TW202028848A - Led light source device having directivity, method for manufacturing led light source device, and projector - Google Patents

Led light source device having directivity, method for manufacturing led light source device, and projector Download PDF

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Publication number
TW202028848A
TW202028848A TW108122144A TW108122144A TW202028848A TW 202028848 A TW202028848 A TW 202028848A TW 108122144 A TW108122144 A TW 108122144A TW 108122144 A TW108122144 A TW 108122144A TW 202028848 A TW202028848 A TW 202028848A
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refractive index
source device
light source
light
index layer
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TW108122144A
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Chinese (zh)
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榎本實
伊藤達
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日商福美斯特電子股份有限公司
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S2/00Systems of lighting devices, not provided for in main groups F21S4/00 - F21S10/00 or F21S19/00, e.g. of modular construction
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V5/00Refractors for light sources
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V9/00Elements for modifying spectral properties, polarisation or intensity of the light emitted, e.g. filters
    • F21V9/40Elements for modifying spectral properties, polarisation or intensity of the light emitted, e.g. filters with provision for controlling spectral properties, e.g. colour, or intensity
    • GPHYSICS
    • G03PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03BAPPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR
    • G03B21/00Projectors or projection-type viewers; Accessories therefor
    • G03B21/14Details
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L33/00Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L33/48Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
    • H01L33/52Encapsulations
    • H01L33/56Materials, e.g. epoxy or silicone resin

Abstract

Problem: To provide an LED light source device and a projector capable of irradiating light with a greater luminous flux amount, and a small light distribution angle with uniform intensity. Solution: This LED light source device has: an LED chip 14; a reflector 20 surrounding the periphery of the LED chip 14; and a translucent member 30 for which the top surface configured by a translucent material is formed in a lens shape, wherein the translucent member 30 has a first high refractive index layer 31 which is a layer that contacts the LED chip 14 without gaps, and is a layer having a refractive index of light of 90% or greater with respect to the refractive index of light of the LED chip 14.

Description

具有指向性之LED光源裝置、LED光源裝置之製造方法及投影機 LED light source device with directivity, manufacturing method of LED light source device, and projector

本發明係關於具有指向性之LED光源裝置、LED光源裝置之製造方法及投影機。 The present invention relates to an LED light source device with directivity, a manufacturing method of the LED light source device, and a projector.

習知已知設有內周面具反射面機能之反射器的LED光源裝置(例如參照專利文獻1)。 A conventionally known LED light source device is provided with a reflector that functions as a reflecting surface on the inner periphery (see Patent Document 1, for example).

[先前技術文獻] [Prior Technical Literature] [專利文獻] [Patent Literature]

專利文獻1:國際公開第2016/199804號 Patent Document 1: International Publication No. 2016/199804

習知技術因為設有反射器,因而可某程度增加從LED光源裝置所照射光的光束量,且可某程度縮小光的放射角,但近年期待可照射光束量更多、且放射角更小之光的LED光源裝置與投影機。又,具反射器構成的情況,頗難依光強度分佈呈均勻的方式製作反射器,渴求能照射強度均勻光的LED光源裝置與投影機。 The conventional technology is equipped with a reflector, which can increase the amount of light irradiated from the LED light source device to a certain extent, and can reduce the radiation angle of the light to a certain extent, but in recent years, it is expected that the amount of irradiated light beams will be larger and the radiation angle will be smaller. Zhiguang's LED light source device and projector. Moreover, in the case of a reflector structure, it is quite difficult to fabricate the reflector in a way that the light intensity distribution is uniform, and there is a demand for LED light source devices and projectors that can irradiate light with uniform intensity.

本發明目的在於提供:可照射光束量更多、且放射角小、強度均勻之光的LED光源裝置、LED光源裝置之製造方法及投影機。 The object of the present invention is to provide an LED light source device, a method for manufacturing the LED light source device, and a projector that can irradiate light with a larger amount of light beam, a small emission angle, and uniform intensity.

