JP5897862B2 - Semiconductor light emitting device - Google Patents

Semiconductor light emitting device Download PDF

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JP5897862B2
JP5897862B2 JP2011226142A JP2011226142A JP5897862B2 JP 5897862 B2 JP5897862 B2 JP 5897862B2 JP 2011226142 A JP2011226142 A JP 2011226142A JP 2011226142 A JP2011226142 A JP 2011226142A JP 5897862 B2 JP5897862 B2 JP 5897862B2
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emitting device
light emitting
light
led
refractive index
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JP2013089645A (en
JP2013089645A5 (en
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篤 白石
篤 白石
浩 塚田
浩 塚田
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Citizen Holdings Co Ltd
Citizen Electronics Co Ltd
Citizen Watch Co Ltd
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Citizen Watch Co Ltd
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2224/00Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
    • H01L2224/93Batch processes
    • H01L2224/95Batch processes at chip-level, i.e. with connecting carried out on a plurality of singulated devices, i.e. on diced chips
    • H01L2224/97Batch processes at chip-level, i.e. with connecting carried out on a plurality of singulated devices, i.e. on diced chips the devices being connected to a common substrate, e.g. interposer, said common substrate being separable into individual assemblies after connecting

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Description

本発明はLED素子等の半導体発光素子を備えた半導体発光装置及びその製造方法に関するものであり、詳しくは半導体発光素子の発光面上に透光部材を介して反射部材を備えた半導体発光装置及びその製造方法に関する。   The present invention relates to a semiconductor light emitting device including a semiconductor light emitting element such as an LED element and a method for manufacturing the same, and more particularly, to a semiconductor light emitting device including a reflective member on a light emitting surface of a semiconductor light emitting element via a translucent member, and It relates to the manufacturing method.

近年、LED素子(以下特に断らない限りLEDと略記する)は半導体発光素子であるため、長寿命で優れた駆動特性を有し、さらに小型で発光効率が良く、鮮やかな発光色を有することから、カラー表示装置のバックライトや照明等に広く利用されるようになってきた。本発明においても半導体発光素子を樹脂等でパッケージ化した半導体発光装置として、LED発光装置を事例として説明する。   In recent years, an LED element (hereinafter abbreviated as “LED” unless otherwise specified) is a semiconductor light-emitting element, and therefore has a long life and excellent driving characteristics, and is small, has high luminous efficiency, and has a bright emission color. It has come to be widely used for backlights and lighting of color display devices. In the present invention, an LED light emitting device will be described as an example of a semiconductor light emitting device in which a semiconductor light emitting element is packaged with a resin or the like.

特に近年、LEDの発光特性として知られている強い指向性を緩和するため、LEDの周囲を透光部材である透光性樹脂で被覆し、さらに被覆した透光性樹脂の上面側に反射層を設けたLED発光装置(例えば特許文献1)や、LEDの周囲を透光部材である透光性樹脂で被覆し、さらに被覆した透光性樹脂の上面側に、前記透光性樹脂より低い屈折率の低屈折率樹脂層を設けたLED発光装置(例えば特許文献2)が提案されている。   In particular, in recent years, in order to relieve the strong directivity known as the light emission characteristics of the LED, the periphery of the LED is coated with a translucent resin as a translucent member, and a reflective layer is formed on the coated translucent resin. The LED light-emitting device (for example, Patent Document 1) provided with LED, and the periphery of the LED is coated with a translucent resin that is a translucent member, and further, the upper surface side of the coated translucent resin is lower than the translucent resin An LED light emitting device (for example, Patent Document 2) provided with a low refractive index resin layer having a refractive index has been proposed.

以下、反射部材(反射層)を透光部材の上面に配設した従来のLED発光装置に付いて説明する。なお、理解し易いように発明の趣旨を外さない範囲において図面を一部簡略化し、また部品名称も本願にそろえている。図8は特許文献1に示されたLED発光装置100の断面図である。LED発光装置100は、回路基板102の上面に配設した配線電極(図示せず)にフリップチップ実装したLED101と、LED101を覆うようにして封止する透光性樹脂104(透光部材)と、透光性樹脂104の上面に形成した反射部材106を備えている。反射部材106は、半透過反射性の金属箔膜よりなり、蒸着またはメッキ法で形成する。反射部材106の反射率(又は透過率)及び面積、並びに透光性樹脂104の厚み等を任意に設定することにより、正面方向の光出射量や出射光の広がり角について制御が可能となる。例えば、反射部材106を透過する透過光Psの量や側面方向へ出射する側面光Poの光路長を調節して指向特性を改善することができる。このLED発光装置100は少ない構成部品からなるにもかかわらず方位角で変化する発光ムラを緩和している。   Hereinafter, a conventional LED light emitting device in which a reflective member (reflective layer) is disposed on the upper surface of the translucent member will be described. For ease of understanding, the drawings are partially simplified within the scope not departing from the spirit of the invention, and component names are also included in the present application. FIG. 8 is a cross-sectional view of the LED light emitting device 100 disclosed in Patent Document 1. The LED light emitting device 100 includes an LED 101 flip-chip mounted on a wiring electrode (not shown) disposed on the upper surface of a circuit board 102, and a translucent resin 104 (translucent member) that seals the LED 101 so as to cover it. The reflective member 106 formed on the upper surface of the translucent resin 104 is provided. The reflection member 106 is made of a transflective metal foil film and is formed by vapor deposition or plating. By arbitrarily setting the reflectance (or transmittance) and area of the reflecting member 106, the thickness of the translucent resin 104, and the like, it is possible to control the amount of light emitted in the front direction and the spread angle of the emitted light. For example, the directivity can be improved by adjusting the amount of transmitted light Ps transmitted through the reflecting member 106 and the optical path length of the side light Po emitted in the side surface direction. The LED light emitting device 100 mitigates unevenness in light emission that varies with the azimuth even though it is composed of few components.

