JP6058195B2 - Light emitting device - Google Patents

Description

  The present invention relates to a light emitting device including a light emitting diode (LED) chip and a reflective layer for efficiently extracting light from the LED chip to the outside, and in particular, alteration, deterioration, and reflectance of the reflective layer. The present invention relates to a light emitting device that prevents a decrease.

  FIG. 11 is a cross-sectional view showing a conventional light emitting device using an LTCC (low temperature co-fired ceramics) substrate (see Patent Document 1). The light emitting device includes an LTCC substrate 50, a silver epoxy 52, a reflective barrier 51, a transparent epoxy 53, and an LED die 54. In this conventional example, the emitted light from the LED die 54 is reflected by the reflection barrier 51, and the loss of the emitted light is reduced. Further, the heat from the LED die 54 is radiated to the related thermal diffusion part (not shown) and the LTCC substrate 50 by the reflection barrier 51. LTCC packaging of light emitting devices using LTCC substrates is particularly suitable for dissipating heat generated by closely packed LED dies or LED arrays.

  FIG. 12 is a cross-sectional view showing an LTCC chip carrier having wire bonding (see Patent Document 2). The LTCC chip carrier includes a heat spreader 67, a second layer LTCC61, and a top layer LTCC60 on a mother board 65 in this order. The top layer LTCC 60 has a cavity in the center. In the cavity, one LED chip 4 is fixed with an adhesive or the like on a thermal via 62 formed so as to penetrate the second layer LTCC 61. The LED chip 4 is connected by wire bonding to a second layer terminal 64 formed on the second layer LTCC 61 by a wire 90. Second layer terminal 64 is connected to top terminal 63 formed on top layer LTCC 60 via via 68. Further, the top terminal 63 is connected to an external terminal 66 formed on the mother board 65 by wire bonding. The top terminal 63, the second layer terminal 64, the external terminal 66, and the heat spreader 67 are formed of a conductor that can be fired simultaneously. The cavities in the top layer LTCC 60 containing the LED chip are sealed with epoxy resin 69 or other organic material. Further, for heat dissipation, a heat sink 70 is installed under the mother board 65 by various methods.

  LTCC has a higher intrinsic thermal conductivity than organic materials. Further, by providing the thermal via 62 and the metallized conductor surface, the thermal conductivity can be further increased and the heat dissipation of the light emitting device can be improved.

  Further, as a technique for improving the light emission efficiency of the LED, a technique of providing a metal reflection layer between the light emitting layer of the LED and the support substrate has been proposed (see Non-Patent Document 1). This is because the amount of light emitted from the LED can be increased by reflecting the light emitted from the LED toward the support substrate by the metal reflection layer.

Special Table 2007-533082 (announced November 15, 2007) JP 2007-129191 A (published May 24, 2007)

HITACHI Cable (Hitachi Cable Co., Ltd.), “Developing 65 Lumen / Watt High Brightness Red LED Chip”, News Release: Product, [online], December 17, 2007, Hitachi Cable Co., Ltd. [May 2008 1 day search], Internet (http://www.hitachi-cable.co.jp/products/news/20071217.html)

  However, the conventional configuration causes the following problems.

  The LTCC substrate is a substrate made of a composite material of ceramics and glass. Depending on the material, the LTCC substrate transmits or absorbs light from the LED chip, leading to a decrease in light emission output. However, in the conventional configurations described in Patent Documents 1 and 2, no measures are taken for light reflection and light transmission countermeasures on the surface of the LTCC substrate. Moreover, in the said conventional structure, since the structure which has a level | step difference on the side of a LED chip mounting surface is taken, it becomes a loss of emitted light. Therefore, the conventional configuration is not a configuration that realizes a high-power LED.

  Further, in the configuration shown in Non-Patent Document 1, there is a problem that the metal reflective layer is altered or deteriorated due to, for example, external moisture or oxygen, and the reflectance is reduced due to it.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a light emitting device with high light extraction efficiency.

The light-emitting device according to one embodiment of the present invention is provided on the ceramic substrate, the ceramic substrate, the first external terminal and the second external terminal that are exposed to the outside, and the ceramic substrate. A metal layer, a light emitting diode chip electrically connected to the first external terminal and the second external terminal , and provided above the upper surface of the metal layer, and larger than the thickness of the metal layer A plurality of metal vias having a thickness and connected to the lower side of the metal layer, a phosphor-containing resin that covers the light-emitting diode chip, and provided on the phosphor-containing resin. and a transparent resin having an outer shape, the first external terminal has a first horizontal portion extending along the surface of the ceramic substrate, the second external terminal along the surface of the ceramic substrate A second horizontal portion extending; the first horizontal portion including a first external exposed portion exposed to the outside; and the second horizontal portion including a second external exposed portion exposed to the outside. And the first external exposed portion overlaps the metal layer in a direction perpendicular to the surface of the ceramic substrate so that the first external exposed portion faces the metal layer, and the second external exposed portion The second externally exposed portion overlaps the metal layer in a direction perpendicular to the surface of the ceramic substrate so that the externally exposed portion of the ceramic substrate faces the metal layer, and the ceramic substrate has a rectangular shape. When viewed from a direction perpendicular to the surface of the ceramic substrate, the diameter of the transparent resin is smaller than each side of the ceramic substrate .

  According to one embodiment of the present invention, since the loss of emitted light can be reduced and effectively used, the light emission amount of the light emitting device can be increased.

1 is a schematic plan view showing a light emitting device of Embodiment 1. FIG. It is a schematic plan view which shows the wiring pattern of the light emission part of the said light-emitting device. It is a schematic sectional drawing which shows the manufacturing process of the said light-emitting device. It is a schematic sectional drawing which shows the said light-emitting device. It is a perspective view which shows the fluorescent lamp type LED lighting fixture using the said light-emitting device. It is a side view which shows the lightbulb type LED lighting fixture using the said light-emitting device. (A) is a schematic sectional drawing which shows the light-emitting device of Embodiment 2, (b) is the schematic plan view. 6 is a schematic cross-sectional view showing a light emitting device according to Embodiment 3. FIG. FIG. 6 is a schematic cross-sectional view showing a light emitting device according to a fourth embodiment. FIG. 10 is a schematic cross-sectional view showing a light emitting device according to a fifth embodiment. It is a schematic sectional drawing which shows the conventional light-emitting device. It is a schematic sectional drawing which shows the conventional light-emitting device. FIG. 10 is a plan view and a cross-sectional view illustrating a structure of a light emitting device according to a sixth embodiment. It is a flowchart which shows the manufacturing method of a light-emitting device. It is sectional drawing which shows the structure of a laminated body. It is sectional drawing which shows the manufacturing method of a light-emitting device. FIG. 10 is a cross-sectional view illustrating a structure of a light emitting device according to a seventh embodiment. FIG. 10 is a cross-sectional view illustrating a structure of a light emitting device according to an eighth embodiment. FIG. 20 is a schematic diagram showing a structure of a surface light source according to a ninth embodiment.

[Embodiment 1]
FIG. 1 shows a schematic view of a light emitting device 1000 according to one embodiment of the present invention as viewed from above. The light emitting device 1000 has a structure in which a silver reflective layer (not shown) and a glass layer (covering layer) 3 are formed in this order on a low temperature co-fired ceramic (LTCC) substrate 1, and a light emitting unit 1001 is provided thereon. ing. The light emitting unit 1001 is sealed with a phosphor-containing sealing resin 6. A positive electrode external connection terminal 8 and a negative electrode external connection terminal 7 are further provided on the LTCC substrate 1, and an external wiring 15 is connected to each external connection terminal. The external wiring 15 is wired outside through an external wiring hole 16 provided in the LTCC substrate 1. The LTCC substrate 1 has a mounting portion 13 for fixing the light emitting device 1000 to another device with a screw. Here, the outer shape of the light-emitting device 1000 is substantially square, and the shape of the light-emitting portion 1001 is substantially rectangular.

  FIG. 2 is a plan view showing a wiring pattern and the like of the light emitting device 1000. On the glass layer 3 formed on the LTCC substrate 1, a plurality of elongated rectangular wiring patterns (connection portions) 9 are formed in parallel to each other and at a distance from each other. The wiring pattern 9 is connected to the positive electrode external connection terminal 8 and the negative electrode external connection terminal 7. Between the wiring patterns 9, a chip mounting portion 41 for mounting an LED chip (semiconductor device) is provided.

  FIG. 3A to FIG. 3D and FIG. 4 are schematic sectional views showing a method for manufacturing the light emitting device 1000.

  (A) A silver film is formed on the LTCC substrate 1 having a thickness of 2 mm by using a plating method to form a silver reflecting layer (light reflecting layer) 2 having a thickness of 0.2 mm.

  A glass layer 3 having a thickness of 0.006 mm is formed on the silver reflective layer 2.

  A wiring pattern 9 (thickness 0.07 mm, width 0.45 mm, interval 2 mm) is formed on the glass layer 3 by screen printing. Here, the glass surface is cleaned without roughening the glass layer to give wettability, and then subjected to a special treatment to strengthen the chemical bond, and then the catalyst is activated and adjusted for the glass material. A method of directly applying electrolytic nickel plating was used.

