、本発明ではこちらの方が好ましい。また、両者の被覆部材の特性を考慮して、両者の複合的な成形体とでき、例えば、多孔質成形体の一部、外表面側に樹脂を含浸させ、発光素子側の内表面側では多孔質とした構造とできる。このように、被覆部材若しくはそれにより光源部を包囲する包囲体は、内部領域と外部とが連通されたり、気体透過性であったりしてもよく、少なくとも光が漏れ出さない形態であれば良い。 Further, the covering member 30 contains at least one kind of light-reflecting material 35 in the base material. By containing a light-reflecting material, the reflectance of the coating member is increased, and more preferably, when the particles having low absorptivity are used, light absorption and loss are reduced, and a coating member having a light scattering property can be obtained. Specifically, translucent particles are used. The light-reflecting material is one kind of oxide selected from the group consisting of Ti, Zr, Nb, Al and Si, or at least one kind of AlN and MgF, and specifically, TiO 2 and ZrO 2 , Nb 2 O 5 , Al 2 O 3 , MgF, AlN, and SiO 2 . Since the particles of the light-reflecting material are one kind of oxide selected from the group consisting of Ti, Zr, Nb, and Al, the material can have high reflectivity and low absorptivity, and the substrate, especially the light-transmitting material can be used. It is preferable because the difference in refractive index from the resin is increased. In addition, the covering member can also be configured by a molded body of the light-reflecting material, specifically, an agglomerate obtained by aggregating the particles, a sintered body, or other porous material, and the like. Further, it may be a molded product by the sol-gel method, and it is preferable because the difference in the refractive index between the light-reflecting material and the air in the porous material can be increased, the light reflectivity can be enhanced, and the material can be made of an inorganic material. On the other hand, a covering member provided with a base material such as the above resin is capable of molding into a desired shape and controllability of the covering region, and also has improved sealing performance and airtightness. preferable. Further, in consideration of the characteristics of both the covering members, a composite molded body of both can be formed. For example, a part of the porous molded body, the outer surface side is impregnated with resin, and the inner surface side of the light emitting element side is It can have a porous structure. As described above, the covering member or the enclosing body that encloses the light source unit by the covering member may be such that the inner region communicates with the outside or may be gas permeable, and at least the form does not leak light. ..

上述した母材中に光反射性材料35を含有する被覆部材30では、その含有濃度、密度により光の漏れ出す深さが異なるため、発光装置の形状、大きさに応じて、適宜濃度、密度を調整すると良い。例えば、比較的小さな発光装置で肉厚を小さくする場合、高濃度の光反射性材料を備えることが好ましい。一方、光反射性材料を含有する被覆部材の原料の調製、その原料の塗布、成形などの製造に適するように、その濃度、粒径を適宜でき、粒径は従来のフィラー等と同様のものを用いることができ、上記多孔質体についても同様である。一例として、光反射性材料35の含有濃度は20重量パーセント濃度以上、被覆部材30の肉厚は20μm以上とするのが好適である。この範囲であれば、生産性も良く、発光面である第1の面から高輝度で指向性の高い放出光が得られる。さらに、樹脂基材中には、その他のフィラーを添加してもよい。例えば、熱伝導性材料を付加することができ、光源部による発熱を効率良く拡散でき、信頼性を向上させ、高出力化できる。熱伝導性材料として、具体的には0.8W/K・m以上の熱伝導率が好ましく、例えばAg、Cu等の金属材料や、ダイヤモンド、アルミナ、AlN、ガラス等熱引きの良いセラミックス材料が挙げられ、これらを混合して含有させてもよい。また、顔料などを混合させて着色して、特定の波長の光を吸収させることもできる。 In the covering member 30 containing the light-reflecting material 35 in the base material described above, the depth at which light leaks differs depending on the concentration and density of the base material. Should be adjusted. For example, when the wall thickness is made small with a relatively small light emitting device, it is preferable to provide a high-concentration light-reflecting material. On the other hand, its concentration and particle size can be appropriately adjusted so that it is suitable for the preparation of the raw material of the covering member containing the light-reflecting material, the coating of the raw material, the molding, etc., and the particle diameter is similar to that of conventional fillers and the like. Can be used, and the same applies to the porous body. As an example, it is preferable that the content concentration of the light reflective material 35 is 20% by weight or more, and the wall thickness of the covering member 30 is 20 μm or more. Within this range, the productivity is good, and emitted light with high brightness and high directivity can be obtained from the first surface, which is the light emitting surface. Further, other fillers may be added to the resin base material. For example, a heat conductive material can be added, heat generated by the light source can be efficiently diffused, reliability can be improved, and high output can be achieved. As the heat conductive material, specifically, a heat conductivity of 0.8 W/K·m or more is preferable, and for example, a metal material such as Ag or Cu, or a ceramic material having good heat dissipation such as diamond, alumina, AlN or glass. These may be included, and these may be mixed and contained. Further, a pigment or the like may be mixed and colored to absorb light having a specific wavelength.

被覆部材による被覆領域は上述の通りであるが、これについて以下に詳述する。光源部の側面、また波長変換部材の側面が被覆されることで、側面からの光の漏れ出しを回避でき、さらに側面より外方へ放出するのを抑止して、全体の発光色における色ムラや輝度ムラを低減できる。また、光源部の一部が露出され、具体的には発光素子、波長変換部材、またその他の部材の側面を被覆して上面が露出され、その発光領域を制限することで、放出光の指向性と出射面における輝度を高められる。さらに、光源部、特に波長変換部材で発生する熱を被覆部材30へ伝導させ、被覆されない場合より放熱性を高められる。また、波長変換部材40の側面に加えて、発光素子側表面(第2の面)の一部も被覆するとよく、具体的には、図1,2に示すように、波長変換部材40と基板50との間に被覆部材30を充填させ、発光素子10の周囲を被覆部材30により被包する。つまり、第2の面において、発光素子10と接合する対向領域を除く露出領域が被覆される。このように、第2の面に光学的な接続領域と、被覆部材30の被覆領域とが設けられ、また被覆領域から延在して発光素子側面が被覆されることで、この接続領域に一次光を高効率に導光でき、波長変換部材中の光を第2の面側で反射させ基板50での光吸収を抑制できる。さらに、複数の発光素子10が接合される場合に隣接素子では上記課題が大きくなるが、その素子間についても被覆部材30が充填され、第2の面で隣接する素子接合領域の間の離間領域が被覆されることで、上記効果が得られ好ましい。 The area covered by the covering member is as described above, which will be described in detail below. By covering the side surface of the light source section and the side surface of the wavelength conversion member, it is possible to prevent light from leaking from the side surface, and also to prevent light from being emitted outward from the side surface, resulting in color unevenness in the overall emission color. And uneven brightness can be reduced. In addition, a part of the light source is exposed, specifically, the side surfaces of the light emitting element, the wavelength conversion member, and other members are covered to expose the upper surface, and the emission area is limited to direct the emitted light. And the brightness on the emission surface can be enhanced. Furthermore, the heat generated in the light source part, particularly the wavelength conversion member, is conducted to the covering member 30, and the heat dissipation property can be improved as compared with the case where it is not covered. In addition to the side surface of the wavelength conversion member 40, a part of the light emitting element side surface (second surface) may be covered. Specifically, as shown in FIGS. The covering member 30 is filled between the covering member 50 and 50, and the periphery of the light emitting element 10 is covered with the covering member 30. That is, the exposed surface is covered on the second surface except the facing area that is joined to the light emitting element 10. In this way, the optical connection region and the coating region of the coating member 30 are provided on the second surface, and the side surface of the light-emitting element is extended from the coating region to coat the side surface of the light emitting element, so that the primary region is formed in the connection region. Light can be guided with high efficiency, and the light in the wavelength conversion member can be reflected on the second surface side to suppress light absorption in the substrate 50. Further, when a plurality of light emitting elements 10 are joined, the above-mentioned problem is increased in the adjacent elements, but the covering member 30 is filled also between the elements, and the separation area between the element joining areas adjacent to each other on the second surface is provided. It is preferable that the above-mentioned effects are obtained by coating

なお、本発明の発光装置は、被覆部材30の表出面側は、光源部の第1の面(出射面)の周囲を形成し、光透過部材の反射領域、その対向領域を形成する構造であり、その他の表出面領域、また内部側は種々の形態が採用できる。例えば、被覆部材30が波長変換部材40の側面を覆って表出面を形成すればよく、その内部側の光源部側面又は周囲は、接して又は離間して包囲される形態とでき、この場合、発光素子と接触又は離間した被覆部材が設けられる。図示するように波長変換部材の側面および第2の面から連続して発光素子10を被包させて、光源部が埋め込まれることが製造上好ましい。一方、内部側ではこのように接触する場合の他、被覆部材30を発光素子10の側面の外方に離間して配置させることもでき、その間に空隙が設けられていることで空隙との界面反射が実現でき、また樹脂等の被覆部材の光、熱による劣化を防止でき好ましい。さらに複数の発光素子10の離間領域にもその空隙を設ける構造とできる。このとき、好適には発光素子10との屈折率差を高くするように、上記空隙の内部空間を空気・気体との屈折率差の高い露出部を形成することが好ましい。 The light emitting device of the present invention has a structure in which the exposed surface side of the covering member 30 forms the periphery of the first surface (emission surface) of the light source unit, and forms the reflection region of the light transmitting member and the opposing region thereof. Various other forms can be adopted for the other exposed surface area and the inner side. For example, the covering member 30 may cover the side surface of the wavelength conversion member 40 to form the exposed surface, and the side surface or the periphery of the light source section on the inner side thereof may be in contact with or separated from each other. In this case, A covering member that is in contact with or separated from the light emitting element is provided. As shown in the figure, it is preferable in manufacturing that the light emitting element 10 is encapsulated continuously from the side surface and the second surface of the wavelength conversion member to embed the light source unit. On the other hand, on the inner side, in addition to such contact, the covering member 30 can be arranged outside of the side surface of the light emitting element 10 so as to be spaced apart. It is preferable because reflection can be realized and deterioration of the covering member such as resin due to light or heat can be prevented. Further, a structure may be provided in which the gaps are provided also in the separated regions of the plurality of light emitting elements 10. At this time, it is preferable to form an exposed portion having a high refractive index difference between air and gas in the inner space of the void so that the refractive index difference with the light emitting element 10 is increased.