次に上記LED発光装置100の発光動作を説明する。図示しないマザー基板に半田付け等により接続した回路基板102の駆動電極(図示せず)からLED101へ駆動電流を供給するとLED101が発光する。仮に反射部材106がない場合、LED101は側面方向に光を出射するとしても、上方への出射光は極めて強くなる。このため、LED101の真上が極端に強く周辺が弱い発光状態となる。このLED発光装置100を照明装置に組み込むと、LED101の強い輝度ムラによりこの照明装置はLED101の中心のみが明るく周囲が暗いものとなってしまう。   Next, the light emitting operation of the LED light emitting device 100 will be described. When a drive current is supplied to the LED 101 from a drive electrode (not shown) of the circuit board 102 connected to a mother board (not shown) by soldering or the like, the LED 101 emits light. If there is no reflecting member 106, the LED 101 emits light in the side surface direction, but the upward emitted light becomes extremely strong. For this reason, the LED 101 is in a light emitting state in which the portion directly above the LED 101 is extremely strong and the periphery is weak. When this LED light emitting device 100 is incorporated in a lighting device, due to strong luminance unevenness of the LED 101, only the center of the LED 101 is bright and the surroundings are dark.

上記問題を解決するためLED発光装置100では、LED101を封止している透光性樹脂104の上面に反射部材106を配設している。すなわちLED101の真上から出射しようとする極端に強い放射光を反射部材106によって阻止または抑制し、さらに反射部材106によって反射させ周囲から放射させている。これでLED101の正面が局部的に明るくなるという輝度ムラを改善している。   In order to solve the above problem, in the LED light emitting device 100, the reflecting member 106 is disposed on the upper surface of the translucent resin 104 that seals the LED 101. That is, extremely strong radiated light that is going to be emitted from directly above the LED 101 is blocked or suppressed by the reflecting member 106, and further reflected by the reflecting member 106 and emitted from the surroundings. This improves luminance unevenness in which the front surface of the LED 101 is locally brightened.

LED101の発光動作を光線P1〜3で説明する。LED101から出射する光線のうち、出射角の小さい光線P1の一部は反射部材106を通過して通過光Ps1として上方に出射し、光線P1の他の一部は点線で示すように反射部材106と回路基板102の間で反射を繰り返した後、透光樹脂104の側面から側面光Po1として出射する。光線P2は反射部材106と回路基板102の間で反射を繰り返し側面光P02として出射する。また光線P3は反射部材106で反射し透光性樹脂104の側面から側面光Po3として出射する。なお、光線の一部は様々な界面で反射し透光樹脂104の内部に戻るものもある。反射部材106としては白色樹脂や金属層のようにLED101の発光を反射させる材料が使われる。 The light emitting operation of the LED 101 will be described with the light beams P1 to P3. Among the light beams emitted from the LED 101, a part of the light beam P1 having a small emission angle passes through the reflecting member 106 and is emitted upward as the passing light Ps1, and the other part of the light beam P1 is reflected by the reflecting member 106 as indicated by a dotted line. After being repeatedly reflected between the circuit board 102 and the circuit board 102, the light is emitted from the side surface of the translucent resin 104 as side light Po <b> 1. The light ray P2 is repeatedly reflected between the reflecting member 106 and the circuit board 102 and emitted as side light P02. The light beam P3 is reflected by the reflecting member 106 and emitted from the side surface of the translucent resin 104 as side surface light Po3. Some of the light rays may be reflected at various interfaces and return to the inside of the translucent resin 104. As the reflecting member 106, a material that reflects light emitted from the LED 101, such as a white resin or a metal layer, is used.

次に特許文献2に記載された従来技術について説明する。特許文献2には、回路基板上に実装した半導体発光素子が透光性高屈折率の第1樹脂で被覆され、その第1樹脂の外側を透光性低屈折率の第2樹脂で被覆する2層構成の半導体発光装置が記載されている。この半導体発光装置は、半導体発光素子の屈折率N1、第1樹脂の屈折率N2、第2樹脂の屈折率N3の関係を、N1>N2>N3>1としている。これで半導体発光素子から出射する光線を順次外側に屈折させてゆき、出射光が出来るだけ中心から外側へ向かうようにして発光や輝度のムラを緩和している。なお特許文献2の本来の目的は、化合物半導体発光素子と封止樹脂界面での反射率の低減及び全反射の臨界角を広くすることにより光の外部取り出し効率を改善することである。   Next, the prior art described in Patent Document 2 will be described. In Patent Document 2, a semiconductor light-emitting element mounted on a circuit board is covered with a first resin having a high light-transmitting refractive index, and the outside of the first resin is covered with a second resin having a low light-transmitting refractive index. A two-layer semiconductor light emitting device is described. In this semiconductor light emitting device, the relationship among the refractive index N1 of the semiconductor light emitting element, the refractive index N2 of the first resin, and the refractive index N3 of the second resin is N1> N2> N3> 1. In this way, the light emitted from the semiconductor light emitting element is sequentially refracted outward, so that the emitted light is directed from the center to the outside as much as possible to alleviate light emission and luminance unevenness. The original purpose of Patent Document 2 is to improve the external light extraction efficiency by reducing the reflectance at the interface between the compound semiconductor light emitting element and the sealing resin and widening the critical angle of total reflection.

特開2001−257381号公報(図1)Japanese Patent Laying-Open No. 2001-257381 (FIG. 1) 特開平10−65220号公報(図5)Japanese Patent Laid-Open No. 10-65220 (FIG. 5)

上記特許文献1及び2では反射部材の配置や透光部材の積層化により輝度ムラを改善してきた。平面型照明装置ではこのムラの改善に加え薄型化が要請されており、その解決手段のひとつとしてLED体発光装置の側面から出射する光を利用するものが知られている。この手法は、LED発光装置の側面から出射する光を、まず水平方向に広げ、次に反射器等で垂直方向(照射方向)に向けるものであり、レンズ等の光学素子が不要となる。しかしながら特許文献1,2で示されたLED発光装置では、輝度ムラは改善するとしても、平面型照明装置の薄型化を目指するには側面方向への光出射効率が充分でない。   In Patent Documents 1 and 2 described above, luminance unevenness has been improved by disposing reflective members and laminating translucent members. In the flat type lighting device, in addition to the improvement of the unevenness, a reduction in thickness is required. As one of the means for solving the problem, one that uses light emitted from the side surface of the LED body light emitting device is known. In this method, light emitted from the side surface of the LED light-emitting device is first spread in the horizontal direction and then directed in the vertical direction (irradiation direction) by a reflector or the like, and an optical element such as a lens becomes unnecessary. However, in the LED light-emitting devices disclosed in Patent Documents 1 and 2, even if the luminance unevenness is improved, the light emission efficiency in the side surface direction is not sufficient for aiming at thinning the flat illumination device.