本發明第1態樣的LED光源裝置,係具備有:LED晶片、包圍上述LED晶片周圍的反射器、以及由透光性材料構成且上表面形成透鏡狀的透光性構件;其中,上述透光性構件係具有第1高折射率層,該第1高折射率層係無空隙地鄰接於上述LED晶片之層,且相對於上述LED晶片的光折射率,具有達90%以上光折射率的層。 The LED light source device according to the first aspect of the present invention includes an LED chip, a reflector surrounding the LED chip, and a light-transmitting member composed of a light-transmitting material and having a lens-like upper surface; The optical member has a first high refractive index layer, which is adjacent to the layer of the LED chip without voids, and has an optical refractive index of 90% or more relative to the optical refractive index of the LED chip的层。 The layer.

上述LED光源裝置中,上述透光性構件係更進一步具備有:光折射率較低於上述第1高折射率層的低折射率層;上述低折射率層係可構成無空隙地積層於上述第1高折射率層的上表面。 In the above LED light source device, the translucent member system further includes: a low refractive index layer having a light refractive index lower than that of the first high refractive index layer; and the low refractive index layer system may be configured to be laminated without voids on the The upper surface of the first high refractive index layer.

上述LED光源裝置中,上述透光性構件係更進一步具備有:光折射率較高於上述低折射率層的第2高折射率層;上述第2高折射率層係可構成無空隙地積層於上述低折射率層的上表面,且上表面形成透鏡狀。 In the above-mentioned LED light source device, the translucent member system further includes: a second high refractive index layer having a higher light refractive index than the low refractive index layer; and the second high refractive index layer system may constitute a laminated layer without voids On the upper surface of the low refractive index layer, the upper surface is formed into a lens shape.

上述LED光源裝置中,上述第1高折射率層係由透光性樹脂或玻璃構成;上述低折射率層係由透光性樹脂構成;上述第2高折射率層係由透光性樹脂或玻璃構成。 In the LED light source device, the first high refractive index layer is made of translucent resin or glass; the low refractive index layer is made of translucent resin; and the second high refractive index layer is made of translucent resin or glass. Composition of glass.

上述LED光源裝置中,上述第2高折射率層係可構成上表面與底面形成透鏡狀。 In the above LED light source device, the second high refractive index layer may be configured to form a lens with an upper surface and a bottom surface.

上述LED光源裝置中,上述第1高折射率層係可構成上表面形成透鏡狀。 In the above LED light source device, the first high refractive index layer may be configured to form a lens on the upper surface.

上述LED光源裝置中,上述第1高折射率層係可構成設有含螢光體之螢光體層。 In the above LED light source device, the first high refractive index layer may be formed with a phosphor layer containing a phosphor.

上述LED光源裝置中,上述透光性構件並未含硫。 In the LED light source device, the light-transmitting member does not contain sulfur.

本發明第2態樣的LED光源裝置,係具備有:LED晶片、包圍上述LED晶片周圍的反射器、以及由透光性材料構成且上表面形成透鏡狀的透光性構件;其中,上述透光性構件係無空隙地鄰接於上述LED晶片,且亦無空隙地鄰接於上述反射器的上表面。 The LED light source device according to the second aspect of the present invention is provided with: an LED chip, a reflector surrounding the LED chip, and a light-transmitting member composed of a light-transmitting material and having a lens-like upper surface; The optical member is adjacent to the LED chip without gaps, and also adjacent to the upper surface of the reflector without gaps.

上述LED裝置中,上述透光性構件係相對於上述LED晶片的光折射率,具有達80%以上的光折射率。 In the LED device, the light-transmitting member has a light refractive index of 80% or more with respect to the light refractive index of the LED chip.

上述LED裝置中,上述透光性構件係一體成形。 In the LED device, the light-transmitting member is integrally formed.