本発明において、光透過部材は光入射側表面に、光源部の入射領域の外側に反射領域を備え、その反射領域は、光透過部材の表面、更には被覆部材との界面に設けられるため、その反射機能が各部材の材質、表面形態に大きく依存する。実施の形態1では、光反射材料を含有する被覆部材と、その上に成形された光透過部材との界面に形成されることで、好適な反射、散乱機能を備える。具体的には、互いに透光性の材料であることでその透光性の材料同士の界面が形成され、高い反射率が得られ、さらに被覆部材内の光反射性材料による散乱機能が付与される。これにより、光取り出し効率の向上、輝度、色むらの改善が図れ、特に装置が小型化した場合、すなわち光源部Lの割合が大きく、又は光透過部材の径が小さく若しくは形状が球面から変形、扁平、した場合にその効果が増大する。このとき、界面を構成する各部材に屈折率差が設けられると特に好ましく、大きい屈折率が、光透過部材側であると上記透光性材料界面の反射率が向上し、装置の出力が向上し好ましく、被覆部材側であるとその内部に多くの光が取り込まれ、散乱されるため、配向性、輝度・色度分布に優位となり好ましい。従って、上述の光透過部材の光学素子機能や後述の両部材の界面、反射面の形状だけでなく、両部材の材料、組成、加えて被覆部材中の上記反射材料の濃度、分布状態を調整することによっても、本発明の発光装置はその発光特性を適宜制御することができるものとなる。特に光源部に波長変換部材を内包する場合には、その形状等の部材の性質により、光源部出射光の色度、輝度分布が特有のものとなるが、これを反射領域による機能によって制御でき好ましい。さらに、両部材が樹脂であることでその樹脂界面を所望の形状とでき、後述するように、種々の指向性等、発光特性の装置を設計でき好ましい。 In the present invention, the light transmissive member is provided on the light incident side surface with a reflective region outside the incident region of the light source unit, and the reflective region is provided on the surface of the light transmissive member, and further at the interface with the covering member. The reflection function largely depends on the material and surface morphology of each member. In the first embodiment, the covering member containing the light reflecting material and the light transmitting member formed on the covering member are formed at the interface, so that the reflecting member has suitable reflection and scattering functions. Specifically, the mutually translucent materials form an interface between the translucent materials, a high reflectance is obtained, and further, a scattering function is imparted by the light reflective material in the covering member. It Thereby, it is possible to improve the light extraction efficiency, improve the brightness, and the color unevenness, and particularly when the device is downsized, that is, the proportion of the light source unit L is large, or the diameter of the light transmitting member is small or the shape is deformed from the spherical surface, The effect is increased when flattened. At this time, it is particularly preferable that a difference in refractive index is provided to each member forming the interface, and if the refractive index is large on the side of the light transmitting member, the reflectance of the interface of the translucent material is improved and the output of the device is improved. However, it is preferable that the side of the coating member has a large amount of light taken in and scattered therein, which is superior in orientation and luminance/chromaticity distribution. Therefore, not only the optical element function of the above-mentioned light transmitting member and the interface between both members, which will be described later, the shape of the reflecting surface, but also the material and composition of both members, as well as the concentration and distribution state of the above-mentioned reflecting material in the covering member are adjusted. Also by doing so, the light emitting device of the present invention can appropriately control its light emitting characteristics. Especially when the wavelength conversion member is included in the light source section, the chromaticity and brightness distribution of the light emitted from the light source section is unique due to the shape and other properties of the member, which can be controlled by the function of the reflection area. preferable. Furthermore, since both members are made of resin, the resin interface can be formed into a desired shape, and as will be described later, it is possible to design a device having various directivity and other light emission characteristics, which is preferable.

以上説明したように、本発明の発光装置は、光源部を囲む2つの領域を有して、一方の光透過部材側は発光面を備える導光領域で、他方の被覆部材側はそれより光反射率の高い被覆領域であり、更に光源部はその出射面が被覆領域から露出されて導光領域に結合した入射領域と、導光・被覆領域の境界に反射領域が設けられた構造となっている。この2つの領域でもって光源部を囲み、その接合部、又は境界領域に入射領域と反射領域を設けることで、上述した各機能、効果を適宜発現させ、それを制御し、所望の発光特性、小型化が可能な発光装置が得られる。特に光源部の出射面が面光源であること、面状の入射領域であることにより、それに連続する境界部分の反射領域が連携して機能でき好ましい。一方、後述する装置140、モデルDD,DAの検討に観るように、被覆領域が好適に形成されること、すなわち2つの領域の境界に設けられることが好ましい。例えば、被覆部材より幅広な光透過部材の外縁で、被覆部材から露出された実装基板と対向すること、境界が設けられることで、反射率の低い基板表面により装置の特性に大きく影響を及ぼす。また、他の例では、光源部の側面や実装側表面において、光源部からの漏れ光、若しくはその経路が設けられる場合には、光量が多いため、出力、効率低下に大きく影響する。例えば、発光素子の側面、入射領域に対向する表面(基板側、実装側)が被覆部材から露出され、またそこに基板表面など被覆部材より低反射率、高い光吸収率の表面が露出されることで、その影響が顕著となる。従って、光源部の周囲を覆うか、露出される低反射率、高吸収率の表面を覆うか、いずれか一方、好ましくは両方が成されていると好ましく、実施の形態1のように被覆部材が充填される形態はその両方を備えた構造である。然るに、被覆領域は導光領域の略全領域に対向して設けられること、被覆部材の表面に光透過部材の光入射側表面が内包されることが好ましく、その被覆領域、部材により光源部の出射表面以外の領域が覆われることが好ましい。具体的には、図示するように発光素子の対向表面側にアンダーフィルとして被覆部材を設け、両方を備えた構造とし、例えば、発光素子や光源部を覆うプリコートやアンダーフィルが透明樹脂で低反射率、高吸収率の表面、基板表面が露出されたり、光源部からの光漏れ経路が形成されたり、するのを防ぐ構造となっている。従って、被覆部材、被覆領域により、光源部の出射側に対向する表面が内包され、すなわち、該対向側の被覆部材、被覆領域の表面(図の基板50側表面)が光源部から被覆部材により分離されることが好ましい。 As described above, the light emitting device of the present invention has two regions surrounding the light source unit, one light transmitting member side being a light guide region having a light emitting surface, and the other covering member side being lighter than that. It is a covered area with high reflectance, and the light source part has a structure in which an incident area where the exit surface is exposed from the covered area and is coupled to the light guide area and a reflective area are provided at the boundary between the light guide and covered areas. ing. By enclosing the light source part with these two regions and providing the incident region and the reflection region at the joint part or the boundary region, the above-mentioned respective functions and effects are appropriately expressed and controlled, and desired emission characteristics, A light emitting device that can be downsized can be obtained. In particular, it is preferable that the emission surface of the light source section is a surface light source and is a planar incident area so that the reflection area at the boundary portion continuing to it can function in cooperation. On the other hand, as shown in the examination of the device 140 and the models DD and DA, which will be described later, it is preferable that the covering region is preferably formed, that is, it is provided at the boundary between the two regions. For example, the outer edge of the light transmissive member, which is wider than the covering member, faces the mounting substrate exposed from the covering member and is provided with a boundary, so that the characteristics of the device are greatly affected by the substrate surface having a low reflectance. Further, in another example, when the light leaking from the light source section or the path thereof is provided on the side surface or the mounting side surface of the light source section, the amount of light is large, so that the output and efficiency are greatly reduced. For example, the side surface of the light emitting element and the surface (the substrate side and the mounting side) facing the incident area are exposed from the covering member, and the surface having a lower reflectance and a higher light absorption rate than the covering member such as the substrate surface is exposed there. Therefore, the influence becomes remarkable. Therefore, it is preferable that either the periphery of the light source portion or the exposed surface of low reflectance and high absorption rate is covered, or preferably both of them are formed, and the covering member as in the first embodiment. Is a structure having both of them. Therefore, it is preferable that the covering region is provided so as to face substantially the entire region of the light guide region, and the light incident side surface of the light transmitting member is included in the surface of the covering member. It is preferable that the area other than the emission surface is covered. Specifically, as shown in the figure, a covering member is provided as an underfill on the opposing surface side of the light emitting element, and a structure having both is provided. The structure has a structure that prevents the exposure of the surface having a high absorption rate and a high absorptivity, the surface of the substrate, and the formation of a light leakage path from the light source section. Therefore, the surface of the light source section facing the emission side is included by the covering member and the covering area, that is, the surface of the facing covering material and the covering area (the surface on the substrate 50 side in the figure) is covered by the covering member from the light source section. It is preferably separated.