上記特許文献1に記載されたLED発光装置100の各光線P1、P2、P3に着目すると、図8に示す如く出射角の小さい光線P1、出射角の中間の大きさの光線P2は、点線で示す如く反射部材106と回路基板102の間で反射を繰り返したのち透光性樹脂104の側面より側面光Po1、Po2として出射する。これに対し出射角の大きい光線P3だけは、反射部材106の反射だけで透光性樹脂104の側面より側面光Po3として出射する。すなわちLED101から出射する強い光線P1,P2は透光性樹脂104の側面より出射するまでに反射部材106と回路基板102の間で反射を繰り返す。この結果、多くの発光成分は、反射による損失をともなってLED装置側面から出射するので光量が減り出射効率が悪くなる。   When attention is paid to the light beams P1, P2, and P3 of the LED light emitting device 100 described in Patent Document 1, a light beam P1 having a small emission angle and a light beam P2 having an intermediate size between the output angles are shown by dotted lines as shown in FIG. As shown in the figure, after reflection is repeated between the reflecting member 106 and the circuit board 102, the light is emitted as side light Po 1 and Po 2 from the side surface of the translucent resin 104. On the other hand, only the light beam P3 having a large emission angle is emitted as side light Po3 from the side surface of the translucent resin 104 only by the reflection of the reflection member 106. That is, the strong light beams P1 and P2 emitted from the LED 101 are repeatedly reflected between the reflecting member 106 and the circuit board 102 before being emitted from the side surface of the translucent resin 104. As a result, many light-emitting components are emitted from the side surface of the LED device with a loss due to reflection, so that the amount of light is reduced and the emission efficiency is deteriorated.

また、特許文献2に記載の半導体発光装置では、屈折率の異なる2層構成の封止樹脂によって、半導体発光素子の中心部分から出射する強い光線を中心部より外側に向かわせることができる。しかしながら特許文献2の構造では、上方向に出射する光線は進行方向がやや横方向に少し傾くだけでやはり上方向に向かうため、横方向の配光成分はそれほど多くならない。   Further, in the semiconductor light emitting device described in Patent Document 2, a strong light beam emitted from the central portion of the semiconductor light emitting element can be directed outward from the central portion by the two-layer sealing resin having different refractive indexes. However, in the structure of Patent Document 2, the light emitted in the upward direction is slightly inclined in the lateral direction and is also directed in the upward direction, so that the light distribution component in the lateral direction does not increase so much.

そこで本発明の目的は、上記問題点を解決しようとするものであり、半導体発光素子と、この半導体発光素子の側面及び上面を被覆する透光性樹脂と、この透光性樹脂の上面の設けられた反射部材とを有する半導体発光装置において、横方向に出射する光の取り出し効率を改善することである。   SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to solve the above-described problems. A semiconductor light emitting device, a translucent resin that covers the side surface and the upper surface of the semiconductor light emitting device, and an upper surface of the translucent resin are provided. In the semiconductor light emitting device having the reflection member thus formed, the extraction efficiency of the light emitted in the lateral direction is improved.

上記目的を達成するため本発明における半導体発光装置の構成は、下記の通りである。
半導体発光素子と前記半導体発光素子の側面及び上面を被覆する透光性樹脂と、該透光性樹脂の上部に設けられた第1の反射部材とを有する半導体発光装置において、前記第1の反射部材は平板状であり、前記透光性樹脂の上面と前記第1の反射部材の間に前記透光性樹脂より屈折率の低い平板状の低屈折率層を設け、前記半導体発光素子が突起電極を有し、前記透光性樹脂の下面に第2の反射部材を備え、該第2の反射部材から前記突起電極が露出していることを特徴とする。
In order to achieve the above object, the structure of the semiconductor light emitting device in the present invention is as follows.
In the semiconductor light-emitting device having a light-transmitting resin for covering the semiconductor light-emitting element side and top surfaces of the semiconductor light emitting element, and a first reflecting member provided on the upper portion of the light transmitting resin, the first reflection The member has a flat plate shape, a flat low refractive index layer having a lower refractive index than that of the light transmitting resin is provided between the upper surface of the light transmitting resin and the first reflecting member, and the semiconductor light emitting element projects. It has an electrode, The 2nd reflective member is provided in the lower surface of the said translucent resin, The said protruding electrode is exposed from this 2nd reflective member, It is characterized by the above-mentioned.

上記構成によれば、透光性樹脂の上面と反射部材の間に透明性樹脂より屈折率の低い低屈折率層を設けている。この低屈折率層により半導体発光素子から出射した光線が透光性樹脂から低屈折率層に入射するとき側面方向に屈折する。このため反射部材と回路基板の間での反射回数が減少し、横方向に出射する側面光が増加して横方向への光取り出し効率が改善する。また、回路基板の省略によって半導体発光装置の薄型化が可能となる。
According to the above configuration, the low refractive index layer having a refractive index lower than that of the transparent resin is provided between the upper surface of the translucent resin and the reflecting member. By this low refractive index layer, light emitted from the semiconductor light emitting element is refracted in the lateral direction when entering the low refractive index layer from the translucent resin. For this reason, the number of reflections between the reflecting member and the circuit board is reduced, and the side light emitted in the lateral direction is increased to improve the light extraction efficiency in the lateral direction. In addition, the semiconductor light emitting device can be thinned by omitting the circuit board.

前記透光性樹脂には前記半導体発光素子の発光を波長変換する蛍光粒子が混入されており、前記低屈折率層は透明であると良い。   The translucent resin is mixed with fluorescent particles for converting the wavelength of light emitted from the semiconductor light emitting element, and the low refractive index layer is preferably transparent.