Here, the LTCC substrate 1 is made of a mixed material of borosilicate glass (Na ₂ O—B ₂ O ₃ —SiO ₂ ) and SiO ₂ . The silver reflection layer 2 is made of silver or a silver alloy (Ag, AgPt, Ag—Bi, Ag—Nd alloy) containing silver as a main component. The glass layer 3 is a transparent borosilicate glass (Na ₂ O—B ₂ O ₃ —SiO ₂ ) placed on a carrier blade (carrier film, endless belt) by one of the doctor blade methods (a method for forming ceramics into a sheet). A molding method in which the thickness of the slip (the slurry produced by dispersing the raw material powder in a solvent) is precisely controlled by adjusting the distance between the knife edge (doctor blade) and the carrier. : Http://www.oit.ac.jp/www-ee/server/aplab/res/slurry.html).

(B) LED chips 4 (short side width 0.24 mm, long side 0.48 mm, thickness 0.14 mm, 36 pieces) are fixed between the wiring patterns 9 on the glass layer 3 using silicone resin. Next, the LED chip 4 and the wiring pattern 9 are electrically connected using a bonding wire (connection part) W. The LED chip 4 has a configuration of a generally used LED chip.

  (C) A substantially rectangular silicone rubber sheet 5 is disposed so as to surround an area where the LED chip 4 is installed, and is adhered to the glass layer 3.

(D) Next, a sealing resin (silicone) 6 containing a phosphor (Eu: BOSE ((Ba · Sr) ₂ SiO ₄ : Eu)) is injected into the silicone rubber sheet 5 and the sealing material containing this phosphor is contained. The curing resin is thermoset.

  After injecting a mixture of a fluorescent substance and a silicone resin, which is a translucent resin, into the frame of the silicone rubber sheet 5, the resin is cured by maintaining the temperature at 150 ° C. for 30 minutes to contain the phosphor. A stop resin 6 is formed. Thereafter, the silicone rubber sheet 5 is removed.

  FIG. 4 is a cross-sectional view showing the light emitting unit 1001 thus formed on the LTCC substrate 1.

  The sealing resin 6 containing a phosphor was formed so as to obtain light with x, y = (0.345, 0.35) in the CIE chromaticity table. In this way, the light emitting unit 1001 is manufactured.

  With the configuration as described above, among the light emitted from the LED chip 4, in particular, the light from the lower surface (substrate side) direction is reflected by the silver reflective layer 2 sandwiched between the LTCC substrate 1 and the glass layer 3. Therefore, the light emitted from the LED chip 4 is effectively utilized without loss. Therefore, the light emission amount of the light emitting device 1000 can be increased. The silver reflection layer 2 has a function as a light reflection layer and a function to dissipate heat generated in the LED chip 4 in the surface direction of the package (horizontal direction with respect to the LTCC substrate 1). Further, since the LTCC substrate 1 having high thermal conductivity and good heat dissipation is used, the LED chip 4 can be integrated. Therefore, deformation of the light-emitting device due to heat can be suppressed, and color misalignment and the like can be suppressed.

  Moreover, in this Embodiment, since the silver reflection layer 2 is covered with the glass layer 3, the quality change and deterioration of a reflection layer, and the fall of a reflectance can be suppressed. The glass layer 3 has high isolation against oxygen or moisture compared to a general resin, and can suppress the secular change of the silver reflection layer 2. In addition, since both the LTCC substrate 1 and the glass layer 3 contain glass and the adhesion between the substrate and the glass layer is improved, the effect of isolating the silver reflective layer 2 from oxygen or moisture is even higher.

  As the material of the reflective layer, any metal or non-metal material that reflects the light emitted from the LED chip can be used in addition to the above-described silver or silver alloy. For example, when an arbitrary metal or non-metal material having a light reflectance of 90% or more is used, the emitted light toward the LTCC substrate 1 can be effectively used, and the light emission amount of the light emitting unit 1001 can be increased.

  The wiring pattern 9 is preferably made of a material containing chemically stable gold. Further, in the present embodiment, since the nickel layer is formed between the wiring pattern 9 and the glass layer 3, the adhesion between the wiring pattern 9 made of gold and the glass layer 3 is improved, and the deterioration of the wiring pattern 9 or the like. Aging over time can be further suppressed. A chromium layer may be formed instead of the nickel layer.

Here, the glass powder as a material of the glass layer 3 and the LTCC substrate 1 is preferably borosilicate glass having a composition of Na ₂ O—B ₂ O ₃ —SiO ₂ . This is because the thermal expansion coefficient is small, the thermal shock temperature is high, and a lot of boron oxide is contained, so that it is chemically very durable.

  The silicone rubber sheet 5 (see FIG. 3D) has a function like a dam (prevents resin leakage) when a translucent resin containing a phosphor is applied. Therefore, the silicone rubber sheet 5 has a feature that can be called a dam sheet. Further, the dam sheet can be used many times. In addition, the shape of the light emitting portion 1001 (the shape of the phosphor-containing sealing resin 6) can be easily changed to various shapes by changing the shape of the dam sheet.

  The glass layer 3 and the silver reflection layer 2 are formed over the entire mounting surface of the LED chip 4 surrounded by the silicone rubber sheet 5.

  Here, by setting the mounting area of the LED chip 4 as in this configuration, the mounting pitch of the LED chip 4 can be freely determined along the direction parallel to the wiring pattern 9. Brightness adjustment, chromaticity adjustment, and heat generation measures can be easily performed.

  As an application example of a lighting fixture manufactured using the light emitting device 1000, FIG. 5 shows a schematic diagram of a fluorescent lamp LED lamp 7000, and FIG. The light bulb shaped LED lamp 9000 has a base 14. The configurations of the fluorescent lamp type LED lamp 7000 and the light bulb type LED lamp 9000 are the same as those of a general fluorescent lamp type LED lamp and a light bulb type LED lamp except that the light emitting device 1000 is provided.

[Embodiment 2]
FIG. 7A is a schematic cross-sectional view showing a light emitting device 1002 according to another embodiment of the present invention, and FIG. 7B is a plan view thereof. For convenience of explanation, members having the same functions as those used in the first embodiment are denoted by the same member numbers, and description thereof is omitted. The light emitting device 1002 includes a low-temperature co-fired ceramic (LTCC) substrate 10, a silver reflective layer 2 formed on the LTCC substrate 10, a glass layer 3 covering the silver reflective layer 2, and an LED chip 4 installed on the glass layer 3. And a positive electrode external connection terminal 81 and a negative electrode external connection terminal 71 formed on the glass layer 3. The LED chip 4 and the external connection terminals 81 and 71 are electrically connected by bonding wires W. The LED chip 4 and the bonding wire W are sealed with a dome-shaped phosphor-containing sealing resin 61. The external connection terminals 81 and 71 are formed to extend to the opposite side surfaces of the LTCC substrate 10.

  The LTCC substrate 10 is composed of multilayer (ten layers) LTCC layers 10a to 10j, and a plurality of heat radiation vias 21 made of silver penetrate each layer of the LTCC substrate 10, that is, perpendicular to the LTCC substrate 10. Each is formed in a direction and connected to the silver reflection layer 2. Here, the LTCC substrate 10 is produced by laminating ten green sheets. In the present embodiment, four LED chips 4 are installed. FIG. 7A shows a cross section of one LED chip for simplicity.

  A method for manufacturing the light emitting device 1002 will be described below.

Step (1): Ceramic powder (Al ₂ O ₃ powder 30% by weight) and glass powder (borosilicate glass powder 70% by weight) are blended and mixed at a constant ratio to obtain a raw material. An organic binder (acrylic resin) and a solvent (toluene) are added to the mixed raw materials and dispersed until uniform, thereby producing a material for a green sheet called slurry. The slurry is applied on the PET film with a constant thickness by a doctor blade molding machine, and wound up through a drying process. The sheet-like material produced here is called a green sheet (thickness 0.1 mm). The green sheet is cut to an optimum size. Drilling (punching) to be a via for the heat dissipation via 21 is performed. The hole is filled with a heat dissipation material (silver paste) to produce a single LTCC layer (thickness 0.1 mm). The LTCC layers (10a, 10b, 10c, 10d, 10e, 10f, 10g, 10h, 10i, and 10j) thus fabricated are stacked (10 layers), thermocompression bonded, and subjected to a firing step (850 ° C.) to the LTCC substrate. 10 is produced.

Step (2): On the LTCC substrate 10 (thickness 1 mm), a silver film (thickness 0.25 mm) is formed using a plating method, and the silver reflective layer 2 is formed. Here, borosilicate glass (Na ₂ O—B ₂ O ₃ —SiO ₂ ) was used as the glass powder of the green sheet, and Al ₂ O ₃ was used as the ceramic powder.

Step (3): A glass layer 3 (thickness: 0.01 mm) is formed on the silver reflective layer 2. The glass layer 3 was prepared transparent borosilicate glass _{(Na 2 O-B 2 O} 3 -SiO 2) using a doctor blade method.

  Step (4): External connection terminals 71 and 81 (thickness 0.7 mm, width 0.45 mm) are formed of gold on the glass layer 3 by using a screen printing method.

  Step (5): The LED chip 4 (short side width 0.24 mm, long side 0.48 mm, thickness 0.14 mm, 4 pieces) is fixed on the glass layer 3 using a silicone resin (not shown). Next, the LED chip 4 and the external connection terminals 71 and 81 are electrically connected using the bonding wires W.