導光領域と被覆領域の境界に設けられる反射表面は、各領域の互いに対向する表面にそれぞれ設けられ、実施の形態1のように両者が接合する場合にはその界面に設けられる。前者は、実施の形態2のように、互いに離間して対向する場合に、光透過部材と被覆部材の各対向表面にそれぞれ反射機能が付与され、重畳されるため、高い光取り出し効率となる。後者は境界領域、部材の界面で反射機能が付与されるため、指向性を制御しやすくなる。従って、その反射表面は、各領域、各部材の成形において、所望の反射機能とでき、その表面の傾斜が入射領域に対して略平坦であれば、光源部の出射方向に光が取り出され、他方、実施の形態2のように、反射面が外側に傾斜した場合、例えばその法線方向が光源部の光軸に対し外側に傾斜した場合は、は広い指向性となり、逆に内側に傾斜した場合は高輝度な発光となり、好ましい。また、凸曲面、凹曲面など種々の光学表面を設けた構造して、所望の発光特性を得ることができ、さらに光反射材料を含有する散乱性の被覆部材の場合には、各領域、各部材の各対向表面で異なる反射機能とでき、両者が接合する場合には上述した界面反射と内部散乱機能を付与でき、両者が離間する場合は、被覆部材表面の乱反射により光り取り出しが促進される構造とできる。以上のように被覆領域、被覆部材の反射率、例えば、光反射材料の濃度は、実施の形態、実施例のように一定であってもよく、それの異なる領域を設けたり、それを分布させたりしてもよい。これにより、各領域、部位で異なる反射機能を付与でき、例えば、光源部側の内側領域とそれより外側の外側領域で、光反射材料の濃度を変えたり、異なる濃度の被覆部材で各領域を形成したり、して、内側、外側の各領域で異なる散乱性の発光装置とすることができる。例えば、外側領域を高濃度の光反射材料として散乱性を高めて、放出光の外縁部分の色ムラを低減することができる。 The reflecting surfaces provided at the boundary between the light guide region and the covering region are provided on the surfaces of the respective regions which face each other, and when the two are joined as in the first embodiment, they are provided at the interface thereof. In the former case, when facing each other while being separated from each other, as in the second embodiment, a reflecting function is given to each of the facing surfaces of the light transmitting member and the covering member, and they are superimposed, so that the light extraction efficiency is high. In the latter case, since the reflection function is provided at the boundary region and the interface between the members, it becomes easy to control the directivity. Therefore, the reflecting surface can have a desired reflecting function in molding of each region and each member, and if the inclination of the surface is substantially flat with respect to the incident region, light is extracted in the emitting direction of the light source unit, On the other hand, when the reflecting surface is inclined outward, as in the case of the second embodiment, for example, when the normal direction is inclined outward with respect to the optical axis of the light source unit, has a wide directivity and conversely is inclined inward. In that case, high-luminance light emission is obtained, which is preferable. Further, a structure provided with various optical surfaces such as a convex curved surface and a concave curved surface can obtain desired light emitting characteristics, and in the case of a scattering coating member containing a light reflecting material, each region, each Different reflection functions can be provided on the respective facing surfaces of the member, and when the two are joined, the above-mentioned interface reflection and internal scattering function can be imparted, and when the two are separated, diffused reflection on the surface of the covering member promotes light extraction. Can be a structure. As described above, the coating region, the reflectance of the coating member, for example, the concentration of the light-reflecting material may be constant as in the embodiments and examples, and different regions may be provided or distributed. You may Thereby, different reflection functions can be imparted to each region and part, for example, the concentration of the light-reflecting material may be changed between the inner region on the light source side and the outer region outside it, or each region may be covered by a covering member having a different concentration. The light emitting device can be formed to have different scattering properties in each of the inner and outer regions. For example, the outer region may be made of a high-concentration light-reflecting material to enhance the scattering property and reduce the color unevenness of the outer edge portion of the emitted light.

(光透過部材)
光透過部材20は、発光素子10の第1の面または波長変換部材40の第1の面と接合されて光の取り出し効率を向上させることができる。光透過部材20は、少なくとも発光側の表面21と光入射側の表面とを有し、発光側の表面21は目的に応じて種々の形状に形成することができる。例えば、上述のように、発光側の表面21を凸曲面、球面(半球面)の凸レンズ形状とすることで、全方位角の光入射に対して均一な透過特性(臨界角)とでき、光を効率良く外部に取り出すことができる。また、球面に限らず、所望の曲率、凸レンズ形状、例えば砲弾型とすることで球面よりも光の放射角を小さくすることができる。このほか、凹曲面、凹レンズ形状とすることで光を拡散させてもよく、実施の形態4、図9で説明するように、所望の指向性とする光学素子としても良い。
(Light transmitting member)
The light transmissive member 20 may be bonded to the first surface of the light emitting element 10 or the first surface of the wavelength conversion member 40 to improve the light extraction efficiency. The light transmitting member 20 has at least a light emitting side surface 21 and a light incident side surface, and the light emitting side surface 21 can be formed into various shapes depending on the purpose. For example, as described above, by forming the surface 21 on the light emitting side into a convex lens shape having a convex curved surface and a spherical surface (hemispherical surface), uniform transmission characteristics (critical angle) can be obtained with respect to light incident in all azimuth angles. Can be taken out efficiently. Further, the radiation angle of light can be made smaller than that of the spherical surface by using not only the spherical surface but also a desired curvature and a convex lens shape, for example, a bullet shape. Besides, the light may be diffused by forming a concave curved surface or a concave lens shape, and as described in Embodiment 4 and FIG. 9, it may be an optical element having a desired directivity.

光透過部材20は、上記被覆部材30の基材と同様に、例えばエポキシ樹脂、シリコーン樹脂、変成シリコーン樹脂、ユリア樹脂、ウレタン樹脂、アクリル樹脂、ポリカーボネイト樹脂、ポリイミド樹脂などの樹脂材料を用いて形成することができる。なお、光透過部材20は、発光素子10や波長変換部材40を保護する封止材としての役割も果たすため、耐候性、耐熱性、硬度に優れる材料が好ましく、エポキシ樹脂、又は硬質のシリコーン樹脂が好ましく、ガラスを用いてもよい。さらに、光透過部材20に、上述のような蛍光体、及び/又はTiO2などの上述の光散乱粒子、及び/又は石英ガラス等の上述のフィラー、その他、上述の顔料などを適宜添加して所望の発光特性とすることができ、透光性部材、接着材15等の透光性の樹脂材料についても同様である。また、光透過部材20は圧縮成形、トランスファー成形などにより、所望の大きさ、並びに上記のような所望の形状に成形することができる。 The light transmitting member 20 is formed using a resin material such as an epoxy resin, a silicone resin, a modified silicone resin, a urea resin, a urethane resin, an acrylic resin, a polycarbonate resin, a polyimide resin, or the like, like the base material of the covering member 30. can do. Since the light transmitting member 20 also plays a role as a sealing material that protects the light emitting element 10 and the wavelength conversion member 40, a material excellent in weather resistance, heat resistance, and hardness is preferable, such as an epoxy resin or a hard silicone resin. Are preferable, and glass may be used. Furthermore, the above-mentioned phosphor, and/or the above-mentioned light-scattering particles such as TiO 2 , and/or the above-mentioned filler such as quartz glass, and the above-mentioned pigment, etc. are appropriately added to the light-transmissive member 20. A desired light emitting property can be obtained, and the same applies to a transparent resin material such as a transparent member and the adhesive 15. Further, the light transmitting member 20 can be molded into a desired size and a desired shape as described above by compression molding, transfer molding, or the like.

(実装基板)
一方、図1の発光装置100において、上記の発光素子10が実装される基板50は、少なくとも表面に素子の電極と接続される配線51を形成したものが利用でき、また外部接続用の配線52(図7,9)などが設けられても良い。基板の材料は、例として窒化アルミニウム(AlN)で構成され、単結晶、多結晶、焼結基板、他の材料としてアルミナ等のセラミック、ガラス、Si等の半金属あるいは金属基板、またそれらの積層体、複合体が使用でき、金属性、セラミックは放熱性が高いため好ましい。なお、基板50は配線が無くてもよく、例えば図5の素子で成長基板側を実装して素子の電極を装置の電極にワイヤー接続する形態、波長変換部材に配線を設けて接続する形態でもでもよい。また、図示する発光装置のように、被覆部材30が実装基板50の上に設けられる形態の他、実装基板50の外側側面も覆う形態でもよい。また実装基板50は、少なくともその表面が高反射性材料で構成されることが好ましい。図1,2に示すように、発光素子10は、導電性接着材60により配線51上に接着されて外部と電気的に接続される。導電性接着材60は、半田、Agペースト、Auバンプなどが利用できる。
(Mounting board)
On the other hand, in the light emitting device 100 of FIG. 1, as the substrate 50 on which the light emitting element 10 is mounted, one having a wiring 51 connected to an electrode of the element formed on at least the surface can be used, and a wiring 52 for external connection can be used. (FIGS. 7 and 9) and the like may be provided. The material of the substrate is, for example, aluminum nitride (AlN), and is made of single crystal, polycrystal, sintered substrate, other materials such as ceramics such as alumina, glass, semi-metal or metal substrate such as Si, and laminated layers thereof. A body or a composite body can be used, and metal and ceramic are preferable because they have high heat dissipation. It should be noted that the substrate 50 may not have wiring. For example, the growth substrate side may be mounted with the element of FIG. 5 to connect the electrode of the element to the electrode of the device by wire, or the wiring may be provided to the wavelength conversion member to connect. But it's okay. Further, as in the illustrated light emitting device, the cover member 30 may be provided on the mounting substrate 50, or the outer side surface of the mounting substrate 50 may be covered. Further, it is preferable that at least the surface of the mounting substrate 50 is made of a highly reflective material. As shown in FIGS. 1 and 2, the light emitting element 10 is bonded onto the wiring 51 by a conductive adhesive material 60 and electrically connected to the outside. As the conductive adhesive material 60, solder, Ag paste, Au bump, or the like can be used.