上記構成によれば、半導体発光素子の発光の一部は透光性樹脂に含まれる蛍光体で波長変換される。蛍光体から出射する波長変換光は方位角依存性がないため反射部材に対し小さな入射角をもつ成分も含まれる。この小さな入射角をもつ光は横方向に出射しずらい。一方、低屈折率層は透明であるため新たな発光がなく、反射部材に対し小さな入射角をもつ成分を増加させることはない。このように低屈折率層が透明であると、小さな入射角をもつ成分が増加することによる損失を防ぐことができる。   According to the said structure, a part of light emission of a semiconductor light-emitting device is wavelength-converted with the fluorescent substance contained in translucent resin. Since the wavelength-converted light emitted from the phosphor has no azimuth angle dependency, a component having a small incident angle with respect to the reflecting member is also included. This light having a small incident angle is difficult to emit in the lateral direction. On the other hand, since the low refractive index layer is transparent, there is no new light emission, and a component having a small incident angle with respect to the reflecting member is not increased. Thus, when the low refractive index layer is transparent, loss due to an increase in components having a small incident angle can be prevented.

前記第1の反射部材が半透過反射層又は微細な貫通孔を有する反射板であると良い。   The first reflecting member may be a transflective layer or a reflecting plate having fine through holes.

前記反射部材は、低屈折率層の上面に金属性の反射層が蒸着又はスッパッタリングにより形成されると良い。   In the reflecting member, a metallic reflecting layer may be formed on the upper surface of the low refractive index layer by vapor deposition or sputtering.

上記製造方法によれば、まず低屈折率層と反射層とが一体化したフィルム状の屈折率反射層を準備する。この屈折率反射層は大判フィルムである。次に回路基板が連結した集合基板に実装され、透光性樹脂で封止された多数の半導体発光素子の上面にこの大判の屈折率反射層を一括して接着する。最後に集合基板を個々の半導体発光装置に切断分離すれば、半導体発光装置の効率的な量産化が可能となる。   According to the manufacturing method, first, a film-like refractive index reflective layer in which a low refractive index layer and a reflective layer are integrated is prepared. This refractive index reflective layer is a large format film. Next, the large refractive index reflective layer is bonded to the upper surfaces of a large number of semiconductor light emitting elements mounted on a collective substrate connected with circuit boards and sealed with a light-transmitting resin. Finally, if the aggregate substrate is cut and separated into individual semiconductor light emitting devices, efficient mass production of the semiconductor light emitting devices can be achieved.

上記の如く本発明によれば、透光性樹脂の上面と反射部材の間に前記透光性樹脂より屈折率の低い低屈折率層を設けることにより、透光性樹脂から低屈折率層へ入射する光が半導体発光装置の側面方向に屈折し、反射部材への入射角が大きくなる。この結果反射部材と回路基板の間での反射回数が減少し、横方向に出射する側面光が増加して横方向への光取り出し効率が改善する。   As described above, according to the present invention, by providing a low refractive index layer having a refractive index lower than that of the translucent resin between the upper surface of the translucent resin and the reflecting member, the translucent resin is changed to the low refractive index layer. Incident light is refracted in the side surface direction of the semiconductor light emitting device, and the incident angle to the reflecting member is increased. As a result, the number of reflections between the reflecting member and the circuit board is reduced, the side light emitted in the lateral direction is increased, and the light extraction efficiency in the lateral direction is improved.

本発明の第1実施形態におけるLED発光装置を示し、(a)は断面図、(b)は上面図、(c)は側面図、(d)は下面図である。The LED light-emitting device in 1st Embodiment of this invention is shown, (a) is sectional drawing, (b) is a top view, (c) is a side view, (d) is a bottom view. 図1(a)に示すLED発光装置の出射特性を示す断面図である。It is sectional drawing which shows the emission characteristic of the LED light-emitting device shown to Fig.1 (a). 図2に示すLED発光装置を側面反射器付きのマザー基板に取り付けた状態を示す断面図である。It is sectional drawing which shows the state which attached the LED light-emitting device shown in FIG. 2 to the mother board | substrate with a side reflector. 本発明のLED発光装置の第1製造方法における工程図である。It is process drawing in the 1st manufacturing method of the LED light-emitting device of this invention. 本発明のLED発光装置の第2製造方法における工程図である。It is process drawing in the 2nd manufacturing method of the LED light-emitting device of this invention. 本発明のLED発光装置の第3製造方法における工程図である。It is process drawing in the 3rd manufacturing method of the LED light-emitting device of this invention. 本発明の第2実施形態におけるLED発光装置の断面図である。It is sectional drawing of the LED light-emitting device in 2nd Embodiment of this invention. 従来技術のLED発光装置における出射特性を示す断面図である。It is sectional drawing which shows the emission characteristic in the LED light-emitting device of a prior art.

(第1実施形態)
以下図面により本発明の実施形態を説明する。図1は本発明の第1実施形態におけるLED発光装置10(半導体発光装置)を示し、(a)はLED発光装置10の断面図、(b)は(a)に示すLED発光装置10の上面図、(c)は側面図、(d)は下面図を示している。
(First embodiment)
Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows an LED light emitting device 10 (semiconductor light emitting device) according to a first embodiment of the present invention, where (a) is a cross-sectional view of the LED light emitting device 10, and (b) is an upper surface of the LED light emitting device 10 shown in (a). (C) is a side view, (d) is a bottom view.

図1(a)に示すLED発光装置10の断面図おいて、回路基板2の上面に設けられた2個の配線電極3aは、スルーホール電極3bを通して駆動電極3cに接続している。配線電極3aにはLED1がフリップチップ実装(以後FC実装と略記する)されている。LED1の上面及び側面は蛍光粒子を混入した透光性樹脂4(以後蛍光樹脂4と記す)で被覆されており、この蛍光樹脂4の上面には、蛍光樹脂4よりも屈折率の低い低屈折率層5が接着され、さらに低屈折率層5の上面には第1の反射部材である反射部材6が接着されている。   In the cross-sectional view of the LED light emitting device 10 shown in FIG. 1A, the two wiring electrodes 3a provided on the upper surface of the circuit board 2 are connected to the drive electrode 3c through the through-hole electrode 3b. The LED 1 is flip-chip mounted (hereinafter abbreviated as FC mounting) on the wiring electrode 3a. The upper surface and the side surface of the LED 1 are covered with a translucent resin 4 mixed with fluorescent particles (hereinafter referred to as a fluorescent resin 4), and the upper surface of the fluorescent resin 4 has a low refractive index having a refractive index lower than that of the fluorescent resin 4. The refractive index layer 5 is adhered, and the reflective member 6 as the first reflective member is adhered to the upper surface of the low refractive index layer 5.