  Step (6) Next, a sealing resin (silicone) 61 containing a phosphor (Eu: BOSE) is formed, and the phosphor-containing sealing resin 61 is thermally cured. The phosphor-containing sealing resin 61 is formed by mixing a fluorescent material and a silicone resin, which is a translucent resin, and maintaining the temperature at 150 ° C. for 30 minutes to cure the resin. In the present embodiment, the phosphor-containing sealing resin 61 is formed so as to obtain light with x, y = (0.345, 0.35) in the CIE chromaticity table. Thus, the light emitting part is manufactured.

  Here, the silver reflection layer 2 is effective for taking out the light emitted from the LED chip 4 toward the LTCC substrate 10 to the outside. Moreover, in this Embodiment, since the silver reflection layer 2 is covered with the glass layer 3, the quality change and deterioration of a reflection layer, and the fall of a reflectance can be suppressed. The glass layer 3 has high isolation against oxygen or moisture compared to a general resin, and can suppress the secular change of the silver reflection layer 2.

  In addition, the heat dissipation via 21 formed of silver can effectively dissipate the heat to the outside in order to transfer the heat generated from the LED chip 4 in the vertical direction of the substrate. This effect becomes more prominent because the heat generated from the LED chip 4 is efficiently transferred to the heat dissipation via 21 via the silver reflection layer 2 due to the contact between the silver reflection layer 2 and the heat dissipation via 21. . The heat dissipation via 21 can be formed not only of silver but also of any metal. Further, similarly to the silver reflection layer 2, it may be formed of a silver alloy (AgPt, Ag—Bi, Ag—Nd alloy) containing silver as a main component.

  Further, a heat sink (not shown) may be installed below the LTCC substrate 10 of the light emitting device 1002. Thereby, the heat dissipation of the light emitting device can be further improved, and color shift due to heat generation can be suppressed. In that case, it is preferable that the thermal radiation via 21 is in contact with the heat sink.

  The heat dissipation via 21 has an effect of reflecting the light from the LED chip 4 that has been transmitted into the LTCC substrate 10, and the heat dissipation via 21 is formed in a region where the silver reflective layer 2 is not formed when viewed from the surface of the LTCC substrate 10. By extending the arrangement, it is possible to further improve the light extraction to the front surface side of the LTCC substrate 10.

[Embodiment 3]
FIG. 8 is a schematic cross-sectional view showing a light emitting device 1005 according to another embodiment of the present invention. For convenience of explanation, members having the same functions as those used in the second embodiment are denoted by the same member numbers, and description thereof is omitted. The present embodiment is different from the second embodiment in that instead of the phosphor-containing sealing resin, the phosphor-containing resin portion 63 containing the phosphor and the phosphor-containing resin portion 63 are formed to be covered. The LED chip 4 and the bonding wire W are sealed with a dome-shaped sealing resin composed of the transparent resin portion 64. Each of the phosphor-containing resin portion 63 and the transparent resin portion 64 has a dome shape.

  By configuring as described above, the phosphor-containing resin portion 63 can be protected by the transparent resin portion 64. Moreover, since the sealing resin and each resin part are dome-shaped, the refractive direction of the irradiation light from the LED chip 4 changes continuously. Therefore, spatial unevenness of the intensity of irradiation light can be reduced.

  As the transparent resin portion 64, it is preferable to use a material that can ensure transparency and has high hardness, but the material is not particularly limited.

[Embodiment 4]
FIG. 9 is a schematic cross-sectional view showing a light emitting device 1003 according to another embodiment of the present invention. For convenience of explanation, members having the same functions as those used in the second embodiment are denoted by the same member numbers, and description thereof is omitted. The light emitting device 1003 includes a low temperature co-fired ceramic (LTCC) substrate 11, a silver reflective layer 2 formed on the LTCC substrate 11, a glass layer 3 that covers only the silver reflective layer 2 on the LTCC substrate 11, and a glass layer 3. The LED chip 4 is installed, and includes a positive electrode external connection terminal 81 and a negative electrode external connection terminal 71 formed on the LTCC substrate 11. The LED chip 4 and the external connection terminals 81 and 71 are electrically connected by bonding wires W. The LED chip 4, the bonding wire W, and the external connection terminals 81 and 71 are sealed with a phosphor-containing sealing resin 62. The LTCC substrate 11 is composed of multilayer (ten layers) LTCC layers 11a to 11j, and a plurality of heat radiation vias 21 formed of silver are formed through each layer, that is, in a direction perpendicular to the LTCC substrate 11. It is connected to the silver reflection layer 2. The external connection terminals 81 and 71 are connected to two wiring vias (heat dissipation vias) 22 penetrating the LTCC substrate 11, and each wiring via 22 is connected to an external terminal 82 formed on the lower surface side of the LTCC substrate 11. 72, respectively. Here, the LTCC substrate 11 is produced by laminating 10 green sheets. In this embodiment, four LED chips 4 are provided. For simplicity, FIG. 9 shows a cross section of one LED chip.

  A method for manufacturing the light emitting device 1003 will be described below.

Step (1): Ceramic powder (Al ₂ O ₃ powder 30% by weight) and glass powder (borosilicate glass powder 70% by weight) are mixed and mixed at a constant ratio. An organic binder (acrylic resin) and a solvent (toluene) are added to the mixed raw materials and dispersed until uniform, thereby producing a material for a green sheet called slurry. The slurry is applied on the PET film with a constant thickness by a doctor blade molding machine, and wound up through a drying process. The sheet-like material produced here is called a green sheet (thickness 0.1 mm). The green sheet is cut to an optimum size. A drilling process (punching process) to be a via for the heat dissipation via 21 and the wiring via 22 is performed. A material (silver paste) is filled in the holes to be the heat dissipation vias 21 and the wiring vias 22 to produce one LTCC layer (thickness 0.1 mm). Each LTCC layer (11a, 11b, 11c, 11d, 11e, 11f, 11g, 11h, 11i, and 11j) manufactured in this way is laminated (10 layers), thermocompression-bonded, and subjected to a firing process (850 ° C.) to the LTCC substrate. 11 is produced.

Step (2): On the LTCC substrate 11 (thickness 1 mm), a silver film 2 (thickness 0.25 mm) is formed using a plating method, and the silver reflective layer 2 is formed. Here, borosilicate glass (Na ₂ O—B ₂ O ₃ —SiO ₂ ) was used as the glass powder of the green sheet, and Al ₂ O ₃ was used as the ceramic powder.

Step (3): A glass layer 3 (thickness 0.007 mm) is formed on the silver reflective layer 2. The glass layer 3 was prepared transparent borosilicate glass _{(Na 2 O-B 2 O} 3 -SiO 2) using a doctor blade method.

  Step (4): External connection terminals 81 and 71 (thickness 0.7 mm, width 0.45 mm) are placed on the wiring via 22 of the LTCC substrate 11 with gold so as to sandwich the glass layer 3 by screen printing. Form.

  Step (5): The LED chip 4 (short side width 0.24 mm, long side 0.48 mm, thickness 0.14 mm, 4 pieces) is fixed on the glass layer 3 using a silicone resin. The LED chip 4 and the external connection terminals 81 and 71 are electrically connected using a bonding wire W.

  Step (6): Next, a sealing resin (silicone) 62 including a phosphor (Eu: BOSE) is formed, and the phosphor-containing sealing resin 62 is thermally cured. The phosphor-containing sealing resin 62 is formed by mixing a fluorescent material and a silicone resin, which is a translucent resin, and maintaining the temperature at 150 ° C. for 30 minutes to cure the resin. In the present embodiment, the phosphor-containing sealing resin 62 is formed so as to obtain light with x, y = (0.345, 0.35) in the CIE chromaticity table. Thus, the light emitting part is manufactured.

  Here, heat from the LED chip 4 is transmitted to the external connection terminals 81 and 71 via the bonding wires W. External terminals 82 and 72 formed on the lower side of the LTCC substrate 11 are connected to the external connection terminals 81 and 71 via the wiring vias 22, respectively. Therefore, the heat transmitted to the external connection terminals 81 and 71 is transmitted to the external terminals 82 and 72 and radiated. This effect is more conspicuous because the heat generated from the LED chip 4 is efficiently transferred to the wiring via 22 via the bonding wire W due to the contact between the external connection terminals 81 and 71 and the wiring via 22. Become. The wiring via 22 can be formed of any metal other than silver. Further, similarly to the silver reflection layer 2, it may be formed of a silver alloy (AgPt, Ag—Bi, Ag—Nd alloy) containing silver as a main component. The wiring via 22 connected to the external connection terminals 81 and 71 on the LTCC substrate 11 can be provided because the glass layer 3 covers only the silver reflection layer 2.

  Here, the silver reflection layer 2 is effective for taking out the light emitted from the LED chip 4 toward the LTCC substrate 10 to the outside. Moreover, in this Embodiment, since the silver reflection layer 2 is covered with the glass layer 3, the quality change and deterioration of a reflection layer, and the fall of a reflectance can be suppressed. The glass layer 3 has high isolation against oxygen or moisture compared to a general resin, and can suppress the secular change of the silver reflection layer 2.

  Here, a heat sink (not shown) may be installed below the LTCC substrate 11 of the light emitting device 1003. In that case, it is preferable that the thermal radiation via 21 is in contact with the heat sink.