(枠体、積層基板、基材)
図1に示す発光装置100は、枠体55を有し、被覆部材30の保持部材である。枠体55は、セラミックや樹脂などで形成することができる。光反射性の高いアルミナが好ましいが、表面に反射膜を形成すればこれに限らない。樹脂であれば、スクリーン印刷等を用いるほか、成形体を実装基板に接着してもよい。また、被覆部材30と同様に光反射性材料を用いるなどして、反射率を高くすると好ましい。また、上記添加部材同様に、枠体を目的に応じて着色してもよい。なお、この枠体は、被覆部材を充填又は成形後に、取り外すこともできる。また、枠体として、積層基板56、基材などでキャビティ構造を有する装置基体など、発光素子の実装基板に一体に形成されている形態でもよい。
(Frame, laminated substrate, base material)
The light emitting device 100 shown in FIG. 1 has a frame body 55 and is a holding member for the covering member 30. The frame body 55 can be formed of ceramic, resin, or the like. Alumina, which has high light reflectivity, is preferable, but it is not limited to this as long as a reflective film is formed on the surface. If it is a resin, screen molding or the like may be used, and the molded body may be adhered to the mounting substrate. Further, it is preferable to increase the reflectance by using a light-reflecting material like the covering member 30. Further, like the above-mentioned addition member, the frame body may be colored depending on the purpose. The frame body can be removed after filling or molding the covering member. Further, the frame body may be formed integrally with the mounting substrate of the light emitting element, such as the laminated substrate 56, a device substrate having a cavity structure made of a base material or the like.

(接着材)
発光素子10と波長変換部材40との界面には接着材15が介在されてもよく、これにより双方の部材を固着する。この接着材15は、発光素子10からの出射光を波長変換部材40側へと有効に導光でき、双方の部材を光学的に連結できる材質が好ましい。その材料としては上記各部材に用いられる樹脂材料が挙げられ、一例としてシリコーン樹脂などの透光性の接着材料を用いる。その他の各部材間、例えば実施の形態2(図7)における接着材55のように、光路上で同様な透光性の接着材を設けても良い。
(Adhesive)
An adhesive material 15 may be interposed at the interface between the light emitting element 10 and the wavelength conversion member 40, whereby both members are fixed. The adhesive 15 is preferably made of a material that can effectively guide light emitted from the light emitting element 10 to the wavelength conversion member 40 side and can optically connect both members. Examples of the material include resin materials used for the above-mentioned members, and as an example, a translucent adhesive material such as silicone resin is used. A similar translucent adhesive may be provided between the other members, for example, the adhesive 55 in the second embodiment (FIG. 7) on the optical path.

(発光装置の製造方法)
図1に示される例の発光装置100の製造方法の一例として、図6を用いて以下に説明する。まず、図6(A)に示すように、基板58上または発光素子10に、バンプ60を形成し、それを介して発光素子10をフリップチップ実装する。この例ではサブマウント基板58上で、1つの発光装置に対応する領域に各々1個のLEDチップを並べて実装する(但し、LEDチップの個数は適宜変更できる)。次に、発光素子10の第1の面側(サファイア基板1裏面あるいは基板除去した場合であれば窒化物半導体11露出面)に、接着材であるシリコーン樹脂を塗布して、波長変換部材40を積層する。その後、そのシリコーン樹脂を熱硬化して、発光素子10と波長変換部材40とを接着する。さらに、発光素子10の周囲に所定の大きさ、形状の枠体57を立設させておく。ここでは、枠体57の高さは波長変換部材40の第1の面より低いが、略同じか高くしてもよい。
(Method of manufacturing light emitting device)
An example of a method of manufacturing the light emitting device 100 of the example shown in FIG. 1 will be described below with reference to FIG. First, as shown in FIG. 6A, bumps 60 are formed on the substrate 58 or on the light emitting element 10, and the light emitting element 10 is flip-chip mounted via the bumps 60. In this example, one LED chip is arranged and mounted in a region corresponding to one light emitting device on the submount substrate 58 (however, the number of LED chips can be appropriately changed). Next, a silicone resin as an adhesive is applied to the first surface side of the light emitting element 10 (the back surface of the sapphire substrate 1 or the exposed surface of the nitride semiconductor 11 when the substrate is removed) to form the wavelength conversion member 40. Stack. Then, the silicone resin is thermally cured to bond the light emitting element 10 and the wavelength conversion member 40. Further, a frame 57 having a predetermined size and shape is provided upright around the light emitting element 10. Here, the height of the frame 57 is lower than that of the first surface of the wavelength conversion member 40, but may be substantially the same or higher.

次に、枠体57内に、波長変換部材40の側面を被覆するように、ディスペンサ(液体定量吐出装置)71等により光反射性粒子を含有する液状の樹脂31をポッティングする。滴下された樹脂36は、表面張力によって発光素子10の壁面側を這い上がり、波長変換部材40の側面を被覆する。そして、この樹脂36を硬化させて被覆部材37とする。ここで、被覆部材37は波長変換部材40の第1の面より低い位置に窪んだ凹部がその表面に形成され、言い換えると、波長変換部材40の第1の面が最高位に配置された凸状の窓部となっており、被覆部材37の表面はその周辺で傾斜面となる。次に、図6(B)に示すように、被覆部材37および波長変換部材40上に、同様のディスペンサ等によって、光透過部材となる液状の熱硬化性樹脂26を適量滴下する。続いて、図6(C)に示すように、その上から、半球状のレンズ型が形成されている上金型72で所定の圧力を加えて樹脂層26を圧縮し、その状態で所定時間保持して樹脂層26を1次硬化させる。ここで、金型における加熱温度および加熱時間は、樹脂が所定の形状を保持するのに十分な硬度に達するような条件に設定することが好ましい。例えば、1次硬化温度は100〜170℃、好ましくは約120〜150℃にする。また、硬化時間は200〜900秒、好ましくは250〜600秒とする。また、上金型72の内面の形状によって、所望のレンズ径や曲率半径を持ったレンズを形成することもできる。 Next, a liquid resin 31 containing light-reflecting particles is potted in the frame 57 by a dispenser (liquid metering device) 71 or the like so as to cover the side surface of the wavelength conversion member 40. The dropped resin 36 creeps up on the wall surface side of the light emitting element 10 due to the surface tension, and covers the side surface of the wavelength conversion member 40. Then, the resin 36 is cured to form a covering member 37. Here, in the covering member 37, a concave portion that is recessed at a position lower than the first surface of the wavelength conversion member 40 is formed on the surface thereof, in other words, a convex portion in which the first surface of the wavelength conversion member 40 is arranged at the highest position. The window portion is shaped like a window, and the surface of the covering member 37 becomes an inclined surface in the periphery thereof. Next, as shown in FIG. 6(B), an appropriate amount of liquid thermosetting resin 26 serving as a light transmitting member is dropped on the covering member 37 and the wavelength converting member 40 by the same dispenser or the like. Subsequently, as shown in FIG. 6C, a predetermined pressure is applied from above by the upper mold 72 having a hemispherical lens mold to compress the resin layer 26, and in that state for a predetermined time. The resin layer 26 is held and the resin layer 26 is primarily cured. Here, it is preferable that the heating temperature and the heating time in the mold are set to conditions such that the resin reaches a hardness sufficient to maintain a predetermined shape. For example, the primary curing temperature is 100 to 170°C, preferably about 120 to 150°C. The curing time is 200 to 900 seconds, preferably 250 to 600 seconds. Further, depending on the shape of the inner surface of the upper mold 72, it is possible to form a lens having a desired lens diameter and a desired radius of curvature.

さらに、図6(D)に示すように、所望のレンズ形状となった樹脂成形体27が形成された一連の発光装置が設けられた基板を型から取り出し、所定の条件で加熱して樹脂成形体27を2次硬化させる。2次硬化の条件は、樹脂成形体27の硬化が十分となるように、例えば2次硬化の温度は1次硬化と同等以上にし、2次硬化の時間を1次硬化よりも長時間に設定することが好ましい。エポキシ樹脂、硬質シリコーン樹脂の場合、2次硬化の時間を3〜5時間程度にする。2次硬化をこのように十分に行えば、樹脂成形体80内に未反応の硬化成分が残り、発光装置の信頼性に悪影響を与えることを防止できる。また、型から取り出した後に2次硬化を行うことにより、工程のスループットを高めることができる。最後に、所定の位置(例えば、図6(D)における点線A)でもってダイシングを行い、所望の大きさに切り出し、個片化すれば図1の発光装置100が得られる。 Further, as shown in FIG. 6D, the substrate provided with the series of light emitting devices in which the resin molded body 27 having the desired lens shape is formed is taken out from the mold and heated under predetermined conditions to mold the resin. The body 27 is secondarily cured. The conditions of the secondary curing are, for example, the temperature of the secondary curing is set equal to or higher than that of the primary curing so that the resin molded body 27 is sufficiently cured, and the time of the secondary curing is set to be longer than the primary curing. Preferably. In the case of epoxy resin and hard silicone resin, the time for secondary curing is set to about 3 to 5 hours. If the secondary curing is sufficiently performed in this way, it is possible to prevent unreacted curing components from remaining in the resin molded body 80 and adversely affecting the reliability of the light emitting device. Further, by performing secondary curing after taking out from the mold, the throughput of the process can be increased. Finally, dicing is performed at a predetermined position (for example, the dotted line A in FIG. 6D), cut into a desired size, and individualized to obtain the light emitting device 100 in FIG.

