JP6019906B2 - Light emitting device and manufacturing method thereof - Google Patents

Description

  The present invention relates to a light emitting device and a method for manufacturing the same.

  Conventionally, there has been proposed a light emitting device in which a resin frame is provided in an annular shape on a substrate, a portion surrounded by the resin frame is divided into two or more areas by a resin partition, and a light emitting portion is formed in each area. (See Patent Document 1).

JP 2012-4519 A

  However, the conventional light emitting device is still large.

  Therefore, an object of the present invention is to provide a light emitting device that is smaller than the conventional one.

  According to the present invention, the above problem is solved by the following means. That is, a substrate, a plurality of light emitting elements mounted on the substrate, a first resin that surrounds the plurality of light emitting elements, a second resin that has a partition portion that partitions an area surrounded by the first resin, The second resin has a terminal portion connected to the partition portion and formed on the first resin along the first resin. .

1 is a schematic perspective view of a light emitting device according to a first embodiment of the present invention. It is a figure explaining the manufacturing method of the light-emitting device which concerns on 1st Embodiment of this invention. It is a figure explaining the manufacturing method of the light-emitting device which concerns on 1st Embodiment of this invention. It is a figure explaining the manufacturing method of the light-emitting device which concerns on 1st Embodiment of this invention. It is a figure explaining the manufacturing method of the light-emitting device which concerns on 1st Embodiment of this invention. It is a figure explaining the manufacturing method of the light-emitting device which concerns on 1st Embodiment of this invention. It is a figure explaining the manufacturing method of the light-emitting device which concerns on 1st Embodiment of this invention. It is a schematic perspective view of the light-emitting device which concerns on 2nd Embodiment of this invention.

  EMBODIMENT OF THE INVENTION Below, the form for implementing this invention is demonstrated, referring attached drawing.

  FIG. 1 is a schematic perspective view of a light emitting device according to a first embodiment of the present invention.

  As shown in FIG. 1, the light emitting device 10 according to the first embodiment of the present invention includes a substrate 20, a plurality of light emitting elements 30 mounted on the substrate 20 (the light emitting element 30 includes a second resin 50, a second resin 50, and a second resin 50. Since it is covered with the first sealing member 60 and the second sealing member 70, it does not appear in FIG. 1), and is surrounded by the first resin 40 and the first resin 40 that surround the plurality of light emitting elements 30. The second resin 50 having a partition portion 50 a for partitioning the region, the first sealing member 60 and the second sealing member 70 covering the plurality of light emitting elements 30, and the plurality of light emitting elements 30 provided on the substrate 20. And a wiring pattern 80 connected thereto.

  Here, the 2nd resin 50 has the termination | terminus part 50b. The end portion 50 b is connected to the partition portion 50 a and is formed along the first resin 40 on the first resin 40. The light emitting device 10 according to the first embodiment of the present invention has such a terminal portion 50b for the following reason.

  That is, in general, when a resin is applied, the resin is discharged from a nozzle and applied onto the substrate. However, since the resin has a certain viscosity, it cannot be immediately separated from the nozzle even after it has been applied in place. That is, since the nozzle and the resin are connected even if the discharge of the resin from the nozzle is stopped, in order to separate the nozzle and the resin, it is necessary to further move the nozzle and attach the excess resin to the substrate. Therefore, the area on the substrate is wasted correspondingly.

  Therefore, in the light emitting device 10 according to the first embodiment of the present invention, the first resin 40 is formed in a shape surrounding the plurality of light emitting elements 30, so that the excess resin when the application is finished is added. The first resin 40 itself is attached (more specifically, the excess resin is attached to the first resin 40 along the start end portion 40a on the start end portion 40a of the first resin 40 as the end portion 40b. 2A to F for the start end 40a and the end 40b of the first resin 40), and the second resin 50 from the inside to the outside of the region surrounded by the first resin 40. This was applied to 40 until the partition portion 50a was reached, and then the excess resin was attached to the first resin 40 along the first resin 40 as the end portion 50b.

  In this case, since the excess resin of the first resin 40 and the second resin 50 does not adhere to the substrate 20, it is not necessary to secure a region for attaching these on the substrate 20, and the substrate 20 is reduced in size. As a result, it is possible to provide a light-emitting device that is smaller than the conventional one.

  Note that it is also possible to obtain a small light emitting device by forming the first resin 40 after the second resin 50 is formed (that is, the terminal portion 50b of the second resin 50 is located under the first resin 40). May be formed). However, in the case of this form, the second resin 50 is pulled in the direction in which the first resin 40 is formed at the portion where the first resin 40 and the second resin 50 intersect, and the second resin 50 is maintained in a desired shape. It is difficult. Therefore, as in the first embodiment of the present invention, the second resin 50 is formed after the first resin 40 is formed (that is, the terminal portion 50b of the second resin 50 is formed on the first resin 40). Is preferred.