上述LED裝置中,更進一步具備有:防流出部,該防流出部係將上述透光性材料填充於上述反射器內部而一體成形上述透光性構件時,供防止上述透光性材料流出於外部用。 The above-mentioned LED device is further provided with: an outflow prevention portion for preventing the outflow of the light-transmitting material when the light-transmitting member is integrally formed by filling the light-transmitting material inside the reflector External use.

上述LED裝置中,上述透光性構件係未含硫。 In the LED device, the light-transmitting member system does not contain sulfur.

本發明的投影機,係具備有:紅色光用LED光源裝置、將從上述紅色光用LED光源裝置放射出的光進行調變的紅色光用穿透式液晶面板、綠色光用LED光源裝置;將從上述綠色光用LED光源裝置放射出的光進行調變的綠色光用穿透式液晶面板、藍色光用LED光源裝置、將從上述紅色光用LED光源裝置放射出的光進行調變的紅色光用穿透式液晶面板、將紅色光、綠色光及藍色光進行合成的雙色稜鏡、以及將來自雙色稜鏡的合成光進行投影的投影光學系統;其中,上述紅色光用LED光源裝置、上述綠色光用LED光源裝置及上述藍色光用LED光源裝置,係由上述LED光源裝置構成。 The projector of the present invention includes: an LED light source device for red light, a transmissive liquid crystal panel for red light that modulates the light emitted from the above-mentioned LED light source device for red light, and an LED light source device for green light; A transmissive liquid crystal panel for green light, an LED light source device for blue light that modulates light emitted from the above-mentioned LED light source device for green light, and an LED light source device that modulates light emitted from the above-mentioned LED light source device for red light A transmissive liquid crystal panel for red light, a two-color beam that combines red light, green light, and blue light, and a projection optical system that projects synthesized light from the two-color beam; wherein the above-mentioned LED light source device for red light The LED light source device for green light and the LED light source device for blue light are composed of the LED light source device.

根據本發明可提供:能照射光束量多、放射角小、且 均勻之光的LED光源裝置、LED光源裝置之製造方法及投影機。 According to the present invention, it is possible to provide: a large amount of irradiated beams, a small radiation angle, and Uniform light LED light source device, manufacturing method of LED light source device, and projector.