[Embodiment 5]
FIG. 10 is a schematic cross-sectional view showing a light emitting device 1004 according to another embodiment of the present invention. For convenience of explanation, members having the same functions as those used in the fourth embodiment are denoted by the same member numbers, and description thereof is omitted. The light emitting device 1004 includes an alumina substrate 12, a silver reflection layer 2 formed on the alumina substrate 12, a glass layer 3 covering only the silver reflection layer 2, an LED chip 4 installed on the glass layer 3, and the alumina substrate 12. It consists of a positive electrode external connection terminal 81 and a negative electrode external connection terminal 71 formed above. The LED chip 4 and the external connection terminals 81 and 71 are electrically connected by bonding wires W. The LED chip 4, the bonding wire W, and the external connection terminals 81 and 71 are sealed with a phosphor-containing sealing resin 62, but the entire surface of the alumina substrate 12 is not covered in the depth direction of FIG. 10. Absent. On the alumina substrate 12, there is an unsealed region so that the positive electrode connection land 81 and the negative electrode connection land 71 are exposed on the surface and can be connected to an external power source (not shown). In the present embodiment, 36 LED chips 4 are provided. FIG. 9 shows a cross section of one LED chip for simplicity.

  A method for manufacturing the light emitting device 1004 will be described below.

  Step (1): A silver film 2 (thickness 0.2 mm) is formed on an alumina substrate 12 (thickness 2 mm) using a plating method to form a silver reflection layer 2.

Step (2): A glass layer 3 (thickness 0.006 mm) is formed on the silver reflective layer 2. The glass layer 3 was prepared transparent borosilicate glass _{(Na 2 O-B 2 O} 3 -SiO 2) using a doctor blade method.

  Step (3): External connection terminals 81 and 71 (thickness 0.07 mm, width 0.45 mm, length 2 mm) are formed on the alumina substrate 12 by screen printing.

  Process (4): LED chip 4 (short side width 0.24mm, long side 0.48mm, thickness 0.14mm, 36 pieces) is fixed on the glass layer 3 using a silicone resin. Next, the LED chip 4 and the external connection terminals 81 and 71 are electrically connected using the bonding wires W.

  Step (5): Next, a sealing resin (silicone) 62 containing a phosphor (Eu: BOSE) is injected, and the phosphor-containing sealing resin is thermally cured. The phosphor-containing sealing resin 62 is formed by mixing a fluorescent material and a silicone resin, which is a translucent resin, and maintaining the temperature at 150 ° C. for 30 minutes to cure the resin. In the present embodiment, the phosphor-containing sealing resin 62 is formed so as to obtain light with x, y = (0.345, 0.35) in the CIE chromaticity table. Thus, the light emitting part is manufactured.

  Moreover, in this Embodiment, since the silver reflection layer 2 is covered with the glass layer 3, the quality change and deterioration of a reflection layer, and the fall of a reflectance can be suppressed. The glass layer 3 has high isolation against oxygen or moisture compared to a general resin, and can suppress the secular change of the silver reflection layer 2.

  The external connection terminals 81 and 71 on the glass layer 3 are preferably made of a material containing chemically stable gold.

  In each embodiment, the glass powder that is a material of the glass layer and the LTCC substrate includes silica glass, soda-lime glass, borosilicate glass, aluminoborosilicate glass, zinc borosilicate glass, aluminosilicate glass, and / or phosphate glass. In particular, borosilicate glass is suitable.

Moreover, the ceramic powder which is the material of the LTCC substrate is SiO ₂ , Al ₂ O ₃ , ZrO ₂ , TiO ₂ , ZnO, MgAl ₂ O ₄ , ZnAl ₂ O ₄ , MgSiO ₃ , MgSiO ₄ , Zn ₂ SiO ₄ , Zn ₂ TiO ₄ , SrTiO ₃ , CaTiO ₃ , MgTiO ₃ , BaTiO ₃ , CaMgSi ₂ O ₆ , SrAl ₂ Si ₂ O ₈ , BaAl ₂ Si ₂ O ₈ , CaAl
₂ Si ₂ O ₈ , Mg ₂ Al ₄ Si ₅ O ₁₈ , Zn ₂ Al ₄ Si ₅ O ₁₈ , AlN, SiC, mullite, zeolite and the like. In addition, the LTCC substrate can be replaced with a substrate based on ceramics.

  As the material of the sealing resin, a transparent resin excellent in weather resistance such as epoxy resin, urea resin or silicone resin, or a light-transmitting inorganic material such as silica sol or glass excellent in light resistance is suitably used. Further, the sealing resin may contain a diffusing agent together with the phosphor. As a specific diffusing agent, barium titanate, titanium oxide, aluminum oxide, silicon oxide, calcium carbonate, silicon dioxide or the like is preferably used.

  As the LED chip, a blue LED chip in which a gallium nitride-based light emitting portion is formed on a sapphire substrate is used.

  As the phosphor, a Ce: YAG (cerium activated yttrium / aluminum / garnet) phosphor, Eu: BOSE or SOSE (europium activated strontium / barium / orthosilicate) phosphor, a europium activated α-sialon phosphor, or the like is preferably used. Can do.

  In addition, when forming the resin sealing body (phosphor containing sealing resin), the sealing resin for molds may be dripped. Further, the resin sealing body may be formed by using a mold. As the shape of the resin sealing body, for example, the resin sealing body is formed in a hemispherical shape that protrudes upward. It is also possible to provide a lens function.

  Here, the LED chip can be bonded with a thermosetting resin (adhesive resin) or the like. Specific examples include silicone resins, epoxy resins, acrylic resins, and imide resins.

  In each of the embodiments described above, a blue LED chip made of a gallium nitride compound semiconductor is used as the LED chip, but a blue LED chip made of a ZnO (zinc oxide) compound semiconductor may be used. It goes without saying that InGaAlP-based and AlGaAs-based compound semiconductor LED chips may be used.

  In each embodiment, the P-side electrode and the N-side electrode are formed on one surface of the LED chip, and two wire bondings are performed with the surface as the upper surface. However, the connection shape of the LED chip is as follows. Not limited to this. Wiring may be formed on the glass layer, and the terminals of the LED chip may be directly connected to the wiring with solder or the like. Moreover, although blue light emission was shown as an LED chip, the luminescent color is not limited to this, For example, you may use the thing of ultraviolet light emission and the thing of green light emission. In addition, the method of obtaining white by converting the light emitted from the LED chip with a phosphor has been shown, but without using the phosphor, for example, red, green, and blue LED chips are used for each white or light bulb color. You may obtain the color necessary for lighting.

[Embodiment 6]
(Light emitting device)
A plan view and a cross-sectional view showing the structure of the light-emitting device of Embodiment 6 are shown in FIGS. 13 (a) and 13 (b). In FIG. 13B, the light emitting device 2001 includes a package 110 having a cup-shaped recess 108, an LED chip 112, and a phosphor 114. The LED chip 112 is die-bonded to a chip mounting portion 113 which is a substantially central portion of the bottom surface of the recess 108, and is covered with a sealing resin 116 in which a phosphor 114 is dispersed. Primary light emitted from the LED chip 112 (for example, blue light having a light emission peak in a blue wavelength range of 400 nm to 500 nm) and secondary light emitted from the phosphor 114 excited by the primary light (for example, wavelength of 550 nm). The yellow light having a light emission peak in the yellow wavelength region of 600 nm or less is mixed, and is emitted as white light from the emission surface 118 which is the surface on the opening side of the recess 108.

  The inner wall surface and the bottom surface of the recess 108 are coated with a silver reflective layer 120 made of a metal such as Ag so as to have a high reflectance, and are covered with a glass layer 121 so that the reflectance is maintained for a long period of time. .

  In FIG. 13A, the bottom surface of the recess 108 includes a pair of electrode pads 123 formed by separating a part of the silver reflective layer 120. The LED chip 112 is die-bonded to the chip mounting portion 113, and the electrode pad 122 of the LED chip 112 and the electrode pad 123 of the package 110 are electrically connected by wire bonding. Note that the surface of the electrode pad 123 is exposed at a portion to which the wire W is connected, and the electrode pad 123 is not covered with the glass layer 121.

  The lower surface of the light emitting device 2001 is a mounting surface 126 facing a mounting substrate (not shown), and an external connection terminal 128 is formed on the mounting surface 126, and the electrode pad 123 and the external connection terminal 128 are interposed between them. Conductive vias 130 are interposed. The via 130 forms a current path to the LED chip 112 by connecting the external connection terminal 128 to a wiring pattern formed on the mounting substrate.

(Production method)
Next, a method for manufacturing the light emitting device 2001 will be described. FIG. 14 is a flowchart showing a method for manufacturing a light emitting device, FIG. 15 is a cross-sectional view showing the structure of the laminate, and FIG. 16 is a cross-sectional view showing a method for manufacturing the light emitting device.

  Hereinafter, the package forming method will be described in order. The package shown in the present embodiment is a low-temperature co-fired ceramic package formed by firing a laminated body in which a sheet-like material called a green sheet is punched and processed such as paste filling is laminated. (LTCC).

  Hereinafter, a method for forming the green sheet 150 will be described. First, an organic binder and a solvent are mixed in a mixed material of alumina ceramic powder and glass, which is the main material, and dispersed uniformly to prepare a material called slurry. Next, the slurry is applied on the PET film with a certain thickness by a film forming apparatus, and wound up through a drying process, whereby the green sheet 150 is obtained. Next, the green sheet 150 is cut into a predetermined size, and a hole such as a recess 108, a via 130, an electrode pad 123, and a glass layer 121 where a component of the package 110 is to be formed is formed, and processing such as paste filling is performed. Apply. These are accurately aligned and stacked to form a stacked body 155 (FIG. 15D).