(実施の形態2)
図7(a)は、本発明の実施の形態2に係る発光装置200の概略断面図であり、図7
(b)は、その光源周辺部を説明するための概略断面図である。発光装置200において、光透過部材20を除く他の構造については実施の形態1と実質上同様であり、したがって同様の構成については同一の符号を付して適宜説明を省略する。この発光装置200は、直径R(=W)の半球状に予め成形された光透過部材20が透光性接着材28を介して波長変換部材40の第1の面に接着された構成となっている。この発光装置200では、光透過部材20の光入射側の表面に、径L2で接着材28と接合する入射領域82とその外側の反射領域92とが設けられている。反射領域92と被覆部材の表面93とは離間され、その間には空隙85が設けられており、反射領域92は光透過部材20の底面であり、空気との界面を成して反射させることができ、光の取り出し効率を向上させることができる。図4に示す上述の解析結果からわかるように、本実施の形態2における発光装置200は、実施の形態1の発光装置100より光の取り出し効率が高く、特に光源が大きい場合、光透過部材が小さく、装置が小型の場合において優れた構成となっている。なお、透光性接着材28は、接合する光透過部材20とほぼ同程度の屈折率を有する材料であることが好ましい。これは、光透過部材20と透光性接着材28との界面における光の反射を低減し、光結合効率を良好にするためであり、略同じ材料で構成すると、例えば略同じ樹脂で形成するとそれを容易に実現できる。
(Embodiment 2)
FIG. 7A is a schematic sectional view of the light emitting device 200 according to Embodiment 2 of the present invention.
(B) is a schematic sectional view for explaining the peripheral portion of the light source. In the light emitting device 200, the structure other than the light transmitting member 20 is substantially the same as that of the first embodiment, and therefore, the same configurations are denoted by the same reference numerals and the description thereof will be appropriately omitted. The light emitting device 200 has a configuration in which a light transmitting member 20 preformed in a hemispherical shape having a diameter R (=W) is bonded to a first surface of a wavelength converting member 40 via a light transmitting adhesive material 28. ing. In this light emitting device 200, an incident area 82 that joins the adhesive 28 with a diameter L2 and a reflective area 92 outside the incident area 82 are provided on the light incident side surface of the light transmitting member 20. The reflective region 92 and the surface 93 of the covering member are separated from each other, and a space 85 is provided between them, and the reflective region 92 is the bottom surface of the light transmitting member 20 and forms an interface with the air to reflect the light. Therefore, the light extraction efficiency can be improved. As can be seen from the above-described analysis result shown in FIG. 4, the light emitting device 200 according to the second embodiment has a higher light extraction efficiency than the light emitting device 100 according to the first embodiment. It is small and has an excellent configuration when the device is small. The translucent adhesive material 28 is preferably a material having a refractive index substantially the same as that of the light transmissive member 20 to be joined. This is for reducing the reflection of light at the interface between the light transmitting member 20 and the light transmitting adhesive 28 and improving the optical coupling efficiency. If the light transmitting member 20 and the light transmitting adhesive 28 are made of substantially the same material, for example, if they are made of substantially the same resin. It can be achieved easily.

また、介在する透光性接着材28には、光源部側の入射領域82の対向領域、つまり光入射側の表面に、光源部の出射面である波長変換部材40の第1の面との界面に径L1の入射領域81と、被覆部材の表面との界面に反射領域91とが設けられている。この径L2は径L1より大きいことが好ましく、これにより光源部から光透過部材20へ効率良く光を導光することができる。また、反射領域91が設けられていることで、被覆部材の表面で透光性接着材内の戻り光などを反射、散乱せしめ、光透過部材20への光結合効率を高めることができる。なお、透光性接着材28の光源部側の被覆領域(上記光入射領域81と反射領域91)と、接着材から露出された被覆部材の反射領域93との被覆・接合領域の範囲によって、光源部より外側の反射領域91と92の割合を調整でき、例えば光透過部材20の光入射側の表面の略全領域が、透光性接着材28により被覆されてもよい。この場合、光透過部材と被覆部材との間は透光性接着材で満たされ透明な領域となり、光透過部材20から透光性接着材28内への光の透過が促進され、実施の形態1と同様に被覆部材の表面の反射領域91にて戻り光を反射させて外部に取り出す構造となる。すなわち、透光性接着材が介在して、入射面側25が光源部の出射面81と被覆部材表面93と離間されることで、その各表面に挟まれた離間領域内で光が伝搬して、表面93で反射、散乱され、他方、それに対向する反射領域92でも反射されるため、効率的な反射構造とできる。 Further, the intervening translucent adhesive material 28 is provided in a region facing the incident region 82 on the light source unit side, that is, on the surface on the light incident side, with the first face of the wavelength conversion member 40 which is the emission face of the light source unit. An incident area 81 having a diameter L1 is provided at the interface, and a reflective area 91 is provided at the interface with the surface of the covering member. The diameter L2 is preferably larger than the diameter L1, so that light can be efficiently guided from the light source section to the light transmitting member 20. In addition, since the reflective region 91 is provided, the return light in the translucent adhesive material is reflected and scattered on the surface of the covering member, and the optical coupling efficiency to the light transmissive member 20 can be improved. Depending on the range of the covering/joining area between the covering area (the light incident area 81 and the reflecting area 91) on the light source section side of the translucent adhesive 28 and the reflecting area 93 of the covering member exposed from the adhesive, The ratio of the reflection areas 91 and 92 outside the light source section can be adjusted, and for example, substantially the entire area of the surface of the light transmitting member 20 on the light incident side may be covered with the translucent adhesive material 28. In this case, a space between the light transmissive member and the covering member is filled with the translucent adhesive to form a transparent region, which promotes the transmission of light from the light transmissive member 20 into the translucent adhesive 28. In the same manner as in No. 1, the reflection area 91 on the surface of the covering member reflects the returning light and takes it out to the outside. That is, the incident surface side 25 is separated from the emission surface 81 of the light source section and the surface 93 of the covering member through the translucent adhesive, so that the light propagates in the separation area sandwiched between the surfaces. Then, the light is reflected and scattered by the surface 93, and is also reflected by the reflection area 92 facing the surface 93, so that an efficient reflection structure can be obtained.

(実施の形態3)
図8は、本発明の実施の形態3に係る発光装置の光源部周辺を説明するための概略断面図である。なお、ここで説明する発光装置の光源部周辺の構造は、他の実施の形態における発光装置の構成にも適用することができる。光透過部材の入射領域83は、凹凸構造を有し、光源部の発光素子10及び/又は波長変換部材40からの入射光が散乱され、また、戻り光を反射、散乱させることができ、反射領域90による反射機能を補い、発光面からの放出光の指向性を広くでき、また、輝度ムラや色ムラが低減されやすい。特に、1つの波長変換部材40に複数の発光素子10を搭載する場合には、各発光素子10の配置の影響やそれによる配光、輝度ムラ、色ムラの影響が大きく、それが低減されるので好ましい。また、凹凸面により、光結合効率のほか両部材の密着性の向上が期待される。また、このような凹凸構造は、波長変換部材の表面だけでなく、その発光素子側表面、さらに光路上にある各部材の表面に設けて同様な効果を得ることができ、特に光源部と光透過部材との境界領域、若しくは光源部内、例えば、基板1の半導体層11側表面に設けてもよく、実施例では詳述していないがそのような構造を用いている。波長変換部材の凹凸表面43などの凹凸構造は、研磨、ドライエッチング、ウエットエッチングなどにより設けることができ、不規則な凹凸構造のほか、規則的なパターンの凹凸構造も形成できる。
(Embodiment 3)
FIG. 8 is a schematic cross-sectional view for explaining the vicinity of the light source unit of the light emitting device according to Embodiment 3 of the present invention. Note that the structure around the light source portion of the light emitting device described here can be applied to the configurations of the light emitting devices in other embodiments. The incident region 83 of the light transmitting member has a concavo-convex structure so that the incident light from the light emitting element 10 and/or the wavelength conversion member 40 of the light source unit is scattered, and the return light can be reflected and scattered. The reflection function of the region 90 can be supplemented, the directivity of the light emitted from the light emitting surface can be widened, and uneven brightness and uneven color can be easily reduced. In particular, when a plurality of light emitting elements 10 are mounted on one wavelength conversion member 40, the influence of the arrangement of each light emitting element 10 and the influences of light distribution, luminance unevenness, and color unevenness caused thereby are large and reduced. Therefore, it is preferable. Further, the uneven surface is expected to improve the optical coupling efficiency and the adhesion of both members. In addition, such a concavo-convex structure can be provided not only on the surface of the wavelength conversion member, but also on the surface of the light emitting element side thereof, and further on the surface of each member on the optical path to obtain the same effect. It may be provided in the boundary region with the transmissive member or in the light source part, for example, on the surface of the substrate 1 on the semiconductor layer 11 side, and such a structure is used although not described in detail in the examples. The concavo-convex structure such as the concavo-convex surface 43 of the wavelength conversion member can be provided by polishing, dry etching, wet etching, etc., and in addition to the irregular concavo-convex structure, the concavo-convex structure having a regular pattern can be formed.