1、1a、1R、1G、1B‧‧‧LED光源裝置 1, 1a, 1R, 1G, 1B‧‧‧LED light source device

4‧‧‧投影機裝置 4‧‧‧Projector device

11‧‧‧安裝基板 11‧‧‧Mounting board

12、12a‧‧‧佈線層 12, 12a‧‧‧wiring layer

13、13a‧‧‧防焊層 13, 13a‧‧‧Solder mask

14‧‧‧LED晶片 14‧‧‧LED chip

15‧‧‧絕緣層 15‧‧‧Insulation layer

16‧‧‧接著層 16‧‧‧Next layer

17‧‧‧金屬基板 17‧‧‧Metal substrate

18‧‧‧導線 18‧‧‧Wire

20‧‧‧反射器 20‧‧‧Reflector

21‧‧‧上表面 21‧‧‧Upper surface

22‧‧‧開口部 22‧‧‧Opening

23‧‧‧壩部 23‧‧‧Babe

24‧‧‧凹部 24‧‧‧Concave

30、30a、30b‧‧‧透光性構件 30, 30a, 30b‧‧‧Translucent member

31‧‧‧第1高折射率層 31‧‧‧The first high refractive index layer

31a‧‧‧高折射率層 31a‧‧‧High refractive index layer

32‧‧‧低折射率層 32‧‧‧Low refractive index layer

33‧‧‧第2高折射率層 33‧‧‧The second high refractive index layer

41‧‧‧雙色稜鏡 41‧‧‧Two-color 稜鏡

42、42R、42G、42B‧‧‧準直儀透鏡 42, 42R, 42G, 42B‧‧‧Collimator lens

43、43R、43G、43B‧‧‧液晶光閥 43, 43R, 43G, 43B‧‧‧LCD light valve

44‧‧‧投射光學系統 44‧‧‧Projection optical system

311‧‧‧螢光體層 311‧‧‧ Phosphor layer

312‧‧‧非螢光體層 312‧‧‧Non-fluorescent body layer

313‧‧‧底面 313‧‧‧Bottom

L‧‧‧投射光 L‧‧‧Projection light

圖1係本實施形態的投影機概要圖。 Fig. 1 is a schematic diagram of the projector of this embodiment.

圖2係第1實施形態的LED光源裝置平面圖。 Fig. 2 is a plan view of the LED light source device of the first embodiment.

圖3係沿圖2所示LED光源裝置之III-III線的剖視圖。 Fig. 3 is a cross-sectional view taken along the line III-III of the LED light source device shown in Fig. 2.

圖4係模擬所使用LED光源裝置與投影機的說明圖。 Fig. 4 is an explanatory diagram of the LED light source device and the projector used in the simulation.

圖5係實施例1,距LED晶片之光軸的距離與光束密度的關係模擬結果圖。 Fig. 5 is a simulation result diagram of the relationship between the distance from the optical axis of the LED chip and the beam density in Example 1.

圖6係實施例2,距LED晶片之光軸的距離與光束密度的關係模擬結果圖。 Fig. 6 is a simulation result diagram of the relationship between the distance from the optical axis of the LED chip and the beam density in Example 2.

圖7係第2實施形態的LED光源裝置剖視圖。 Fig. 7 is a cross-sectional view of an LED light source device according to a second embodiment.

圖8係第3實施形態的LED光源裝置剖視圖。 Fig. 8 is a cross-sectional view of an LED light source device according to a third embodiment.

圖9係第4實施形態的LED光源裝置剖視圖。 Fig. 9 is a cross-sectional view of an LED light source device according to a fourth embodiment.

圖10係使用不同折射率之透光性構件時,光束量的模擬結果圖。 Figure 10 is a graph showing the simulation results of the beam volume when using translucent members with different refractive indices.

圖11係另一實施形態的LED光源裝置剖視圖。 Fig. 11 is a cross-sectional view of an LED light source device according to another embodiment.

以下,根據圖式說明本發明的實施形態。 Hereinafter, embodiments of the present invention will be described based on the drawings.

《第1實施形態》 "First Embodiment"

(投影機裝置) (Projector device)

圖1所示係本實施形態的投影機裝置4之構成圖。本實施形態的投影機裝置4,係具備有:3個LED光源裝置1、3個準直儀透 鏡42、3個液晶光閥43、雙色稜鏡41、以及投射光學系統44。 Fig. 1 shows a configuration diagram of a projector device 4 of this embodiment. The projector device 4 of this embodiment is equipped with: 3 LED light source devices 1, 3 collimators A mirror 42, three liquid crystal light valves 43, a two-color rim 41, and a projection optical system 44.

LED光源裝置1、準直儀透鏡42及液晶光閥43,係供將R(紅色)、G(綠色)、B(藍色)光放射於雙色稜鏡41用。來自LED光源裝置1R的紅色光(R光)利用準直儀透鏡42R平行化,再利用液晶光閥43R進行光調變。液晶光閥43R係呈矩陣狀配置的穿透式液晶面板(HTPS液晶面板),將R光配合影像訊號依每個像素進行調變的公知光調變器。來自LED光源裝置1G的綠色光(G光)、與來自LED光源裝置1B的藍色光(B光)亦同,利用準直儀透鏡42G、42B平行化,再利用公知液晶光閥43G、43B進行光調變。 The LED light source device 1, the collimator lens 42 and the liquid crystal light valve 43 are used to radiate R (red), G (green), and B (blue) light to the two-color beam 41. The red light (R light) from the LED light source device 1R is parallelized by the collimator lens 42R, and the light is modulated by the liquid crystal light valve 43R. The liquid crystal light valve 43R is a transmissive liquid crystal panel (HTPS liquid crystal panel) arranged in a matrix, and a known light modulator that modulates the R light with the image signal for each pixel. The green light (G light) from the LED light source device 1G and the blue light (B light) from the LED light source device 1B are also parallelized by collimator lenses 42G and 42B, and then performed by well-known liquid crystal light valves 43G and 43B. Light modulation.