  Hereinafter, the configuration of each member will be described in detail.

[substrate]
For the substrate 20, for example, ceramics (Al ₂ O ₃ , AlN, etc.), phenol resin, epoxy resin, polyimide resin, BT resin (bismaleimide triazine resin), polyphthalamide (PPA) resin, or the like can be used.

[First resin, second resin]
For the first resin 40, for example, a light-reflective resin such as a phenol resin, an epoxy resin, a BT resin, a PPA resin, or a silicon resin containing a reflective member such as TiO ₂ , Al ₂ O ₃ , ZrO ₂ , or MgO is used. Can be used. Moreover, for the second resin 50, for example, a light-reflective resin such as a silicon resin, an epoxy resin, or a urea resin, or a light-transmitting resin can be used. The second resin 50 may contain a colorant, a light diffusing agent, and the like.

  In the case where a translucent resin is used for the second resin 50, in the second resin 50, light in adjacent regions (a first region 20a, a second region 20b, a third region 20c, and a fourth region 20d described later) is mixed in color. Can be made. In addition, when a part of the plurality of light emitting elements 30 is covered with the translucent second resin 50, the light from the light emitting elements 30 is particularly easily transmitted through the second resin 50.

  At this time, if the second resin 50 is formed to the outside of the first resin 40, it looks like it shines on the outside of the first resin 40 at the time of driving, and thus the appearance is impaired.

  However, in the light emitting device 10 according to the first embodiment of the present invention, the terminal portion 50b of the second resin 50 is not formed in line with the partition portion 50a, but is bent from the partition portion 50a and overlapped with the first resin 40. Forming. Therefore, the light transmitted through the second resin 50 is not emitted outside the first resin 40, and a light emitting device that is excellent in appearance can be obtained.

  When the second resin 50 is formed under the first resin 40, the outer side of the first resin 40 is driven when the terminal portion 50 b of the second resin 50 is covered with the first resin 40. It does n’t look like it ’s shining.

  The thickness of the second resin 50 can be made thinner than the thickness of the first resin 40. Thus, when the second resin 50 is formed so as to overlap the first resin 40, the second resin 50 hangs outside the first resin 40 (the second resin 50 is formed under the first resin 40. In this case, it is easy to prevent the first resin 40 from protruding to the outside. The thickness of the first resin 40 is preferably 0.5 mm to 1.5 mm, more preferably 0.8 mm to 1.2 mm, and the thickness of the second resin 50 is preferably 0.4 mm to 1.4 mm. More preferably, it is 0.7 mm to 1.1 mm.

  The region surrounded by the first resin 40 includes a first region 20a, a second region 20b, a third region 20c, and a fourth region 20d separated by a partition 50a of the second resin 50. In the first embodiment of the present invention, the shape of the region surrounded by the first resin 40 is a circle, but it may be a polygon such as a quadrangle, hexagon, or octagon. Moreover, although 1st Embodiment of this invention demonstrates the form divided into four area | regions, the area | region enclosed by the 1st resin 40 is divided into 2 area | regions or three by the partition part 50a of the 2nd resin 50. It can be separated into regions, or it can be separated into five or more regions.

[Light emitting element]
The light emitting element 30 is provided in the first region 20a, the second region 20b, the third region 20c, the fourth region 20d, and a gap formed between these regions (a region where the partition portion 50a of the second resin 50 is provided). Has been implemented. A part of the plurality of light emitting elements 30 (the light emitting elements 30 mounted in the gaps formed between the regions) is covered with a partition 50 a of the second resin 50. As the light emitting element 30, for example, various light emitting diodes that emit light such as blue, blue green, green, and red can be used.

  In the first embodiment of the present invention, a light emitting element that emits blue light is used as the light emitting element 30 mounted in the first region 20a to the fourth region 20d, and gaps (partitions of the second resin 50) generated between the regions are used. A light emitting element that emits blue-green light is used as the light emitting element 30 mounted in the region where the portion 50a is provided.

  The light emitting elements 30 mounted on the first region 20a and the third region 20c are for exciting a first phosphor (not shown) included in the first sealing member 60, and the second region 20b and the second region 20c. The light emitting element 30 mounted in the four regions 20d is for exciting a second phosphor (not shown) included in the second sealing member 70. Moreover, the light emitting element 30 mounted in the gap (area where the partition part 50a of the second resin 50 is provided) generated between the areas is for further improving the color rendering.