また、図8に示す発光装置において、発光素子10は、1つの成長基板1上に互いに分離された複数の発光領域(発光層)を有する半導体素子構造11が設けられた構造を有する。このように、単一の発光素子を接合すること、さらに成長基板1を一体として発光領域を分離させた発光素子10とすることで、1つの波長変換部材40に複数の発光素子10を搭載する場合に比して、各発光素子10の配置や配光の影響を低減することができる。さらに、波長変換部材40は、発光素子10の第1の面(成長基板1の裏面)の幅より小さい幅を有しており、すなわち波長変換部材40の少なくとも一対の対向する側面は、発光素子10の側面より内側に位置している。この形態であれば、発光領域を絞ることで相対的に輝度が高められ、また一次光と二次光の混色の割合を面内で均一化でき、実施の形態1のように波長変換部材40の側面が発光素子10の側面と略同一面上に位置する形態であれば、波長変換部材の外縁部において発光素子10からの光量が不足して色ムラが発生しやすくなるが、それを抑制できる。但し、本明細書でいう「略同一面」とは、上述した機能上で実質的に同一面であればよく、例えば波長変換部材40、発光素子10の寸法に比して±10%程度とすることができる。さらに、図8に示す発光装置において、発光素子10と波長変換部材40は、透光性接着材を介さず直接接合されている。このような接合は、表面活性化や熱圧着による結晶接合等により実現でき、比較的屈折率の小さい樹脂材料である接着材を介さないことで、屈折率の異なる界面を増やさず、結合効率を向上でき、また波長変換部材40からの放熱性も高めることができる。 Further, in the light emitting device shown in FIG. 8, the light emitting element 10 has a structure in which a semiconductor element structure 11 having a plurality of light emitting regions (light emitting layers) separated from each other is provided on one growth substrate 1. In this way, by bonding a single light emitting element and further forming the growth substrate 1 into the light emitting element 10 in which the light emitting regions are separated, a plurality of light emitting elements 10 are mounted on one wavelength conversion member 40. Compared with the case, the influence of the arrangement of the light emitting elements 10 and the light distribution can be reduced. Further, the wavelength conversion member 40 has a width smaller than the width of the first surface (the back surface of the growth substrate 1) of the light emitting element 10, that is, at least a pair of opposing side surfaces of the wavelength conversion member 40 has the light emitting element. It is located inside the side surface of 10. With this configuration, the luminance is relatively increased by narrowing the light emitting region, and the ratio of the color mixture of the primary light and the secondary light can be made uniform within the surface, so that the wavelength conversion member 40 as in the first embodiment. If the side surface of the light emitting element 10 is located substantially on the same plane as the side surface of the light emitting element 10, the amount of light from the light emitting element 10 is insufficient at the outer edge portion of the wavelength conversion member, and color unevenness easily occurs. it can. However, the “substantially the same surface” in the present specification may be substantially the same surface in terms of the function described above, and is, for example, about ±10% of the dimensions of the wavelength conversion member 40 and the light emitting element 10. can do. Further, in the light emitting device shown in FIG. 8, the light emitting element 10 and the wavelength conversion member 40 are directly bonded without a translucent adhesive material. Such joining can be realized by surface activation or crystal joining by thermocompression bonding, and by not using an adhesive that is a resin material with a relatively small refractive index, the interface with different refractive indexes is not increased and the bonding efficiency is improved. It is possible to improve the heat dissipation from the wavelength conversion member 40.

(実施の形態4)
図9(a)、(b)及び(c)はそれぞれ、本発明の実施の形態4に係る発光装置300、400、及び500の概略断面図である。本実施の形態4は、本発明に係る発光装置において、光透過部材20、その発光側表面の形状の変形例を示すものであって、各実施の形態に適用でき、また他の主要な構造については実施の形態1と実質上同様であるため、同様の構成については同一の符号を付して適宜説明を省略する。
(Embodiment 4)
9A, 9B and 9C are schematic cross-sectional views of light emitting devices 300, 400 and 500 according to Embodiment 4 of the present invention, respectively. The fourth embodiment shows a modification of the shape of the light transmitting member 20 and the surface of the light emitting side thereof in the light emitting device according to the present invention, which can be applied to each of the embodiments and other main structures. Since the above is substantially the same as that of the first embodiment, the same components are designated by the same reference numerals and the description thereof will be appropriately omitted.

図9(a)に示す例の発光装置300における光透過部材20の発光側の表面21の形状は、半球面からの扁形である凸曲面を有する。より詳細には、図中の黒丸で示すようにその曲率中心が波長変換部材40の表面中央から下方側にYだけ離れた位置にあり、表面21が、それを中心とする直径R(曲率半径r=R/2)の球面の一部で構成され、その径(断面幅)Wは、W=2×(r2−Y21/2、となる。上述した装置140、モデルD
(DA)のように、光透過部材20を扁平な形状とすることで、発光装置を小型化、薄型化できるが、表面21が半球面から変化することにより、光透過部材20の内面での光反射が増大する。しかしながら、本発明の発光装置は、光透過部材20の光入射側の表面の大部分を反射領域90が占めているため、そこで光透過部材内の光を反射、更には光反射材料35により散乱させることで、外部に効率良く取り出すことができる。なお、図では光透過部材20より、十分に断面幅広な被覆部材30となっているが、両方の端部が略同一となるように小さくできることはいうまでもない。また、発光装置300は、基板50上に、発光素子10と電気的に接続されたツェナーダイオードを有する。このように発光素子の電気的に保護する保護素子14は、図示するように被覆部材30内に埋設され、また光源部、反射領域から離間されていれば、他の主要構成部材に対し光学的に悪影響を与えることがなく、また発光装置、被覆部材の径を光透過部材の径と略等しくでき、すなわち光透過部材20より内側に、さらに反射領域90内に配置すれば、発光装置の小型化の支障にならず好ましい。
The shape of the light-emitting side surface 21 of the light transmitting member 20 in the light emitting device 300 of the example shown in FIG. 9A has a convex curved surface which is a flat shape from a hemispherical surface. More specifically, as shown by a black circle in the figure, the center of curvature is located at a position distant from the center of the surface of the wavelength conversion member 40 downward by Y, and the surface 21 has a diameter R (curvature radius) with the center as the center. It is composed of a part of a spherical surface of r=R/2), and its diameter (cross section width) W is W=2×(r 2 −Y 2 ) 1/2 . Device 140, Model D described above
As shown in (DA), by making the light transmitting member 20 have a flat shape, the light emitting device can be made smaller and thinner, but the surface 21 changes from a hemispherical surface, so that the inner surface of the light transmitting member 20 is changed. Light reflection increases. However, in the light emitting device of the present invention, since the reflection area 90 occupies most of the surface of the light transmitting member 20 on the light incident side, the light in the light transmitting member is reflected there and is further scattered by the light reflecting material 35. By doing so, it can be taken out efficiently. In the drawing, the covering member 30 has a cross-sectional width sufficiently wider than that of the light transmitting member 20, but it goes without saying that the covering members 30 can be made smaller so that both ends are substantially the same. Further, the light emitting device 300 has the Zener diode electrically connected to the light emitting element 10 on the substrate 50. As described above, the protective element 14 for electrically protecting the light emitting element is embedded in the covering member 30 as shown in the drawing, and if it is separated from the light source section and the reflection area, it is optically effective with respect to other main constituent members. In addition, the diameters of the light emitting device and the covering member can be made substantially equal to the diameter of the light transmitting member, that is, if the light emitting device and the covering member are arranged inside the light transmitting member 20 and in the reflection region 90, the light emitting device can be downsized. It is preferable because it does not hinder the conversion.

図9(b)に示す例の発光装置400は、光透過部材20の形状が、波長変換部材40の中央の直上で交わる2つの凸曲面からなる上面22と、その側面23と、により構成され、光源部表面からの出射光が入射領域80を通って、上面22を主に反射面として側方に反射し、側面23を主に発光面として装置外部に取り出される。なお、上面22には、その反射機能を高めるために、金属膜や誘電体多層膜、あるいは光反射性材料35を含有する被覆部材などの反射膜、部材を形成してもよい。また、このような発光装置においては、上面22及び反射領域94による反射及び散乱により、取り出し効率が高められ、更に波長変換部材40の出射光の色ムラを緩和している。また、それにより波長変換部材40の側面が被覆部材30から露出されていてもよい。 In the light emitting device 400 of the example shown in FIG. 9B, the shape of the light transmitting member 20 is configured by an upper surface 22 composed of two convex curved surfaces intersecting directly above the center of the wavelength conversion member 40, and a side surface 23 thereof. Light emitted from the surface of the light source unit passes through the incident area 80, is reflected laterally mainly using the upper surface 22 as a reflecting surface, and is extracted outside the device by using the side surface 23 mainly as a light emitting surface. In addition, on the upper surface 22, a reflective film or member such as a metal film, a dielectric multilayer film, or a covering member containing the light reflective material 35 may be formed in order to enhance its reflection function. Further, in such a light emitting device, the extraction efficiency is improved by the reflection and scattering by the upper surface 22 and the reflection region 94, and the color unevenness of the emitted light of the wavelength conversion member 40 is alleviated. Moreover, the side surface of the wavelength conversion member 40 may be exposed from the coating member 30 by it.

図9(c)に示す例の発光装置500は、光透過部材20の形状が、平坦な上面23と、内側の光源部に向かって傾斜した曲面からなる側面24と、により構成される形状を有する。これにより、光源部表面からの出射光が入射領域80を通って、側面24により上方に集光されて上面23から装置外部に取り出される。なお、この側面24には、発光装置400で述べたように同様の反射膜を形成してもよく、また、図中の点線で示すように、枠体56上に新たに別の枠体で光反射性材料35を含有する被覆部材を充填し、光透過部材20を被覆する第2の光反射層の積層構造を形成することもできる。 In the light emitting device 500 of the example shown in FIG. 9C, the light transmitting member 20 has a shape including a flat upper surface 23 and a side surface 24 formed of a curved surface inclined toward the inner light source section. Have. As a result, the light emitted from the surface of the light source unit passes through the incident area 80, is condensed upward by the side surface 24, and is extracted from the upper surface 23 to the outside of the device. A similar reflective film may be formed on the side surface 24 as described in the light emitting device 400, and as shown by a dotted line in the drawing, a new frame is newly formed on the frame 56. It is also possible to fill a covering member containing the light-reflecting material 35 and form a laminated structure of the second light-reflecting layer covering the light-transmitting member 20.