  For example, as shown in FIG. 15, the via 130, the electrode pad 123, and the chip mounting portion 113 are filled with a metal paste in which a metal such as Ag is dispersed in a hole provided in the green sheet 150 (see FIG. 15). 15 (a)) is laminated. Note that the metal paste is electrically connected between adjacent layers, and the electrode pad 123 and the external connection terminal 128 are electrically connected. The pair of electrode pads 123 are separated from each other and insulated and separated.

The glass layer 121 is formed by laminating or depositing a glass paste layer on a metal paste layer. For example, in the chip mounting portion 113, the silver reflective layer 120 is covered with a glass paste filled in a hole provided in the green sheet 150 (FIG. 15B), and the glass layer 121 is formed.

  The surface of the electrode pad 123 is exposed without being covered with glass. This portion is formed by laminating a portion (FIGS. 15B and 15C) in which a hole is provided in a portion where the surface of the electrode pad 123 should be exposed in a portion filled with the glass paste. ing. Therefore, since the surface of the electrode pad 123 is exposed, it is preferable that the electrode pad 123 is made of a material that hardly changes in quality, and is preferably formed of an Au paste or the like as a metal paste.

  The green sheet 150 is repeatedly formed with a plurality of processing patterns subjected to perforation or paste filling so that a plurality of packages 110 are simultaneously formed.

  Next, the laminated body 155 is fired at 700 to 1000 ° C., for example, 850 to 900 ° C. As a result, the alumina powder that is the material of the green sheet 150, the metal paste that is the material of the silver reflecting layer 120, the glass paste that covers the silver reflecting layer 120, and the Au paste that is the material of the electrode pad 123 are fired at the same time. Is completed. At this time, the glass components contained in the glass paste are melted to smoothly cover the surface of the silver reflective layer 120. Further, since the respective materials are fired at the same time, there is an effect that the stress at the interface of each layer is relieved.

  As examples of the layer thicknesses of the layers constituting the package 110, the layer from the chip mounting portion 113 to the mounting surface 126 is 0.5 mm, the silver reflective layer 120 is 0.005 mm, and the glass layer 121 is 0. It can be formed as 01 mm.

  Next, steps after the mounting of the LED chip 112 will be described with reference to FIG. In FIG. 16, the description of the via 130 is omitted.

  A brazing material (not shown) such as silicone paste is applied to the chip mounting portion 113 of each concave portion 108 of the fired laminate 155, and the LED chip 112 is die-bonded thereon. Next, the electrode pad 122 of the LED chip 112 and the electrode pad 123 of the package 110 are connected by wire bonding. At this time, since the electrode pad 123 of the package 110 is not covered with glass, wire bonding can be satisfactorily performed (FIGS. 16A and 16B).

  Next, the sealing resin 116 in which the phosphors 114 are dispersed in advance is filled in the recesses 108 and cured, thereby covering the LED chip 112. As the sealing resin 116, dimethyl silicone or methyl rubber having high heat resistance and high adhesion to glass can be preferably used. For example, when KER2500 (manufactured by Shin-Etsu Chemical Co., Ltd.) is used as dimethyl silicone, it is cured under conditions of 100 ° C. for 60 minutes and after-cured under conditions of 150 ° C. for 300 minutes. Although dimethylsilicone and methyl rubber have lower gas sealing properties than organically modified silicone or the like, the surface of the silver reflective layer 120 is coated with glass, so that alteration of the surface can be suppressed.

  Finally, it is divided into individual light emitting devices. As a dividing method, for example, there is a method using a UV sheet. In this method, the mounting surface 126 attached to the UV sheet 158 is placed on a stage, and a predetermined position of the stacked body 155 is diced by a cutter. Next, there is a method in which the adhesive material of the UV sheet 158 is cured by UV light irradiation and separated into individual pieces.

According to the above configuration, dimethylsilicone or methyl rubber and glass have high adhesion, and peeling between the glass layer 121 covering the silver reflecting layer 120 and the sealing resin 116 can be suppressed. One reason for the high adhesion is presumed to be that the hydroxyl surface is exposed on the surface of the glass and the bonding strength with the silicone resin is high. Further, it is estimated that dimethyl silicone and methyl rubber have higher elasticity than organically modified silicone and the like, so that volume changes such as thermal expansion and contraction are easily absorbed.

  The continuous heat resistance temperature of the sealing resin 116 is preferably 120 ° C. or higher. Here, when the thermal resistance of the package 110 is 200 ° C./W and the heat generation of the LED chip 112 is 0.06 W, the temperature rise of the package 110 is only 12 ° C. However, the lifetime required for the light emitting device 2001 is very long, for example, 40,000 hours, and the continuous heat-resistant temperature as described above is required to satisfy this reliability.

  For example, BOSE (Ba, O, Sr, Si, Eu) can be suitably used as the phosphor 114. In addition to BOSE, SOSE (Sr, Ba, Si, O, Eu), YAG (Ce-activated yttrium, aluminum, garnet), α sialon ((Ca), Si, Al, O, N, Eu), β sialon ( Si, Al, O, N, Eu) or the like can be preferably used. Further, by replacing the LED chip 112 with one emitting blue light, for example, an ultraviolet (near ultraviolet) LED having a light emission peak wavelength of 390 nm to 420 nm can be further improved.

  As described above, the light emitting device 2001 including the silver reflection layer 120, the glass layer 121 covering the silver reflection layer 120, and the resin sealing with the silicone resin has high gas sealing property, high heat resistance, and adhesiveness. High reliability combined with height.

  Note that although the present embodiment has a configuration in which the phosphor 114 is dispersed in the sealing resin 116, it is not necessarily limited to this. For example, a configuration in which the phosphor 114 is deposited only in the vicinity of the LED chip 112 may be covered with the sealing resin 116, or a configuration without the phosphor 114 may be used. In addition, the silver reflecting layer 120 is formed not only on the inner wall of the recess 108 but also on the bank 131 that surrounds the peripheral edge of the emission surface 118 in a ring shape, but it may be configured not to be formed on the bank 131. . In short, if the glass layer 121 is interposed between the sealing resin 116 and the surface of the silver reflective layer 120 or the package 110, the reliability can be improved.

[Embodiment 7]
FIG. 17 is a cross-sectional view showing the structure of the light-emitting device of Embodiment 7. The light-emitting device 2002 includes a glass layer 160 containing a phosphor in which a phosphor 114 is dispersed instead of the glass layer 121, and includes primary light that is blue light emitted from the LED chip 112 and primary light. The secondary light which is yellow light emitted from the excited phosphor 114 is mixed and emitted as white light from the emission surface 118 which is the surface on the opening side of the recess 108.

  The light emitting device 2002 is the same as that in Embodiment 6 except that the phosphor-containing glass layer 160 is formed by laminating or depositing a phosphor-containing glass paste layer on a metal paste layer. The phosphor-containing glass paste is obtained by dispersing phosphors 114 such as BOSE, SOSE, YAG, α sialon, and β sialon in glass powder.

  According to the present embodiment, the phosphor 114 is less settled in the phosphor-containing glass paste, so that the density of the phosphor 114 in the phosphor-containing glass layer 160 can be formed more uniformly. As a result, it is possible to suppress the chromaticity variation of the emitted light. One reason for the low sedimentation of the phosphor 114 is presumably because the glass powder contained in the phosphor-containing glass paste exhibits the action of suppressing the sedimentation of the phosphor 114.

  According to FIG. 17, the phosphor 114 is not dispersed in the sealing resin 116, but a dispersed configuration may be employed.

  Moreover, as an aspect of the glass layer 160 with a fluorescent substance, all or one part of the glass layer 160 with a fluorescent substance can be made into fluorescent substance. Preferably, as shown in FIG. 17, the phosphor is contained in the portion in contact with the sealing resin 116, and the phosphor is not contained in the bank 131. Thereby, it is possible to suppress the action of the phosphor 114 being excited by external light and emitting yellow light on the bank 131.

[Embodiment 8]
FIG. 18 is a cross-sectional view showing the structure of the light emitting device of the eighth embodiment. In this embodiment, a recess is provided on the bottom surface of the recess 108 of the package 110, an electrode pad 123 is formed on the bottom surface of the recess, and the insulating layer 132 is interposed between the electrode pad 123 and the silver reflective layer 120. It is characterized by interposing. The other parts are the same as those in the first embodiment.

  In the vicinity of the electrode pad 123 of the package 110, ceramics as a material of the package 110 is exposed so as to surround the electrode pad 123 in order to separate and insulate the electrode pads 123 from each other. Accordingly, since a part of the emitted light leaks at this portion, the emission efficiency is lowered. In the light emitting device 2001 shown in Embodiment 6, the exposed portion of the ceramic is formed on substantially the same plane as the chip mounting portion 113. On the other hand, in the present embodiment, the exposed portion of the ceramic exists in the recessed portion where the outgoing light does not easily reach. Therefore, light leaking from the exposed portion of the ceramic near the electrode pad 123 is suppressed, and the light extraction efficiency can be improved.