  Note that the above is an example, and in what region the light emitting element that emits light of which color may be mounted may be determined by comprehensively considering luminance, color rendering, and the like of the entire light emitting device.

[Phosphor, sealing member]
The light emitting elements 30 mounted on the first region 20a and the third region 20c are sealed by a first sealing member 60 containing a first phosphor (not shown), and the second region 20b and the fourth region 20d. The light emitting element 30 mounted on is sealed with a second sealing member 70 containing a second phosphor (not shown).

  For example, a YAG phosphor that emits yellow light can be used as the first phosphor (not shown), and a CASN phosphor that emits red light can be used as the second phosphor (not shown). . In this way, since a plurality of phosphors having different emission colors are not mixed in one region, double excitation of the phosphors is suppressed, and a light emitting device with high luminance can be provided. Further, since two types of phosphors (yellow and red) having different emission colors are used as the light emitting device 10 as a whole, a color rendering property exceeding a certain level can be obtained.

  For the first sealing member 60 and the second sealing member 70, silicon resin, epoxy resin, urea resin, or the like can be used. Further, the first sealing member 60 and the second sealing member 70 may contain a colorant, a light diffusing agent, and the like. Different types of sealing members may be used for the first sealing member 60 and the second sealing member 70.

  A covering member that covers the first sealing member 60 and the second sealing member 70 may be provided. Such a covering member is provided, for example, on the inner side of the outer edge of the first resin 40, and is a partition between the first region 20 a, the second region 20 b, the third region 20 c, the fourth region 20 d, and the second resin 50. All the areas provided with 50a are integrally covered. As a material for the covering member, silicon resin, epoxy resin, urea resin, or the like can be used. The covering member may contain a colorant, a light diffusing agent, and the like.

[Wiring pattern]
As the wiring pattern 80, Au or the like can be used.

[Production method]
2A to 2F are views for explaining a method for manufacturing a light emitting device according to the first embodiment of the present invention, in which (a) is a plan view, (b) is a side view, and (c) is ( It is AA sectional drawing in a).

  As shown in FIG. 2, in the first embodiment of the present invention, the first resin 40 and the second resin 50 are formed on the substrate 20 on which the plurality of light emitting elements 30 are mounted by the process described below.

(First resin forming step)
First, as shown in FIG. 2A, the first resin 40 surrounding the plurality of light emitting elements 30 is applied onto the substrate 20 by discharging the first resin 40 from the first nozzle 100a.

  Thereafter, as shown in FIG. 2B, the first resin 40 is disconnected from the first nozzle 100 a by stopping the discharge of the first resin 40 and moving the first nozzle 100 a along the first resin 40. Thereby, the terminal portion 40b of the first resin 40 is formed on the starting end portion 40a of the first resin 40. In this way, excess resin does not adhere to the substrate 20 when the first resin 40 is applied.

(Second resin forming step)
Next, as shown in FIG. 2C, the second resin 50 is discharged onto the substrate 20 from the inside to the outside of the region surrounded by the first resin 40 by discharging the second resin 50 from the second nozzle 100b. Apply.

  Thereafter, as shown in FIG. 2D, the second resin 50 is separated from the second nozzle 100 b by stopping the discharge of the second resin 50 and moving the second nozzle 100 b along the first resin 40. Thereby, the terminal portion 50 b of the second resin 50 is formed on the first resin 40. In this way, excess resin does not adhere to the substrate 20 when the second resin 50 is applied.

(repetition)
Next, as shown in FIG. 2E, the region surrounded by the first resin 40 is partitioned by the second resin 50 by repeating the second resin formation step. Thereby, the partition part 50a of the second resin 50 is formed, and the region surrounded by the first resin 40 is divided into the first region 20a, the second region 20b, the third region 20c, and the fourth region 20d. Further, a part of the plurality of light emitting elements 30 (the light emitting elements 30 mounted in the gaps formed between the regions) is covered with the partition portion 50 a of the second resin 50. In the embodiment of the present invention, the four second resins 50 are connected by overlapping the start ends of the second resins 50. Since the second resin 50 has a certain fluidity, the surface of the second resin 50 is almost flat even in the overlapped portion.

(Sealing process)
Then, as shown in FIG. 2F, the light emitting element 30 mounted in the first region 20a and the third region 20c is sealed with a first sealing member 60 containing a first phosphor (not shown), The light emitting elements 30 mounted in the second region 20b and the fourth region 20d are sealed with a second sealing member 70 containing a second phosphor (not shown).