次にLED発光装置10の全体構成を図1(b)〜(d)により説明する。
図1(b)はLED発光装置10の上面図であり、(a)は(b)のA−A断面図に該当する。(b)において反射部材6としては、適度の光透過性と適度の光反射性を有することが要求されており、例えばアクリル樹脂やエポキシ樹脂に酸化チタン等の反射材を混入した白色樹脂板や薄い金属層、微小貫通孔を有する金属板等が使用できる。
Next, the entire configuration of the LED light emitting device 10 will be described with reference to FIGS.
FIG. 1B is a top view of the LED light emitting device 10, and FIG. 1A corresponds to the AA cross-sectional view of FIG. In (b), the reflecting member 6 is required to have an appropriate light transmittance and an appropriate light reflectivity. For example, a white resin plate in which a reflective material such as titanium oxide is mixed in an acrylic resin or an epoxy resin, A thin metal layer, a metal plate having minute through holes, or the like can be used.

また、(c)に示す側面図の如く、回路基板2の上面には高屈折率の蛍光樹脂4と低屈折率層5とが2層構成されており、さらに低屈折率層5の上面に反射部材6が設けられている。上記高屈折率の蛍光樹脂4の透光性部材としては、耐光性が良く、屈折率の比較的高い、例えば屈折率が1.6程度のポリカ系樹脂、エポキシ系樹脂などが使用できる。また低屈折率層5としては、例えば屈折率1.4程度のシリコーン樹脂等が使用でき、屈折率が1.2〜1.3程度である透明樹脂を選択すればより好ましい。また、(d)はLED発光装置10の下面図であり、回路基板2の下面には2個の駆動電極3cが設けられている。   Further, as shown in the side view of (c), two layers of a high refractive index fluorescent resin 4 and a low refractive index layer 5 are formed on the upper surface of the circuit board 2, and further on the upper surface of the low refractive index layer 5. A reflection member 6 is provided. As the translucent member of the fluorescent resin 4 having a high refractive index, a polycarbonate resin, an epoxy resin, or the like having good light resistance and a relatively high refractive index, for example, a refractive index of about 1.6 can be used. As the low refractive index layer 5, for example, a silicone resin having a refractive index of about 1.4 can be used, and it is more preferable to select a transparent resin having a refractive index of about 1.2 to 1.3. (D) is a bottom view of the LED light emitting device 10, and two drive electrodes 3 c are provided on the bottom surface of the circuit board 2.

次に図2によりLED発光装置10の発光動作を説明する。図2は図1に示すLED発光装置10の発光状態を示す断面図であり、構成については図1(a)のLED発光装置10と同じであり、重複する説明は省略する。また、本実施形態においてはLED1として青色LED、蛍光樹脂4としてはLED1の青色発光を黄色光に変換するYAG蛍光樹脂を用い、LED発光装置10として白色光を出射する発光装置の事例について説明する。   Next, the light emitting operation of the LED light emitting device 10 will be described with reference to FIG. FIG. 2 is a cross-sectional view showing the light emission state of the LED light emitting device 10 shown in FIG. 1, and the configuration is the same as that of the LED light emitting device 10 of FIG. In this embodiment, a blue LED as the LED 1, a YAG fluorescent resin that converts blue light emitted from the LED 1 into yellow light as the fluorescent resin 4, and a light emitting device that emits white light as the LED light emitting device 10 will be described. .

LED発光装置10では駆動電極3cに駆動電流を供給することによってLED1が青色の光線P1,P2,P3等を出射する。その青色の光線の一部は図8に示した半導体発光装置100と同様に半透過性の反射部材6を透過して透過光Ps0、Ps1、Ps2として出射する。   In the LED light emitting device 10, the LED 1 emits blue light rays P1, P2, P3 and the like by supplying a drive current to the drive electrode 3c. A part of the blue light beam is transmitted through the semi-transmissive reflective member 6 and emitted as transmitted light Ps0, Ps1, and Ps2 as in the semiconductor light emitting device 100 shown in FIG.

次にLED1から出射する青色の光線P1,P2,P3の軌跡に付いて説明する。なお、青色の光線P1,P2,P3は、図8に示した光線P1,P2,P3と同じ角度で出射しているものとして比較説明する。
LED1から出射する光線のうち出射角の小さい青色の光線P1は、蛍光樹脂4と低屈折率層5との境界において屈折率差により外側(側面方向)に向くように屈折して進行する。続いて光線P1は反射部材6によって反射した後、再度低屈折率層5と蛍光樹脂4の境界で内側(側面とは反対方向)に向くように屈折する。最後に光線P1は、回路基板2で反射し、蛍光樹脂4の側面から側面光Po1としてLED発光装置10の横方向に出射する。
Next, the locus of the blue light beams P1, P2, P3 emitted from the LED 1 will be described. Note that the blue light beams P1, P2, and P3 are described as being emitted at the same angle as the light beams P1, P2, and P3 shown in FIG.
Of the light rays emitted from the LED 1, the blue light ray P 1 having a small emission angle proceeds while being refracted so as to be directed outward (side direction) due to the difference in refractive index at the boundary between the fluorescent resin 4 and the low refractive index layer 5. Subsequently, the light beam P <b> 1 is reflected by the reflecting member 6, and then refracted again toward the inner side (the direction opposite to the side surface) at the boundary between the low refractive index layer 5 and the fluorescent resin 4. Finally, the light beam P1 is reflected by the circuit board 2 and is emitted from the side surface of the fluorescent resin 4 in the lateral direction of the LED light emitting device 10 as side surface light Po1.