雙色稜鏡41係具有配置成相互正交的2個雙色膜,其中一個雙色膜係將R光反射,而除R光以外的G光與B光則穿透,另一雙色膜係將B光反射,使除B光以外的R光與G光穿透。投射光學系統44係具備有:將由雙色稜鏡41合成的光入射的複數投影透鏡、以及收容複數投影透鏡的投影透鏡筐體;放射投射光L而將彩色影像放大投影於螢幕上。 The two-color film 41 has two two-color films arranged orthogonal to each other. One of the two-color film reflects R light, while G and B light other than R light penetrates, and the other two-color film reflects B light. , So that R light and G light except B light penetrate. The projection optical system 44 is provided with a plurality of projection lenses for incident light synthesized by the dichroic lens 41, and a projection lens housing for accommodating the plurality of projection lenses, and radiates projection light L to enlarge and project a color image on the screen.

(LED光源裝置) (LED light source device)

其次,針對構成圖1所示投影機裝置4的第1實施形態LED光源裝置1進行說明。 Next, the LED light source device 1 of the first embodiment constituting the projector device 4 shown in FIG. 1 will be described.

圖2所示係本實施形態LED光源裝置1的平面圖,圖3所示係沿圖2所示LED光源裝置1的III-III線剖視圖。本實施形態的LED光源裝置1係如圖2、3所示,具備有:安裝基板11、形成於安裝基板11上表面的佈線層12、保護佈線層12的防焊層13、複數LED晶片14、反射器20、以及透光性構件30。另外,圖 2、3所示例中,LED光源裝置1係例示具備有呈串聯3×並聯3的9個LED晶片14構成,LED晶片14的數量並無限定,可為1個、亦可為2~8個、亦可達10個以上。 FIG. 2 shows a plan view of the LED light source device 1 of this embodiment, and FIG. 3 shows a cross-sectional view taken along the line III-III of the LED light source device 1 shown in FIG. 2. The LED light source device 1 of this embodiment is shown in FIGS. 2 and 3, and includes: a mounting substrate 11, a wiring layer 12 formed on the upper surface of the mounting substrate 11, a solder resist layer 13 for protecting the wiring layer 12, and a plurality of LED chips 14 , Reflector 20, and translucent member 30. In addition, the figure In the examples of 2 and 3, the LED light source device 1 is configured with 9 LED chips 14 in series 3×3 in parallel. The number of LED chips 14 is not limited, and it can be 1 or 2 to 8 , It can also reach more than 10.

LED晶片14係表面安裝型配對LED晶片。本實施形態中,LED晶片14係使用放射藍色光之具有藍寶石基板的LED晶片,惟LED晶片14並無特別的限定,亦可使用例如:氮化鎵系(GaN、AlGaN、InGaN)LED晶片、照射紫外線(特別係UVA)的LED晶片。本實施形態中,LED晶片14係利用倒裝晶片安裝焊接於佈線層12,惟並不僅侷限於該構成,例如亦可利用打線接合焊接LED晶片14。 The LED chip 14 is a surface mount type matched LED chip. In this embodiment, the LED chip 14 is an LED chip with a sapphire substrate that emits blue light. However, the LED chip 14 is not particularly limited. For example, gallium nitride-based (GaN, AlGaN, InGaN) LED chips, LED chip irradiated with ultraviolet light (especially UVA). In this embodiment, the LED chip 14 is mounted and soldered to the wiring layer 12 by flip chip mounting, but it is not limited to this configuration. For example, the LED chip 14 may be soldered by wire bonding.