[Embodiment 9]
19A and 19B are schematic views showing the structure of the surface light source of the ninth embodiment. The surface light source 2004 in the present embodiment is a light emitting device 305 having the configuration described in any of the above-described sixth to eighth embodiments, and an emission surface 316 that guides light emitted from the light emitting device 305 and emits light in a planar manner. A light guide plate 310 that emits light, and the light exit surface 118 of the light emitting device 305 is disposed to face the incident end surface 312 of the light guide plate 310. Note that refraction and the like at the incident end surface 312 of the light guide plate 310 are omitted.

  Light emitted from the light emitting device 305 irradiates the incident end surface 312, but part of the light is reflected by the incident end surface 312 and the end surface 314 of the light guide plate 310 and returns to the output surface 118 of the light emitting device 305. On the other hand, the silver reflection layer 120 of the light emitting device 305 is formed not only on the inner wall of the recess 108 but also on the bank 131 that surrounds the emission surface 118 in an annular shape. Accordingly, the light that is reflected by the incident end surface 312 of the light guide plate 310 or the light reflected by the end surface 314 of the light guide plate 310 can be reflected and incident again, so that the light utilization efficiency can be increased. Is expensive.

  The present invention is not limited to the above-described embodiments, and various modifications are possible within the scope shown in the claims, and can be obtained by appropriately combining technical means disclosed in different embodiments. Embodiments are also included in the technical scope of the present invention.

[Summary]
A light emitting device according to an aspect of the present invention includes a ceramic substrate having a light emitting region on an upper portion of a ceramic substrate, and a peripheral region surrounding the light emitting region in an upper portion of the ceramic substrate, and having a substantially square outer shape, The light reflecting layer provided on the light emitting region of the ceramic substrate, the plurality of light emitting diode chips provided on the light reflecting layer, and the peripheral region are located apart from any edge of the ceramic substrate. A plurality of positive electrode external connection terminals and negative electrode external connection terminals; and a plurality of light emitting diode chips connected to the positive electrode external connection terminals and the negative electrode external connection terminals. A plurality of light emitting diode chips that cover the light emitting region without covering the peripheral region, and A sealing resin for sealing, and the positive electrode external connection terminal and the negative electrode external connection terminal are respectively disposed at diagonal portions of the ceramic substrate so as to be located on opposite sides of the sealing resin. Be placed.

  A light-emitting device according to one embodiment of the present invention includes a single substrate having four corners and having a light-emitting region and a peripheral region surrounding the light-emitting region on the top, and the light-emitting device over the light-emitting region of the single substrate. The light reflection layer, a plurality of light emitting diode chips provided on the light reflection layer, provided in the peripheral region, and each positioned away from an arbitrary edge of the single substrate in a top view, Positive electrode external connection terminal and negative electrode external connection terminal, and a plurality of wires provided on the single substrate for connecting the plurality of light emitting diode chips to the positive electrode external connection terminal and the negative electrode external connection terminal A positive electrode external connection terminal and an external of the negative electrode, comprising a pattern and a phosphor-containing sealing resin that covers the light emitting region without covering the peripheral region and seals the plurality of light emitting diode chips Connection terminals, so as to be positioned in between the light emitting regions, respectively arranged in a diagonal part of the single substrate.

  A light-emitting device according to an aspect of the present invention includes a light-emitting region on an upper portion of a ceramic substrate, the ceramic substrate having a peripheral region surrounding the light-emitting region in the upper portion of the ceramic substrate, and the light-emitting region of the ceramic substrate. A light reflection layer provided on the light reflection layer; a plurality of light emitting diode chips provided on the light reflection layer; and a positive electrode external connection terminal located at a distance from an arbitrary edge of the ceramic substrate in the peripheral region, and A negative electrode external connection terminal; a plurality of wiring patterns provided on an upper portion of the ceramic substrate for connecting the plurality of light emitting diode chips to the positive electrode external connection terminal and the negative electrode external connection terminal; A sealing resin that covers the light emitting region without covering the region and seals the plurality of light emitting diode chips. Obtain.

  A light-emitting device according to an aspect of the present invention includes a ceramic substrate, a plurality of external terminals provided on the ceramic substrate so as to be exposed to the outside, a metal radiator disposed in the ceramic substrate, and the plurality of the plurality of external terminals. The light reflecting layer provided on the metal heat dissipating member is not electrically connected to the external terminal, and is electrically connected to the plurality of external terminals, and is formed on the upper surface of the light reflecting layer. A light emitting diode chip provided on an insulator via an insulating material; and a sealing resin that seals the light emitting diode chip, wherein the thickness of the light reflecting layer is smaller than the thickness of the metal radiator, A part of the lower surface of the layer is connected to the upper surface of the metal radiator, and a part of the metal radiator extends to a region where the light reflecting layer is not formed when viewed from the surface of the ceramic substrate. Are arranged The insulator covers the upper and side surfaces of the light reflecting layer of the light reflecting layer, and transmits the light reflected by the light reflecting layer is emitted by the light emitting diode chip.

A light-emitting device according to one embodiment of the present invention includes a ceramic circuit board, a light-emitting diode chip, and a sealing resin that seals the light-emitting diode chip. The ceramic circuit board includes: (i) a ceramic substrate; ii) a first external terminal and a second external terminal provided on the lower surface of the ceramic circuit board so as to be exposed to the outside; (iii) a metal radiator disposed in the ceramic substrate; A light reflecting layer that is not electrically connected to the first external terminal and the second external terminal, and is provided on the metal radiator, and (v) an upper surface of the light reflecting layer and the light reflecting An insulator covering a side surface of the layer and transmitting the light reflected by the light reflecting layer; and (vi) a positive electrode electrically connected to each of the first external terminal and the second external terminal. And the negative electrode, the lower surfaces of the positive electrode and the negative electrode are positioned at the same height as the lower surface of the light reflecting layer, and the light emitting diode chip is positioned above the light reflecting layer. The insulator is provided between the light emitting diode chip and the light reflecting layer, and the light emitting diode chip includes the positive electrode and the negative electrode. It is electrically connected to the first external terminal and the second external terminal via an electrode, and the light reflecting layer is formed on a part of the metal radiator as viewed from the surface of the ceramic substrate. It is also arranged so as to extend to a region where there is not.

  A light-emitting device according to one embodiment of the present invention is a semiconductor device that emits light on a substrate and a light-emitting device having a plurality of external connection terminals. The light-emitting device is formed over the substrate and reflects light emitted from the semiconductor device. A light reflection layer disposed below a mounting surface of the semiconductor device, which is a central region excluding the peripheral portion on the substrate, and covering at least the light reflection layer not disposed on the peripheral portion on the substrate; And the semiconductor device is formed on the coating layer and electrically connected to the external connection terminal via a connection portion. The semiconductor device is sealed with sealing resin so as to cover the semiconductor device and the connection portion, the semiconductor device is a light emitting diode chip, the covering layer is made of glass, and the connection portion is Wiring pattern and Bonn The wiring patterns are formed on the substrate or the coating layer in parallel to each other and at a distance from each other, and a plurality of the semiconductor devices are installed between the wiring patterns, The wiring pattern and the semiconductor device are connected by the bonding wire.

  A light-emitting device according to one embodiment of the present invention is a light-emitting device including a semiconductor device that emits light on a substrate and a plurality of external connection terminals, and light that is formed on the substrate and reflects light emitted from the semiconductor device. A reflection layer; and a coating layer that covers at least the light reflection layer and transmits the light reflected by the light reflection layer. The semiconductor device is formed on the coating layer, and It is electrically connected via a connection terminal and a connection portion, and is sealed with a sealing resin so as to cover the semiconductor device and the connection portion, and the semiconductor device is a light emitting diode chip, The covering layer is made of glass, and the connecting portion is made of a wiring pattern and a bonding wire. The wiring pattern is parallel to each other and spaced from each other on the substrate or the covering layer. Is formed, the semiconductor device is more disposed between the wiring pattern, the said wiring pattern and the semiconductor device are connected by the bonding wire.

  According to the above configuration, since the light reflecting layer reflects the outgoing light from the semiconductor device to the lower side (substrate side), the loss of the outgoing light can be reduced and effectively used. In addition, since the light reflecting layer is covered with the coating layer, the light reflecting layer can be prevented from being deteriorated or deteriorated, and further, the reflectance can be prevented from decreasing.

  In addition, according to the above configuration, the number of semiconductor devices can be freely adjusted, and brightness adjustment, chromaticity adjustment, and heat generation countermeasures of the light emitting device are facilitated.

  The light-emitting device according to one embodiment of the present invention preferably includes a heat radiating via made of metal, which is bonded to the light reflecting layer, the external connection terminal, or both in the substrate.

  According to said structure, the heat dissipation of a light-emitting device can further be improved with the thermal radiation via connected to the light reflection layer or the external connection terminal.

  In the light emitting device according to one embodiment of the present invention, it is preferable that the heat dissipation via is formed in a direction perpendicular to the substrate surface.

  Further, the heat dissipation via is preferably made of silver or a silver alloy containing silver as a main component.

  According to the above configuration, in addition to the heat radiation in the substrate plane direction by the light reflecting layer, the heat radiation property in the substrate vertical direction is enhanced, so that the heat radiation property of the light emitting device is further enhanced. As a result, the semiconductor device can be integrated in a small area.

  In the light emitting device according to one aspect of the present invention, the wiring pattern is preferably made of gold.

  According to said structure, since the wiring pattern is formed with gold | metal | money, secular change by deterioration etc. of a wiring pattern can be suppressed.