また、出射角が中くらいの青色の光線P2と出射角が大きい青色の光線P3も、蛍光樹脂4と低屈折率層5との境界において屈折率差により外側に向くように屈折して進行する。光線P2,P3は、反射部材6によって反射するが、反射部材6への入射角が大きいため低屈折率層5の側面から直接側面光Po2、Po3として出射する。   Further, the blue light beam P2 having a medium emission angle and the blue light beam P3 having a large emission angle are also refracted so as to be directed outward due to the refractive index difference at the boundary between the fluorescent resin 4 and the low refractive index layer 5. . The light beams P2 and P3 are reflected by the reflecting member 6, but are emitted as side light beams Po2 and Po3 directly from the side surface of the low refractive index layer 5 because the incident angle to the reflecting member 6 is large.

上記の如く、LED発光装置10において低屈折率層5を設けることにより、青色の光線P1,P2,P3の反射部材6への入射角は大きくなる。すなわち出射角の小さい青色の光線P1であっても反射部材6と回路基板2との反射を1回ずつ行うだけで側面光Po1として出射し、出射角の大きい青色の光線P2、P3なら反射部材6の反射のみで側面光Po2、Po3として出射する。このようにLED発光装置10は、反射回数の減少によって横方向への光取り出し効率が改善されていることが分かる。   As described above, by providing the low refractive index layer 5 in the LED light emitting device 10, the incident angle of the blue light beams P1, P2, P3 to the reflecting member 6 is increased. That is, even the blue light beam P1 having a small emission angle is emitted as the side light Po1 by performing the reflection between the reflection member 6 and the circuit board 2 only once, and the blue light beams P2 and P3 having a large emission angle are reflected by the reflection member. 6 is emitted as side light Po2 and Po3 only by reflection. Thus, it can be seen that the LED light emitting device 10 has improved light extraction efficiency in the lateral direction due to a decrease in the number of reflections.

以上の結果について図8で示したLED発光装置100の光線の軌跡と、LED発光装置10の光線の軌跡とを比較してみる。LED発光装置100の光線の軌跡では側面光として出射するまでに光線P1が4回反射し、光線P2でも2回反射していたのに対しLED発光装置10の光線の軌跡では、青色の光線P1が2回の反射により側面光として出射し、青色の光線P2,P3にいたっては反射部材6への一回だけの反射により側面光として出射している。このようにしてLED発光装置100に対し、LED発光装置10は反射に伴う発光の減衰が少なくなり、横方向への光出し効率が改善している。またYAG蛍光体による発光もLED1からの発光と同様に低屈折率層5により側面から効率よく出射する。   Regarding the above results, the locus of the light beam of the LED light emitting device 100 shown in FIG. 8 is compared with the locus of the light beam of the LED light emitting device 10. In the locus of the light beam of the LED light emitting device 100, the light ray P1 is reflected four times before being emitted as side light, and the light ray P2 is also reflected twice. In the locus of the light ray of the LED light emitting device 10, the blue light ray P1 is reflected. Is emitted as side light by two reflections, and the blue light beams P2 and P3 are emitted as side light by only one reflection on the reflecting member 6. In this way, the LED light emitting device 10 is less attenuated in light emission due to the reflection than the LED light emitting device 100, and the light emission efficiency in the lateral direction is improved. Similarly to the light emission from the LED 1, the light emission by the YAG phosphor is efficiently emitted from the side surface by the low refractive index layer 5.

次に図3によりLED発光装置10を平面型照明装置に適用する場合を説明する。図3は、LED装置10を平面型照明装置に適用する場合の一例を示しており、この平面型照明装置において側面反射器16を設けたマザー基板12にLED発光装置10を実装した状態を示す断面図である。LED発光装置10の構成及び光線の軌跡については図2に示すLED発光装置10と同じであり、重複する説明は省略する。側面反射器16はLED発光装置10の周囲に配置する。このとき平面型照明装置はLED発光装置10の上方の広い範囲に亘って均一に配光しなければならないので、側面反射器16をLED発光装置10から充分に離し、反射部の傾斜を緩くしておく必要がある。なお図3では説明のため側面反射器16をLED発光装置10に近づけており、反射部の傾斜もきつくなっている。また側面反射器16斜面は拡散反射する。   Next, the case where the LED light emitting device 10 is applied to a flat illumination device will be described with reference to FIG. FIG. 3 shows an example when the LED device 10 is applied to a flat illumination device, and shows a state in which the LED light emitting device 10 is mounted on a mother substrate 12 provided with a side reflector 16 in the flat illumination device. It is sectional drawing. The configuration of the LED light-emitting device 10 and the locus of light rays are the same as those of the LED light-emitting device 10 shown in FIG. The side reflector 16 is disposed around the LED light emitting device 10. At this time, since the flat illumination device has to distribute light uniformly over a wide range above the LED light emitting device 10, the side reflector 16 is sufficiently separated from the LED light emitting device 10, and the inclination of the reflecting portion is relaxed. It is necessary to keep. In FIG. 3, the side reflector 16 is brought close to the LED light emitting device 10 for the sake of explanation, and the inclination of the reflecting portion is also tight. The slope of the side reflector 16 is diffusely reflected.

LED装置10の側面から出射した側面光Po1は直接的に図の上方に向かい、側面光Po2,po3は側面反射器16で反射し上方へ向かう。なお図3で示した側面反射器16とマザー基板12は平面型照明装置の光源部の一部である。側面光Po2、Po3は、直接出射された側面光Po1とともに上方向にむかって広がるため、平面型照明装置を薄型化できる。   The side light Po1 emitted from the side surface of the LED device 10 is directly directed upward in the figure, and the side light Po2 and po3 are reflected by the side reflector 16 and directed upward. The side reflector 16 and the mother substrate 12 shown in FIG. 3 are part of the light source unit of the flat illumination device. Since the side light Po2 and Po3 spread upward along with the directly emitted side light Po1, the flat illumination device can be thinned.