本實施形態中,多數個LED晶片14呈串聯n×並m(例如本實施形態為串聯3×並聯3)二維狀配置,所謂COB(Chip On Board,板上晶片)安裝。為實現高輝度,LED晶片14係使用例如最大額定電流300mA以上、較佳係最大額定電流400mA以上、更佳係最大額定電流500mA以上的LED晶片。例如光閥43為0.5~0.7"的情況,就從光展量(Etendue)的態樣,LED晶片14的大小較佳係3~4mm四方以下、更佳係1.5mm四方以下。 In this embodiment, a large number of LED chips 14 are arranged in series n×parallel m (for example, in this embodiment, series 3×parallel 3) two-dimensional arrangement, so-called COB (Chip On Board) mounting. In order to achieve high brightness, the LED chip 14 uses, for example, an LED chip with a maximum rated current of 300 mA or more, preferably a maximum rated current of 400 mA or more, and more preferably a maximum rated current of 500 mA or more. For example, when the light valve 43 is 0.5-0.7", from the aspect of Etendue, the size of the LED chip 14 is preferably less than 3 to 4 mm square, more preferably less than 1.5 mm square.

例如本實施形態中,LED晶片14係使用最大額定電流2~4A的LED晶片。此情況,由LED晶片14產生的熱量亦多,必需將LED晶片14的熱有效率地散熱。所以,本實施形態中,安裝基板11係使用例如氮化鋁、氮化矽等高散熱性絕緣體。藉此,藉由將LED晶片14的熱有效率地傳導給安裝基板11而進行散熱,便可提升LED光源裝置1的耐久性。例如當在由銅板構成的安裝基板上,為確保絕緣性而積層由玻璃環氧樹脂構成的絕緣層時,由 銅板所構成安裝基板的熱阻(θ jc)係成為晶片每mm2為10~12℃/W,而由氮化鋁所構成安裝基板11的熱阻(θ jc)係2~4℃/W。依此當氮化鋁使用為安裝基板11時,可將由LED晶片14所生成的熱有效率地散熱。 For example, in this embodiment, the LED chip 14 uses an LED chip with a maximum rated current of 2 to 4A. In this case, the heat generated by the LED chip 14 is also large, and the heat of the LED chip 14 must be efficiently dissipated. Therefore, in this embodiment, a high heat dissipation insulator such as aluminum nitride and silicon nitride is used for the mounting substrate 11. Thereby, by efficiently transferring the heat of the LED chip 14 to the mounting substrate 11 for heat dissipation, the durability of the LED light source device 1 can be improved. For example, when an insulating layer made of glass epoxy resin is laminated on a mounting substrate made of copper plate to ensure insulation, the thermal resistance (θ jc) of the mounting substrate made of copper plate is 10~ per mm 2 of the chip. 12°C/W, and the thermal resistance (θ jc) of the mounting substrate 11 made of aluminum nitride is 2 to 4°C/W. Accordingly, when aluminum nitride is used as the mounting substrate 11, the heat generated by the LED chip 14 can be efficiently dissipated.

如圖3所示,在安裝基板11上形成佈線層12。佈線層12係銅箔等金屬膜。另外,佈線層12係電氣式耦接於未圖示之電源與控制裝置。佈線層12係藉由對銅箔施行光蝕刻而除去不需要的部分,便可形成佈線層12。另外,圖2中,省略圖示佈線層12。又,佈線層12所使用的素材並未限定於銅箔膜,亦可使用例如:銀膏、銅膏等金屬。該佈線層12係經使用NiCrAu、NiPdAu等,利用電鍍施行表面處理。 As shown in FIG. 3, a wiring layer 12 is formed on the mounting substrate 11. The wiring layer 12 is a metal film such as copper foil. In addition, the wiring layer 12 is electrically coupled to a power supply and control device not shown. The wiring layer 12 is formed by photoetching the copper foil to remove unnecessary parts. In addition, in FIG. 2, the wiring layer 12 is omitted from the illustration. In addition, the material used for the wiring layer 12 is not limited to the copper foil film, and metals such as silver paste and copper paste may also be used. The wiring layer 12 uses NiCrAu, NiPdAu, etc., and is surface-treated by electroplating.