  In the light-emitting device according to one embodiment of the present invention, it is preferable that a nickel or chromium layer is formed between the wiring pattern and the covering layer.

  According to said structure, the adhesiveness of the coating layer which consists of glass, and a wiring pattern improves, and secular change by deterioration etc. of a wiring pattern can be suppressed.

  In the light emitting device according to one embodiment of the present invention, the sealing resin preferably includes a phosphor.

  According to the above configuration, the phosphor absorbs light from the semiconductor device and emits light of another wavelength, so that other light (for example, white light) is emitted using the semiconductor device that emits single light. A light emitting device can be obtained.

  In the light emitting device according to one aspect of the present invention, the sealing resin includes a phosphor-containing resin portion that includes a phosphor, and a transparent resin portion that is formed so as to cover the phosphor-containing resin portion. It is preferable that

  According to said structure, a fluorescent substance containing resin part can be protected by a transparent resin part.

  In the light emitting device according to one embodiment of the present invention, the outer shape of the sealing resin is preferably a dome shape.

  In the light emitting device according to one aspect of the present invention, it is preferable that the outer shape of the phosphor-containing resin portion and the outer shape of the transparent resin portion are dome-shaped.

  According to said structure, since there is no corner | angular part in the light irradiation direction side of sealing resin, the refractive direction of irradiation light changes continuously. Therefore, there is an effect that unevenness of the intensity of irradiation light can be reduced.

[Additional Notes]
A light-emitting device according to one embodiment of the present invention includes a semiconductor device that emits light on a substrate and a plurality of external connection terminals, and a light reflection layer that is formed on the substrate and reflects light emitted from the semiconductor device. A coating layer that covers at least the light reflection layer and transmits the light reflected by the light reflection layer, and the semiconductor device is formed on the coating layer and has the external connection terminal It is electrically connected through a connection portion, and is sealed with a sealing resin so as to cover the semiconductor device and the connection portion.

According to the above configuration, since the light reflecting layer reflects the outgoing light from the semiconductor device to the lower side (substrate side), the loss of the outgoing light can be reduced and effectively used. In addition, since the light reflecting layer is covered with the coating layer, the light reflecting layer can be prevented from being deteriorated or deteriorated, and further, the reflectance can be prevented from decreasing.

  The light reflecting layer preferably has a light reflectance of 90% or more.

  According to said structure, since the light reflection layer has a high light reflectance, the emitted light amount of a light-emitting device can be increased further.

  The light reflecting layer is preferably made of silver or a silver alloy containing silver as a main component.

  According to said structure, by forming a light reflection layer with a silver or silver alloy layer, the heat_generation | fever of a semiconductor device can be dissipated in the surface direction of a board | substrate, and the heat dissipation of a light-emitting device can be improved. Thereby, the color shift by the heat_generation | fever of a light-emitting device can be suppressed.

  In the light-emitting device according to one embodiment of the present invention, the substrate may have ceramic as a base material. Furthermore, the substrate may be made of a low-temperature co-fired ceramic.

  According to the above configuration, since the low-temperature co-fired ceramic has higher thermal conductivity than a general organic material, the heat dissipation of the light-emitting device can be further increased, and the semiconductor device can be integrated.

In the light-emitting device according to the present invention, it is preferable that the substrate is fired using glass powder and ceramic powder as materials. As the glass powder, for example, one containing silica glass, soda lime glass, borosilicate glass, aluminoborosilicate glass, zinc borosilicate glass, aluminosilicate glass or phosphate glass can be used. The ceramic powder is, for example, SiO ₂ , Al ₂ O ₃ , ZrO ₂ , TiO ₂ , ZnO, MgAl ₂ O ₄ , ZnAl ₂ O ₄ , MgSiO ₃ , MgSiO ₄ , Zn ₂ SiO ₄ , Zn ₂ TiO ₄ , SrTiO ₄ . ₃ , CaTiO ₃ , MgTiO ₃ , BaTiO ₃ , CaMgSi ₂ O ₆ , SrAl ₂ Si ₂ O ₈ , BaAl ₂ Si ₂ O ₈ , CaAl ₂ Si ₂ O ₈ , Mg ₂ Al ₄ Si ₅ O ₁₈ , Zn ₂ Al ₄ Those containing Si ₅ O ₁₈ , AlN, SiC, mullite or zeolite can be used.

  In the light-emitting device according to one embodiment of the present invention, the coating layer is made of glass, and the glass is, for example, silica glass, soda-lime glass, borosilicate glass, aluminoborosilicate glass, zinc borosilicate glass, aluminosilicate glass, or phosphate glass. Can be used.

According to said structure, a board | substrate and a coating layer contain glass powder, the adhesiveness of a board | substrate and a coating layer becomes favorable, further suppresses the secular change by deterioration of a light reflection layer, etc., and a reflectance falls Can be suppressed. In particular, borosilicate glass (Na ₂ O—B ₂ O ₃ —SiO ₂ ) has a low thermal expansion coefficient, a high thermal shock temperature, and a high chemical durability because it contains a large amount of boron oxide. The effect of protecting the reflective layer is high.

  In the light-emitting device according to one embodiment of the present invention, the semiconductor device is a light-emitting diode chip, the coating layer is made of glass, the connection portion is made of a wiring pattern and a bonding wire, and the wiring pattern is the substrate A plurality of the semiconductor devices are installed between the wiring patterns, and the bonding patterns and the semiconductor devices are bonded to the bonding wires. It may be connected by.

  According to said structure, the number of semiconductor devices can be adjusted freely and the brightness | luminance adjustment of a light-emitting device, chromaticity adjustment, and the countermeasure against heat_generation | fever become easy.

  The light-emitting device according to one embodiment of the present invention preferably includes a heat radiating via made of metal, which is bonded to the light reflecting layer, the external connection terminal, or both in the substrate.

  According to said structure, the heat dissipation of a light-emitting device can further be improved with the thermal radiation via connected to the light reflection layer or the external connection terminal.

  The heat dissipation via is preferably formed in a direction perpendicular to the substrate surface.

  Further, the heat dissipation via is preferably made of silver or a silver alloy containing silver as a main component.

  According to the above configuration, in addition to the heat radiation in the substrate plane direction by the light reflecting layer, the heat radiation property in the substrate vertical direction is enhanced, so that the heat radiation property of the light emitting device is further enhanced. As a result, the semiconductor device can be integrated in a small area.

  In the light emitting device according to one embodiment of the present invention, the wiring pattern is preferably made of gold.

  According to said structure, since the wiring pattern is formed with gold | metal | money, secular change by deterioration etc. of a wiring pattern can be suppressed.

  In the light-emitting device according to one embodiment of the present invention, a nickel or chromium layer is preferably formed between the wiring pattern and the coating layer.

  According to said structure, the adhesiveness of the coating layer which consists of glass, and a wiring pattern improves, and secular change by deterioration etc. of a wiring pattern can be suppressed.

  In the light emitting device according to the present invention, the semiconductor device may be installed on the coating layer via an adhesive resin.

  In the light emitting device according to one embodiment of the present invention, the sealing resin preferably includes a phosphor.

  According to the above configuration, the phosphor absorbs light from the semiconductor device and emits light of another wavelength, so that other light (for example, white light) is emitted using the semiconductor device that emits single light. A light emitting device can be obtained.

  In the light-emitting device according to an aspect of the present invention, the sealing resin includes a phosphor-containing resin portion that includes a phosphor, and a transparent resin portion that is formed so as to cover the phosphor-containing resin portion. It is preferable that

  According to said structure, a fluorescent substance containing resin part can be protected by a transparent resin part.

  In the light emitting device according to the present invention, the outer shape of the sealing resin is preferably a dome shape.

  In the light-emitting device according to the present invention, it is preferable that the outer shape of the phosphor-containing resin portion and the outer shape of the transparent resin portion be a dome shape.

According to said structure, since there is no corner | angular part in the light irradiation direction side of sealing resin, the refractive direction of irradiation light changes continuously. Therefore, there is an effect that unevenness of the intensity of irradiation light can be reduced.

  A light-emitting device according to an aspect of the present invention includes a light-emitting diode chip, a package including a silver reflective layer for die-bonding the light-emitting diode chip to a chip mounting portion and reflecting light emitted from the light-emitting diode chip; A light-emitting device including a sealing resin for covering a light-emitting diode chip, wherein the silver reflective layer is covered with a glass layer.

  In the light emitting device according to one embodiment of the present invention, it is preferable that a material of the sealing resin is dimethyl silicone or methyl rubber.

  In the light emitting device according to an aspect of the present invention, the sealing resin absorbs at least a part of the primary light emitted from the light emitting diode chip and converts the secondary light into secondary light having a longer wavelength than the primary light. Is preferably dispersed.

  In the light-emitting device according to one embodiment of the present invention, it is preferable that the silver reflection layer is formed on a peripheral portion of an emission surface of the light-emitting device.

  In the light emitting device according to one aspect of the present invention, it is preferable that a recess is formed in the chip mounting portion, and an electrode pad is formed on the bottom surface of the recess.

  A method for manufacturing a package for a light emitting device according to an aspect of the present invention includes a step of preparing a plurality of green sheets mainly composed of alumina, a step of drilling a part of the green sheet, and a metal in the holes A step of filling at least one of paste or glass paste and a step of laminating and firing the plurality of green sheets so that the metal paste is covered with the glass paste are sequentially provided.