(第1製造方法)
次に図4によりLED発光装置10の第1製造方法について説明する。図4はLED発光装置10の製造工程を示し、(a)はLED実装工程を示し、回路基板2上にLED1をFC実装した状態を示す断面図である。(b)は透光性樹脂封止工程を示し、回路基板2上にFC実装したLED1の側面及び上面を蛍光樹脂4で被覆した状態を示す断面図である。(c)は低屈折率層形成工程を示し、蛍光樹脂4の上面に低屈折率層5を形成した状態を示す断面図である。(d)は反射層形成工程を示し、低屈折率層5の上面に、反射部材6を接着した断面図である。そして(d)の構成は図1(a)に示す半導体発光装置10の完成図である。
(First manufacturing method)
Next, a first manufacturing method of the LED light emitting device 10 will be described with reference to FIG. FIG. 4 shows a manufacturing process of the LED light emitting device 10, (a) shows an LED mounting process, and is a cross-sectional view showing a state where the LED 1 is FC-mounted on the circuit board 2. (B) is a cross-sectional view showing a translucent resin sealing step, in which a side surface and an upper surface of the LED 1 FC-mounted on the circuit board 2 are covered with the fluorescent resin 4. (C) is a cross-sectional view showing a state where the low refractive index layer 5 is formed on the upper surface of the fluorescent resin 4, showing the low refractive index layer forming step. (D) is a cross-sectional view showing a reflective layer forming step in which the reflective member 6 is bonded to the upper surface of the low refractive index layer 5. And the structure of (d) is the completion figure of the semiconductor light-emitting device 10 shown to Fig.1 (a).

(第2製造方法)
次に図5によりLED発光装置10の第2製造方法について説明する。図5はLED発光装置10の第2製造工程を示している。図5の(a),(b)で示した製造工程は図4に示す第1製造方法の(a),(b)と同じであり、重複する説明は省略する。すなわち図5に示す第2製造方法において、図4に示す第1製造方法と異なるところは、図4(c)に示す低屈折率層形成工程が、図5(c)では屈折率反射層形成工程となっているところである。屈折率反射層形成工程では予め低屈折率層5と反射部材6を一体化し、屈折率反射層7を形成する。屈折率反射層7は低屈折率樹脂よりなるフィルム(低屈折率層5)の上面に金属性の反射部材6を接着、または蒸着、スパッタリング等により形成している。(d)は接着工程であり、(b)の透光性樹脂封止工程で作成した蛍光樹脂4の上面に屈折率反射層7を接着する様子を示している。そして(d)の構成は図1(a)に示す半導体発光装置10の完成図である。
(Second manufacturing method)
Next, a second manufacturing method of the LED light emitting device 10 will be described with reference to FIG. FIG. 5 shows a second manufacturing process of the LED light emitting device 10. The manufacturing steps shown in FIGS. 5A and 5B are the same as (a) and (b) in the first manufacturing method shown in FIG. That is, the second manufacturing method shown in FIG. 5 differs from the first manufacturing method shown in FIG. 4 in that the low refractive index layer forming step shown in FIG. It is a process. In the refractive index reflective layer forming step, the low refractive index layer 5 and the reflective member 6 are integrated in advance to form the refractive index reflective layer 7. The refractive index reflective layer 7 is formed by bonding a metal reflective member 6 on the upper surface of a film (low refractive index layer 5) made of a low refractive index resin, vapor deposition, sputtering, or the like. (D) is an adhesion process, and shows a state in which the refractive index reflective layer 7 is adhered to the upper surface of the fluorescent resin 4 created in the translucent resin sealing process of (b). And the structure of (d) is the completion figure of the semiconductor light-emitting device 10 shown to Fig.1 (a).

(第3製造方法)
次に図6によりLED発光装置10の第3製造方法について説明する。図6に示す製造方法は基本的には図5に示す第2製造方法と同じであり、集合工法を適用したものである。図6に示す第3製造方法において、図5に示す第2製造方法と最も異なるところは屈折率反射層7aの作り方である。屈折率反射層7aは、図6(a)に示すごとく低屈折率樹脂の大判シート状の低屈折率層5a上面に金属性の反射層6aを蒸着またはスッパタリングにより形成して作成している。
(Third production method)
Next, a third manufacturing method of the LED light emitting device 10 will be described with reference to FIG. The manufacturing method shown in FIG. 6 is basically the same as the second manufacturing method shown in FIG. 5, and an assembly method is applied. In the third manufacturing method shown in FIG. 6, the most different point from the second manufacturing method shown in FIG. 5 is how to make the refractive index reflection layer 7a. As shown in FIG. 6A, the refractive index reflective layer 7a is formed by forming a metallic reflective layer 6a on the upper surface of a low refractive index resin large-sized low refractive index layer 5a by vapor deposition or sputtering. .

そして(b)に示す如く、まず回路基板2が多数個連結した集合基板2aを準備し、続いて集合基板2a上にLEDを実装し、LED1を蛍光樹脂4で封止してから、最後にLED1の上面に一括して屈折率反射層7aを接着する。その後(c)に示すように切断線Cに沿って切断分離して(d)に示す半導体発光装置10を多数個同時生産する。以上の如く大判シート状の屈折率反射層7aを作成しておくことによって、半導体発光装置10の量産を容易に行うことができる。   Then, as shown in (b), first, a collective substrate 2a in which a large number of circuit boards 2 are connected is prepared, then LEDs are mounted on the collective substrate 2a, LED1 is sealed with a fluorescent resin 4, and finally The refractive index reflection layer 7a is adhered to the upper surface of the LED 1 at once. Thereafter, as shown in (c), the semiconductor light-emitting device 10 shown in (d) is simultaneously produced by cutting and separating along the cutting line C. As described above, the production of the semiconductor light emitting device 10 can be easily performed by preparing the large-sized sheet-like refractive index reflective layer 7a.

(第2実施形態)
LED発光装置10は回路基板2を備えていた。回路基板2にはさまざまな機能があり、その一つとしてLED1の電極ピッチをマザー基板の電極ピッチに合わせている(インターポーザという)。最近ではLED1が大型化してきており、LED1の電極ピッチをマザー基板の電極ピッチに直接的に適合できるようになってきた。この場合、回路基板2を省略できる場合がある。そこで図7により本発明の第2実施形態として、回路基板がなく、あわせて上面に配置した反射部材が異なる形式のLED発光装置20を説明する。図7はLED発光装置20を示す断面図である。LED発光装置20の基本的構成及び発光特性は図2に示すLED発光装置10と同じであり、同一部材には同一番号を付し、重複する説明は省略する。
(Second Embodiment)
The LED light emitting device 10 was provided with a circuit board 2. The circuit board 2 has various functions, and as one of them, the electrode pitch of the LED 1 is adjusted to the electrode pitch of the mother board (referred to as an interposer). Recently, the size of the LED 1 has increased, and the electrode pitch of the LED 1 can be directly adapted to the electrode pitch of the mother substrate. In this case, the circuit board 2 may be omitted. Accordingly, referring to FIG. 7, as a second embodiment of the present invention, an LED light emitting device 20 of a type that has no circuit board and has different reflecting members disposed on the upper surface will be described. FIG. 7 is a cross-sectional view showing the LED light emitting device 20. The basic configuration and light emission characteristics of the LED light-emitting device 20 are the same as those of the LED light-emitting device 10 shown in FIG. 2, and the same members are denoted by the same reference numerals and redundant description is omitted.