以上の各例は、本発明の発光装置において、種々の光透過部材への適用例を示すものであり、図9(b)、(c)の装置においても、上述した反射領域94,95が設けられて、その内側に光源部の入射領域が設けられている。特に図9(a)や他の実施の形態のように凸曲面でなく、種々の形状の光透過部材では、凸曲面よりも光透過部材内部に閉じ込められる光が多くなり、上述した反射領域、その他の構造が好適に作用する。また、光源部の径Lと光透過部材の径Wとの関係においても、上記L/Wの比と光取り出し効率の関係がより顕著となる傾向にあり、効率の落ち込みが大きくなる傾向にあると考えられる。このように図9(b)、(c)の装置は、入射面側で被覆部材に対向する反射領域に加えて、それとは別の表面22,24にも反射領域を備えた構造であり、さらに発光面23を備え、この構造により、一部の反射領域、特に光源部近傍において、被覆部材による好適な反射や散乱ができ、所望の発光特性の装置を実現できる。 The above examples show examples of application to various light transmitting members in the light emitting device of the present invention, and in the devices of FIGS. 9(b) and 9(c), the above-described reflective regions 94 and 95 are also included. The light source unit is provided with an incident region inside the light source unit. In particular, in a light transmitting member having various shapes instead of the convex curved surface as in FIG. 9A and other embodiments, more light is confined inside the light transmitting member than the convex curved surface, and Other structures work well. Also, regarding the relationship between the diameter L of the light source section and the diameter W of the light transmitting member, the relationship between the L/W ratio and the light extraction efficiency tends to become more prominent, and the efficiency drop tends to increase. it is conceivable that. As described above, the devices of FIGS. 9B and 9C have a structure in which, in addition to the reflection region facing the covering member on the incident surface side, the reflection regions are provided on the other surfaces 22 and 24, Further, the light emitting surface 23 is provided, and by this structure, suitable reflection and scattering by the covering member can be achieved in a part of the reflection region, particularly in the vicinity of the light source portion, and a device having a desired light emitting characteristic can be realized.

(実施の形態5)
図10は、本発明の実施の形態5に係る発光装置600の概略断面図であり、発光素子10の実装形態を除く他の主な構造については実施の形態1と実質上同様であり、したがって同様の構成については同一の符号を付して適宜説明を省略する。本発明の発光装置において、光源部は光反射性の被覆部材30に被覆されて光透過部材に光結合されおり、その被覆形態、具体的には発光素子の実装形態、被覆部材の形態については種々の形態を取ることができる。図9の発光装置600はその例であり、基板50を有さず、被覆部材30が直方体形状、板状に成形されて、この成形体が光透過部材20と共に発光装置の表出面を構成している。発光素子10の各電極に接続された導電体61を備え、被覆部材30の裏面側に達して外部接続部が形成されている。この導電体61の延伸方向、露出位置、表面は適宜変更可能であり、例えば光透過部材20と同一面側でその外側に延伸され、露出されてもよい。導電体61は、図9に示すような柱状の形態のほか、層状の形態を組み合わせてもよい。このような発光装置600であれば、光源部の入射領域80を除いて発光素子10などの光源部を被覆部材30でほぼ完全に被包することができ、光源部の出射光が実装基板50、その導体配線等により吸収、損失されることを低減することができ、光源部からの光の取り出し効率を高めることができる。
(Embodiment 5)
FIG. 10 is a schematic cross-sectional view of a light emitting device 600 according to Embodiment 5 of the present invention, and the other main structure except the mounting form of light emitting element 10 is substantially the same as in Embodiment 1, and therefore, The same configurations are denoted by the same reference numerals and description thereof will be omitted as appropriate. In the light-emitting device of the present invention, the light source section is covered with the light-reflecting covering member 30 and optically coupled to the light-transmitting member. Regarding the covering form, specifically, the mounting form of the light-emitting element and the covering member, It can take various forms. The light emitting device 600 of FIG. 9 is an example thereof, and the covering member 30 is molded into a rectangular parallelepiped shape or a plate shape without the substrate 50, and this molded body constitutes the exposed surface of the light emitting device together with the light transmitting member 20. ing. An electric conductor 61 connected to each electrode of the light emitting element 10 is provided, and an external connection portion is formed reaching the back surface side of the covering member 30. The stretching direction, the exposure position, and the surface of the conductor 61 can be changed as appropriate, and for example, the conductor 61 may be stretched outside on the same surface as the light transmitting member 20 and exposed. The conductor 61 may have a columnar shape as shown in FIG. 9 or a combination of layered shapes. With such a light emitting device 600, the light source portion such as the light emitting element 10 can be almost completely covered with the covering member 30 except the incident region 80 of the light source portion, and the light emitted from the light source portion is mounted on the mounting substrate 50. It is possible to reduce absorption and loss due to the conductor wiring and the like, and it is possible to improve the efficiency of extracting light from the light source unit.

このような装置は、例えば、支持基板上に発光素子を載置して、被覆部材を塗布して成形体とし、予め離型剤等により表面処理するなどして、その支持基板から剥がして、光源部が埋め込まれた被覆部材の成形体を取り出す方法により実現できる。その他の構造は、成形体の剥離前、又は後に、上記光透過部材を成形、又は接着してもよく、またその剥離前後で個々の装置に切り出してもよく、さらに金型などの支持基板を用いて光透過部材上にその成形体を形成してもよい。また、光源部の配線構造は、その入射領域80側表面を支持基板と対向して載置し、発光素子の電極、またその上の導体として、成膜、めっき、バンプなどで導電体を形成し、上記被覆部材を形成してもよく、配線側表面を支持基板に対向して載置し、予め発光素子側、支持基板側又はその両方に、上記導電体又は支持基板上の配線層、それらを組み合わせた導電体を設けて、剥離してもよい。 Such an apparatus, for example, mounts a light emitting element on a supporting substrate, applies a covering member to form a molded body, and performs surface treatment with a release agent or the like in advance, and peels it from the supporting substrate. It can be realized by a method of taking out the molded body of the covering member in which the light source unit is embedded. For other structures, the light transmitting member may be molded or adhered before or after peeling of the molded body, and may be cut into individual devices before and after the peeling, and a supporting substrate such as a mold may be formed. The molded body may be formed on the light transmissive member by using it. Further, in the wiring structure of the light source part, the surface on the incident region 80 side is placed so as to face the support substrate, and a conductor is formed by film formation, plating, bumps or the like as an electrode of the light emitting element and as a conductor on the electrode. However, the coating member may be formed, the wiring side surface is placed facing the supporting substrate, the light emitting element side, the supporting substrate side or both in advance, the conductor or the wiring layer on the supporting substrate, You may peel by providing the conductor which combined them.

以下、本発明に係る実施例について詳述する。なお、本発明は以下に示す実施例のみに限定されないことは言うまでもない。 Hereinafter, examples according to the present invention will be described in detail. Needless to say, the present invention is not limited to the examples described below.

(実施例1〜3)
実施例1〜3の発光装置は、図7に示すような発光素子10、又は素子とそれに接合した波長変換部材40が被覆部材に側面を覆われて、露出された光源部の上面の出射面上に接着剤28を介してレンズ20を接着した構造である。具体的には、AlNのセラミックス基板50の配線51上に、発光素子10として約1mm×1mmの略正方形の青色LEDチップ1個を、バンプ60によりフリップチップ実装する。実施例1では、そのLED10の成長基板1であるサファイア基板表面の出射面が露出される状態に、その周囲に充填された被覆部材30でもってLEDチップの側面が被包されている。なお、被覆部材30は、粒径約270nmのTiO2の微粒子である光反射性材料35を約23重量パーセント濃度で含有するシリコーン樹脂である。また、実施例2及び3では、LED10の成長基板1上に、板状の波長変換部材40であるYAGの焼結体1枚を、シリコーン樹脂からなる透光性接着材15により接合する。そして、図示するように、波長変換部材40表面の出射面が露出される状態に、実施例1と同様に、被覆部材30で波長変換部材40の底面の一部および側面、LEDチップの側面等の表面が被包されている。なお、被覆部材30の表面は、図示するように光源部の出射面から連続する側面を這い上がるように表面が光源部付近で傾斜している。波長変換部材40の外形は、寸法が実施例2では約1.1mm×1.1mm、実施例3では約1.5mm×1.5mmの矩形状であり、厚みは約150μmである。そして、各実施例について、被覆部材の表面上において、発光素子10又は波長変換部材40の光源部の出射面を内包して、且つその略中心に光軸が位置するように、シリコーン樹脂からなる直径Rが約4mmの半球レンズ状の光透過部材20を、同じシリコーン樹脂からなる透光性接着材28によりその出射面にそれぞれ接合する。
(Examples 1 to 3)
In the light emitting devices of Examples 1 to 3, the light emitting element 10 as shown in FIG. 7, or the element and the wavelength conversion member 40 bonded to the element are covered with the side surface by the covering member, and the exposed emission surface of the upper surface of the light source unit. It has a structure in which the lens 20 is adhered to the upper surface thereof with an adhesive 28. Specifically, on the wiring 51 of the AlN ceramic substrate 50, one blue LED chip having a substantially square shape of about 1 mm×1 mm is flip-chip mounted by the bump 60 as the light emitting element 10. In the first embodiment, the side surface of the LED chip is covered with the covering member 30 filling the periphery thereof in a state where the emission surface of the surface of the sapphire substrate which is the growth substrate 1 of the LED 10 is exposed. The covering member 30 is a silicone resin containing the light-reflecting material 35, which is fine particles of TiO 2 having a particle diameter of about 270 nm, in a concentration of about 23 weight percent. Further, in Examples 2 and 3, one piece of YAG sintered body, which is the plate-like wavelength conversion member 40, is bonded onto the growth substrate 1 of the LED 10 by the translucent adhesive 15 made of silicone resin. Then, as shown in the drawing, in a state where the emission surface of the surface of the wavelength conversion member 40 is exposed, as in the first embodiment, a part of the bottom surface and the side surface of the wavelength conversion member 40 by the covering member 30, the side surface of the LED chip, and the like. The surface of is encapsulated. The surface of the covering member 30 is inclined in the vicinity of the light source part so as to crawl on the side surface continuous from the emission surface of the light source part as shown in the figure. The outer shape of the wavelength conversion member 40 is a rectangular shape having dimensions of about 1.1 mm×1.1 mm in Example 2 and about 1.5 mm×1.5 mm in Example 3, and the thickness thereof is about 150 μm. Then, in each of the examples, the coating member is made of a silicone resin so that the light emitting element 10 or the light emitting portion of the light source portion of the wavelength conversion member 40 is included on the surface of the coating member and the optical axis is located substantially at the center thereof. The hemispherical lens-shaped light-transmitting member 20 having a diameter R of about 4 mm is bonded to the light-exiting surface thereof with a light-transmitting adhesive 28 made of the same silicone resin.