  FIG. 3 is a schematic perspective view of a light emitting device according to the second embodiment of the present invention.

  As shown in FIG. 3, the light emitting device 110 according to the second embodiment of the present invention is different from the light emitting device according to the first embodiment of the present invention in that two second resins 50 are formed adjacent to each other. Is different.

  As described above, a part of the plurality of light emitting elements 30 is covered with the partition portion 50a of the second resin 50. According to the light emitting device according to the second embodiment of the present invention, the plurality of light emitting elements 30 are Even if they are arranged slightly deviated, they can be covered without leakage. 3 shows a state in which the partition portions 50a of the two adjacent second resins 50 are separated from each other, the partition portions 50a of the two adjacent second resin 50 may partially overlap each other. Needless to say.

Note that the second resin 50 in two, which is formed adjacently, the end portion 50b, are attached toward the opposite direction to each other along the first resin 40 on the first resin 40. Therefore, according to the light emitting device 110 according to the second embodiment of the present invention, the terminal portion 50b of the second resin 50 is not bulky, and a small light emitting device can be provided.

By moving the second nozzle 100b toward the opposite direction to each other along the first resin 40 on the first resin 40, the end portion 50b of the second resin 50 in two, which is formed adjacent, it can be attached towards the opposite direction to each other along the first resin 40 on the first resin 40.

  As mentioned above, although embodiment of this invention was described, these description is related with an example of this invention, and this invention is not limited at all by these description.

DESCRIPTION OF SYMBOLS 10 Light-emitting device 20 Board | substrate 20a 1st area | region 20b 2nd area | region 20c 3rd area | region 20d 4th area | region 30 Light emitting element 40 1st resin 40a Start end part 40b End part 50 Second resin 50a Partition part
50b Termination part 60 1st sealing member 70 2nd sealing member 80 Wiring pattern 100a 1st nozzle 100b 2nd nozzle 110 Light-emitting device

Claims (10)

A substrate, a plurality of light-emitting elements mounted on the substrate, a first resin surrounding the plurality of light-emitting elements, and a second resin having a partition part that partitions an area surrounded by the first resin. A light emitting device,
The first resin is a light-reflective resin;
The second resin is a translucent resin and has a terminal portion connected to the partition portion and formed along the first resin on the first resin.
A light emitting device characterized by that. The light emitting device according to claim 1 in part, wherein the benzalkonium covered by the partition portion before Symbol second resin of said plurality of light emitting elements. The second resin is light-emitting device according to claim 1 or 2, characterized in the Turkey are formed adjacent two. The adjacent two second resin that is formed has a feature that the end portion is formed toward the opposite direction to each other along said first resin in the first on the resin, that The light emitting device according to claim 3 . The region surrounded by the first resin has a first region and a second region separated by the partition part,
The light emitting device mounted in the first region is sealed by a first sealing member containing a first phosphor,
The light emitting device mounted in the second region is sealed by a second sealing member containing a second phosphor.
The light emitting device according to any one of claims 1 to 4, characterized in that. A method of manufacturing a light emitting device in which a plurality of light emitting elements are mounted on a substrate,
A first resin forming step of applying a first resin surrounding the plurality of light emitting elements on the substrate by discharging the first resin from the first nozzle;
By discharging the second resin from the second nozzle, after applying the second resin on the substrate from the inside to the outside of the region surrounded by the first resin, the discharge of the second resin is stopped. A second resin forming step of separating the second resin from the second nozzle by moving the second nozzle along the first resin;
By repeating the second resin forming step, have a, a step of dividing the region surrounded by the first resin in the second resin,
The first resin is a light-reflective resin;
The second resin is a translucent resin.
A method for manufacturing a light-emitting device. Method of manufacturing a light-emitting device according to claim 6 portion of the plurality of light emitting elements, wherein the benzalkonium covered by the previous SL second resin. Method of manufacturing a light-emitting device according to claim 6 or 7, wherein the second resin is characterized by a coated adjacent two Turkey. When applied to two of the second resin, wherein the adjacent, by moving the second nozzle toward the opposite direction to each other along said first resin in the first on the resin, and their end portions method of manufacturing a light emitting device according to claim 8, wherein the first on the resin along the first resin is deposited in the direction opposite to each other, it is characterized. The region surrounded by the first resin has a first region and a second region separated by the second resin,
Sealing the light emitting element mounted in the first region with a first sealing member containing a first phosphor;
And a step of sealing the second sealing member containing a second phosphor emitting element mounted on said second region,
The method for manufacturing a light emitting device according to any one of claims 6 to 9 , wherein

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