図7に示すLED発光装置20は、LED21の側面及び上面を蛍光樹脂4(透光性樹脂)で被覆し、蛍光樹脂4の上面に低屈折率層5と第1の反射部材26が積層している。またLED発光装置20は、LED1の電極面側に第2の反射部材23が配設され、反射部材23から突起電極21aが底面側に露出している。LED発光装置20は突起電極21aをマザー基板との接続用電極とすることにより回路基板を省略し薄型化している。   In the LED light emitting device 20 shown in FIG. 7, the side surface and the upper surface of the LED 21 are covered with the fluorescent resin 4 (translucent resin), and the low refractive index layer 5 and the first reflecting member 26 are laminated on the upper surface of the fluorescent resin 4. ing. In the LED light emitting device 20, the second reflecting member 23 is disposed on the electrode surface side of the LED 1, and the protruding electrode 21 a is exposed from the reflecting member 23 to the bottom surface side. The LED light emitting device 20 is thinned by omitting the circuit board by using the protruding electrode 21a as an electrode for connection with the mother board.

また、反射部材26は、高い反射性の金属板からなり、透光用の微細な複数の貫通孔26aを有する。上記構成の反射部材26においては反射率の高いAl等の金属板を用いることによって、青色の光線P1,P2、P3の反射損失を低減し、横方向に出射される側面光Po1、Po2、Po3の光量をさらに増加させることができる(蛍光体による発光も同様)。また、通過光Ps0、Ps1等も直接微細孔26aを通過して出射されるため光量の減衰が少なくなる。この結果、全体としてLED発光装置20を明るくできる。   The reflecting member 26 is made of a highly reflective metal plate and has a plurality of fine through holes 26a for light transmission. In the reflection member 26 having the above-described configuration, the reflection loss of the blue light beams P1, P2, and P3 is reduced by using a highly reflective metal plate such as Al, and the side light beams Po1, Po2, and Po3 emitted in the lateral direction are reduced. Can be further increased (the same applies to light emission by the phosphor). Further, since the passing lights Ps0, Ps1, etc. are directly emitted through the fine holes 26a, the amount of light attenuation is reduced. As a result, the LED light emitting device 20 can be brightened as a whole.

1,21,101 LED(半導体発光素子)
2,102 回路基板
2a 集合基板
3a 配線電極
3b スルーホール電極
3c 駆動電極
4,104 蛍光樹脂(透光性樹脂)
5 低屈折率層
6,26,106 反射部材
10,20,100 LED発光装置(半導体発光装置)
12 マザー基板
16 側面反射器
21a 突起電極
23 第2反射部材
26a 貫通孔
P1,P2,P3 光線
Ps,Ps1,Ps2 透過光
Po,Po1〜Po4 側面光

1,21,101 LED (semiconductor light emitting device)
2,102 Circuit board 2a Assembly board 3a Wiring electrode 3b Through-hole electrode 3c Drive electrode 4,104 Fluorescent resin (translucent resin)
5 Low refractive index layer 6, 26, 106 Reflective member 10, 20, 100 LED light emitting device (semiconductor light emitting device)
12 Mother board 16 Side reflector 21a Protruding electrode 23 Second reflecting member 26a Through hole P1, P2, P3 Ray Ps, Ps1, Ps2 Transmitted light Po, Po1-Po4 Side light

Claims (4)

半導体発光素子と前記半導体発光素子の側面及び上面を被覆する透光性樹脂と、該透光性樹脂の上部に設けられた第1の反射部材とを有する半導体発光装置において、前記第1の反射部材は平板状であり、前記透光性樹脂の上面と前記第1の反射部材の間に前記透光性樹脂より屈折率の低い平板状の低屈折率層を設け、前記半導体発光素子が突起電極を有し、前記透光性樹脂の下面に第2の反射部材を備え、該第2の反射部材から前記突起電極が露出していることを特徴とする半導体発光装置。 In the semiconductor light-emitting device having a light-transmitting resin for covering the semiconductor light-emitting element side and top surfaces of the semiconductor light emitting element, and a first reflecting member provided on the upper portion of the light transmitting resin, the first reflection The member has a flat plate shape, a flat low refractive index layer having a lower refractive index than that of the light transmitting resin is provided between the upper surface of the light transmitting resin and the first reflecting member, and the semiconductor light emitting element projects. A semiconductor light emitting device comprising an electrode, comprising a second reflecting member on a lower surface of the translucent resin, wherein the protruding electrode is exposed from the second reflecting member. 前記透光性樹脂には前記半導体発光素子の発光を波長変換する蛍光粒子が混入されており、前記低屈折率層は透明であることを特徴とする請求項1に記載の半導体発光装置。   The semiconductor light emitting device according to claim 1, wherein the translucent resin is mixed with fluorescent particles for converting the wavelength of light emitted from the semiconductor light emitting element, and the low refractive index layer is transparent. 前記第1の反射部材が半透過反射層又は微細な貫通孔を有する反射板であることを特徴とする請求項1又は2に記載の半導体発光装置。   3. The semiconductor light emitting device according to claim 1, wherein the first reflection member is a transflective layer or a reflection plate having a fine through hole. 前記第1の反射部材は、低屈折率層の上面に金属性の反射層が蒸着またはスッパッタリングにより形成されたことを特徴とする請求項1から3のいずれか一項に記載の半導体発光装置。 4. The semiconductor light emitting device according to claim 1, wherein the first reflecting member has a metallic reflecting layer formed on the upper surface of the low refractive index layer by vapor deposition or sputtering. 5. apparatus.
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