光透過部材20の径Rに対する光源部の径Lの比(L/R)は、それぞれ実施例1では約0.250、実施例2では約0.275、実施例3では約0.375である。実施例1の青色の単色発光の発光装置は、駆動電流350mAにおいて、発光ピーク波長449nm、発光出力522mWで発光する。また、実施例2の白色発光の発光装置は、駆動電流350mAにおいて光束115lm(色度y値0.38)、駆動電流550mAにおいて光束170lm(同色度y値)で、比較的に高輝度となる。、実施例3の白色発光の発光装置は、駆動電流350mAにおいて光束135lm(色度y値0.38)、駆動電流550mAにおいて光束200lm(同色度y値)で、比較的に高光束となる。 The ratio (L/R) of the diameter L of the light source portion to the diameter R of the light transmitting member 20 is about 0.250 in Example 1, about 0.275 in Example 2, and about 0.375 in Example 3, respectively. is there. The blue monochromatic light-emitting device of Example 1 emits light with an emission peak wavelength of 449 nm and an emission output of 522 mW at a driving current of 350 mA. Further, the white light emitting device of Example 2 has a luminous flux of 115 lm (chromaticity y value of 0.38) at a driving current of 350 mA, and a luminous flux of 170 lm (same chromaticity y value) at a driving current of 550 mA, and has relatively high brightness. .. The white light emitting device of Example 3 has a relatively high luminous flux with a luminous flux of 135 lm (chromaticity y value of 0.38) at a driving current of 350 mA and a luminous flux of 200 lm (same chromaticity y value) at a driving current of 550 mA.

(実施例4〜6)
次に、波長変換部材40の構成を変えて、光透過部材20の有無による発光効率への影響を以下に検証する。実施例4の発光装置は、実施例3と同様であり、実施例5,6の発光装置はそれぞれ、実施例4の波長変換部材40の構成のみ変更し、実施例5では、実施例4と同様のYAGの蛍光体をシリコーン樹脂に分散させたシートを用い、実施例6では、(Sr,Ba)2SiO4:Euのシリケートの蛍光体を実施例5と同様にシリコーン樹脂に分散させたシートである。なお、これらの樹脂のシートは、蛍光体を拡散した樹脂を、離型剤を塗布した板にスピンコートして硬化して、所定の大きさに切り出して作製する。これら実施例4〜6の発光装置において、光透過部材20の有無による発光効率の差異を図11に示す。なお、実施例4,5,6の光透過部材20搭載後をそれぞれD,E,Fとし、光透過部材20搭載前をそれぞれd,e,fとして表記する。図11に示すように、いずれの実施例においても、光透過部材20を搭載することで、同じ色度の発光において高効率化でき、発光効率の向上が確認できる。
(Examples 4 to 6)
Next, by changing the configuration of the wavelength conversion member 40, the influence of the presence or absence of the light transmission member 20 on the light emission efficiency will be verified below. The light emitting device of the fourth embodiment is the same as that of the third embodiment, and the light emitting devices of the fifth and sixth embodiments respectively change only the configuration of the wavelength conversion member 40 of the fourth embodiment. In Example 6, a silicate phosphor of (Sr,Ba) 2 SiO 4 :Eu was dispersed in a silicone resin in the same manner as in Example 5 using a sheet in which the same YAG phosphor was dispersed in a silicone resin. It is a sheet. These resin sheets are produced by spin-coating a resin coated with a release agent with a resin having a phosphor diffused therein, curing the resin, and cutting it into a predetermined size. In the light emitting devices of Examples 4 to 6, the difference in light emission efficiency depending on the presence or absence of the light transmitting member 20 is shown in FIG. It should be noted that after mounting the light transmitting member 20 of Examples 4, 5, and 6 are denoted as D, E, and F, and before mounting the light transmitting member 20 are denoted as d, e, and f, respectively. As shown in FIG. 11, in any of the examples, by mounting the light transmitting member 20, it is possible to increase efficiency in light emission of the same chromaticity, and it can be confirmed that light emission efficiency is improved.

波長変換部材40として焼結体を用いる場合には、焼結体の生成が困難であったり、変換効率が低下したり、2種類以上の蛍光体の焼成に制約が大きくなったり、することがある。一方、樹脂に蛍光体を拡散することにより作製されるシートでは、作製温度が低く蛍光体の特性を崩さないため、蛍光体の種類を問わず作製することができる。例えば、図11に示すように、シリケートの蛍光体を用いた樹脂のシートは、YAGの蛍光体を用いたものより高い変換効率を示している。また、離型剤を塗布した板の表面は平坦であってもよいし、凹凸面として樹脂のシートに凹凸構造を形成することもできる。 When a sintered body is used as the wavelength conversion member 40, it may be difficult to produce a sintered body, the conversion efficiency may be reduced, or the firing of two or more kinds of phosphors may be greatly restricted. is there. On the other hand, a sheet produced by diffusing a phosphor in a resin has a low production temperature and does not impair the characteristics of the phosphor, and thus can be produced regardless of the type of the phosphor. For example, as shown in FIG. 11, the resin sheet using the silicate phosphor exhibits higher conversion efficiency than that using the YAG phosphor. The surface of the plate coated with the release agent may be flat, or a concavo-convex structure may be formed on the resin sheet as a concavo-convex surface.

本発明の発光装置は、照明用光源、LEDディスプレイ、液晶表示装置などのバックライト光源、信号機、照明式スイッチ、各種センサ及び各種インジケータ等に好適に利用できる。 INDUSTRIAL APPLICABILITY The light emitting device of the present invention can be suitably used for a light source for illumination, an LED display, a backlight light source such as a liquid crystal display device, a traffic light, a lighting switch, various sensors and various indicators.

10…発光素子(1…成長基板、2…第1導電型(n型)半導体層、3…活性層、4…第2導電型(p型)半導体層、5…透光性導電層、6…第2の電極(p側パッド電極)、7
…第1の電極(n側パッド電極)、8…保護膜)、11…半導体素子構造、14…保護素子、15…接着材、16…発光部、20(20a〜d)…光透過部材(21…発光側の表面、22,24,25…反射表面、23…発光表面)26…樹脂層、28…接着材、30〜34…被覆部材、35…光反射性材料、40…光透過(波長変換)部材、50,58…実装基体・基材(51〜52…配線パターン、55〜57…枠体又は積層基板又は基材)、60…導電性接着材、61…導電体、71…ディスペンサ、72…上金型
10... Light emitting element (1... Growth substrate, 2... First conductivity type (n type) semiconductor layer, 3... Active layer, 4... Second conductivity type (p type) semiconductor layer, 5... Translucent conductive layer, 6 ...Second electrode (p-side pad electrode), 7
... 1st electrode (n side pad electrode), 8... Protective film, 11... Semiconductor element structure, 14... Protective element, 15... Adhesive material, 16... Light emitting part, 20 (20a-d)... Light transmitting member ( 21... Surface on light emitting side, 22, 24, 25... Reflective surface, 23... Light emitting surface) 26... Resin layer, 28... Adhesive material, 30-34... Covering member, 35... Light reflecting material, 40... Light transmitting ( (Wavelength conversion) member, 50, 58... Mounting substrate/base material (51-52... Wiring pattern, 55-57... Frame body or laminated substrate or base material), 60... Conductive adhesive material, 61... Conductor, 71... Dispenser, 72... Upper mold

Claims (3)

光反射性材料を含有する被覆部材と、
発光側の表面と、前記被覆部材の表面に対向し、該表面内に配置された光入射側の表面とを有する光透過部材と、
前記光透過部材の光入射側表面において、外側の反射領域に囲まれた入射領域に結合し、前記被覆部材に一部が埋め込まれた光源部に、発光素子と、該発光素子の前記入射領域側に結合され、該発光素子に励起される波長変換部材と、を備える発光装置。
A covering member containing a light-reflecting material,
A light-transmitting member having a light-emitting side surface and a light-incident side surface that faces the surface of the covering member and is disposed in the surface;
On the light incident side surface of the light transmitting member, a light emitting element and the incident area of the light emitting element are coupled to an incident area surrounded by an outer reflection area, and a light source part partially embedded in the covering member. And a wavelength conversion member that is coupled to the side and is excited by the light emitting element.
前記光透過部材は、前記発光側が凸曲面で、前記光入射側の少なくとも反射領域が略平坦な表面であり、
前記入射領域の断面幅は、前記光入射側表面の半分以下である請求項1に記載の発光装置。
The light transmitting member is a convex curved surface on the light emitting side, at least the reflection region on the light incident side is a substantially flat surface,
The light emitting device according to claim 1, wherein a cross-sectional width of the incident region is half or less of a surface of the light incident side.
光反射性材料を含有する被覆部材と、
凸曲面の発光側の表面と、前記被覆部材の表面に対向し、該表面内に配置された光入射側の表面とを有する光透過部材と、
前記光透過部材の光入射側表面において、略平坦な表面の反射領域に囲まれた内側の入射領域に結合し、前記被覆部材に一部が埋め込まれた光源部が設けられて、該光源部内に設けられた発光素子と、を備え、
前記入射領域の断面幅は、前記光入射側表面の半分以下である発光装置。
A covering member containing a light-reflecting material,
A light-transmitting member having a light-emitting side surface of a convex curved surface and a light-incident side surface that faces the surface of the covering member and is disposed in the surface;
A light source unit is provided on the light incident side surface of the light transmitting member, the light source unit being coupled to an inner incident region surrounded by a reflection region of a substantially flat surface and partially embedded in the covering member. And a light emitting element provided in
A light-emitting device in which a cross-sectional width of the incident region is half or less of a surface of the light incident side.
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