  As described above, a light-emitting device according to one embodiment of the present invention includes a semiconductor device that emits light over a substrate and a plurality of external connection terminals, and is formed over the substrate and reflects light emitted from the semiconductor device. A light reflecting layer, and a covering layer that covers at least the light reflecting layer and transmits light reflected by the light reflecting layer, and the semiconductor device is formed on the covering layer, It is electrically connected to the external connection terminal via a connection portion, and is sealed with a sealing resin so as to cover the semiconductor device and the connection portion.

  According to the above configuration, the light reflection layer reflects the outgoing light from the semiconductor device to the lower side (substrate side), thereby reducing the loss of the outgoing light and increasing the amount of light emitted from the light emitting device. In addition, since the light reflection layer is covered with the coating layer, the light reflection layer can be prevented from being deteriorated or deteriorated, and further, the reflectance can be prevented from lowering.

  Moreover, since the light-emitting device according to the present invention sufficiently protects the light reflecting layer with a coating layer, the sealing resin may have a slightly low gas sealing property, but has a high heat resistance and is not Dimethyl silicone or methyl rubber having high adhesion can be preferably used.

  The method for manufacturing a light emitting device package according to the present invention is a method for manufacturing a light emitting device package by firing a substrate material on which green sheets are laminated and simultaneously firing a reflective layer and its coating layer. Saves time and costs.

  The light-emitting device according to one embodiment of the present invention can also be expressed as follows.

A light-emitting device according to one embodiment of the present invention is a light-emitting device including a semiconductor device that emits light on a substrate and a plurality of external connection terminals, and light that is formed on the substrate and reflects light emitted from the semiconductor device. A reflection layer; and a coating layer that covers at least the light reflection layer and transmits the light reflected by the light reflection layer. The semiconductor device is formed on the coating layer, and It is electrically connected via a connection terminal and a connection portion, and is sealed with a sealing resin so as to cover the semiconductor device and the connection portion.

  In the light emitting device according to one embodiment of the present invention, the light reflecting layer has a light reflectance of 90% or more.

  In the light emitting device according to one embodiment of the present invention, the light reflecting layer is made of silver or a silver alloy containing silver as a main component.

  In the light-emitting device according to one embodiment of the present invention, the substrate includes ceramic as a base material.

  In the light-emitting device according to one embodiment of the present invention, the substrate includes a low-temperature co-fired ceramic as a base material.

  In the light-emitting device according to one embodiment of the present invention, the low-temperature co-fired ceramic is fired using glass powder and ceramic powder as materials.

  In the light-emitting device according to one embodiment of the present invention, the glass powder includes silica glass, soda-lime glass, borosilicate glass, aluminoborosilicate glass, borosilicate zinc glass, aluminosilicate glass, or phosphate glass.

In the light emitting device according to one embodiment of the present invention, the ceramic powder may be SiO ₂ , Al ₂ O ₃ , ZrO ₂ , TiO ₂ , ZnO, MgAl ₂ O ₄ , ZnAl ₂ O ₄ , MgSiO ₃ , MgSiO ₄ , Zn _2. SiO ₄ , Zn ₂ TiO ₄ , SrTiO ₃ , CaTiO ₃ , MgTiO ₃ , BaTiO ₃ , CaMgSi ₂ O ₆ , SrAl ₂ Si ₂ O ₈ , BaAl ₂ Si ₂ O ₈ , CaAl ₂ Si ₂ O ₈ , Mg ₂ Al ₄ Si ₅ O ₁₈ , Zn ₂ Al ₄ Si ₅ O ₁₈ , AlN, SiC, mullite or zeolite.

  In the light-emitting device according to one embodiment of the present invention, the coating layer is made of glass, and the glass is made of silica glass, soda-lime glass, borosilicate glass, aluminoborosilicate glass, borosilicate zinc glass, aluminosilicate glass, or phosphate glass. Become.

  In the light emitting device according to one aspect of the present invention, the semiconductor device is a light emitting diode chip, the coating layer is made of glass, the connection portion is made of a wiring pattern and a bonding wire, and the wiring pattern is the substrate. A plurality of the semiconductor devices are installed between the wiring patterns, and the bonding patterns and the semiconductor devices are bonded to the bonding wires. Connected by.

  In the light emitting device according to one embodiment of the present invention, the substrate includes a heat dissipation via made of metal that is bonded to the light reflection layer, the external connection terminal, or both.

  In the light emitting device according to one aspect of the present invention, the heat dissipation via is formed in a direction perpendicular to the substrate surface.

  In the light emitting device according to one embodiment of the present invention, the heat dissipation via is made of silver or a silver alloy containing silver as a main component.

  In the light emitting device according to one aspect of the present invention, the wiring pattern is made of gold.

  In the light emitting device according to one embodiment of the present invention, a nickel or chromium layer is formed between the wiring pattern and the covering layer.

  In the light-emitting device according to one embodiment of the present invention, the semiconductor device is provided over the coating layer via an adhesive resin.

  In the light emitting device according to one embodiment of the present invention, the sealing resin contains a phosphor.

  In the light emitting device according to one aspect of the present invention, the sealing resin includes a phosphor-containing resin portion that includes a phosphor, and a transparent resin portion that is formed so as to cover the phosphor-containing resin portion. Has been.

  In the light emitting device according to one embodiment of the present invention, the outer shape of the sealing resin is a dome shape.

  In the light emitting device according to one aspect of the present invention, the outer shape of the phosphor-containing resin portion and the outer shape of the transparent resin portion are dome-shaped.

  In a light emitting device according to an aspect of the present invention, a light emitting diode chip, and a package including a silver reflective layer that reflects the light emitted from the light emitting diode chip while die-bonding the light emitting diode chip to a chip mounting portion; The light emitting device includes a sealing resin that covers the light emitting diode chip, wherein the silver reflective layer is covered with a glass layer.

  In the light emitting device according to one embodiment of the present invention, the sealing resin is made of dimethyl silicone or methyl rubber.

  In the light emitting device according to the aspect of the present invention, the sealing resin absorbs at least a part of the primary light emitted from the light emitting diode chip and converts the secondary light into secondary light having a longer wavelength than the primary light. Are dispersed.

  In the light emitting device according to one aspect of the present invention, the silver reflective layer is formed on a peripheral portion of the emission surface of the light emitting device.

  In the light emitting device according to one aspect of the present invention, a recess is formed in the chip mounting portion, and an electrode pad is formed on the bottom surface of the recess.

  A method for manufacturing a package for a light emitting device according to an aspect of the present invention includes a step of preparing a plurality of green sheets mainly composed of alumina, a step of drilling a part of the green sheet, and a metal in the holes A step of filling at least one of paste or glass paste and a step of laminating and firing the plurality of green sheets so that the metal paste is covered with the glass paste are sequentially provided.

  The present invention can be applied to an illumination device or a backlight of a liquid crystal display.

1, 10, 11 LTCC substrate (substrate)
2,120 Silver reflection layer (light reflection layer)
3, 121 Glass layer 4, 112 LED chip W Bonding wire (connection part)
6, 61, 62 Phosphor-containing sealing resin (sealing resin)
7, 71 Negative electrode external connection terminal (external connection terminal)
8, 81 Positive electrode external connection terminal (external connection terminal)
9 Wiring pattern (connection part)
10a to 10j, 11a to 11j LTCC layer 12 Alumina substrate (substrate)
21 Heat radiation via 22 Wiring via 41, 113 Chip placement part 63 Phosphor-containing resin part 64 Transparent resin part 110 Package 114 Phosphor 1000, 1002, 1003, 1004, 1005, 2001, 2002, 2003
Light emitting device 1001 Light emitting unit 2004 Surface light source

Claims (4)

A ceramic substrate;
A first external terminal and a second external terminal that are exposed to the outside and provided on the ceramic substrate;
A metal layer provided on the ceramic substrate;
A light emitting diode chip electrically connected to the first external terminal and the second external terminal and provided above the upper surface of the metal layer;
A plurality of metal vias having a thickness greater than the thickness of the metal layer and connected to the underside of the metal layer;
A phosphor-containing resin covering the light-emitting diode chip;
Provided on the phosphor-containing resin, comprising a transparent resin having a dome-shaped outer shape,
The first external terminal has a first horizontal portion extending along the surface of the ceramic substrate,
The second external terminal has a second horizontal portion extending along the surface of the ceramic substrate,
The first horizontal portion has a first external exposed portion exposed to the outside,
The second horizontal portion has a second external exposed portion exposed to the outside,
The first external exposed portion overlaps the metal layer in a direction perpendicular to the surface of the ceramic substrate, such that the first external exposed portion faces the metal layer.
The second externally exposed portion overlaps the metal layer in a direction perpendicular to the surface of the ceramic substrate so that the second externally exposed portion faces the metal layer,
The ceramic substrate has a rectangular shape,
The light emitting device according to claim 1, wherein the transparent resin has a diameter smaller than each side of the ceramic substrate when viewed from a direction perpendicular to the surface of the ceramic substrate . The ceramic substrate includes a plurality of ceramic layers,
The plurality of metal vias, the light emitting device according to claim 1 in which the upper Symbol plurality of ceramic layers, characterized that you have to extend in a direction of stacking. The light emitting device according to claim 1 , wherein a position of an upper surface of the light emitting diode chip is higher than a position of an upper surface of the ceramic substrate. The light emitting device according to claim 1 , wherein the ceramic substrate is flat.

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