再者,在部分的佈線層12上積層防焊層13。防焊層13的主要成分係聚矽氧樹脂、玻璃環氧樹脂、聚醯胺樹脂,具有保護佈線層12的機能。又,防焊層13係含有例如:氧化鈦(TiO2)、氧化鋅、氧化鋁等白色無機顏料,亦可具反射材的機能。 Furthermore, a solder resist layer 13 is laminated on part of the wiring layer 12. The main components of the solder mask layer 13 are silicone resin, glass epoxy resin, and polyamide resin, and have the function of protecting the wiring layer 12. In addition, the solder resist layer 13 contains, for example, white inorganic pigments such as titanium oxide (TiO 2 ), zinc oxide, and aluminum oxide, and may also function as a reflective material.

LED光源裝置1中,如圖2、3所示,依包圍LED晶片14周圍的方式設置反射器20。反射器20係可構成至少在內部表面上,設有會引起正反射的鋁等光反射金屬膜。又,亦可反射器全體均由鋁等形成。本實施形態中,經對LED晶片14施行焊接處理後,便在防焊層13上形成反射器20。又,本實施形態中,由1個反射器20包圍複數LED晶片14,但亦可利用反射器20分別包圍各LED晶片14。 In the LED light source device 1, as shown in FIGS. 2 and 3, a reflector 20 is provided so as to surround the periphery of the LED chip 14. The reflector 20 may be configured to be provided with a light-reflecting metal film such as aluminum that causes regular reflection on at least the inner surface. In addition, the entire reflector may be formed of aluminum or the like. In this embodiment, after the LED chip 14 is soldered, the reflector 20 is formed on the solder mask 13. In addition, in this embodiment, the plurality of LED chips 14 are surrounded by one reflector 20, but each LED chip 14 may be surrounded by the reflector 20, respectively.

其次,針對本實施形態的透光性構件30進行說明。透光性構件30係由例如:玻璃、透光性樹脂材料等透光性材料構 成,上表面形成透鏡狀。透光性構件30係如圖3所示,具備有:第1高折射率層31、低折射率層32、及第2高折射率層33。 Next, the translucent member 30 of the present embodiment will be described. The translucent member 30 is made of translucent materials such as glass and translucent resin materials. The upper surface forms a lens shape. As shown in FIG. 3, the light-transmitting member 30 includes a first high refractive index layer 31, a low refractive index layer 32, and a second high refractive index layer 33.

第1高折射率層31係例如由環氧系、聚矽氧系所構成的透明樹脂、或由玻璃構成的透光性層,相對於LED晶片14的光折射率,具有達90%以上之光折射率的透光性層。例如LED晶片14係藍寶石基板的LED晶片時,因為LED晶片的光折射率n係1.768,因而第1高折射率層31的光折射率n便設為1.591以上。即,尋常使用聚矽氧樹脂的透光性樹脂,光折射率係1.4~1.57左右,但若本實施形態的第1高折射率層係使用光折射率n達1.591以上的高折射樹脂。此種高折射樹脂係可使用例如:光折射率n為1.76的LPL-1150(三菱瓦斯化學)、光折射率n為1.74的MR-174(三井化學)、光折射率n為1.64的OKP(Osaka Gas Chemicals)等。 The first high refractive index layer 31 is, for example, a transparent resin made of epoxy or silicone, or a translucent layer made of glass, and has a refractive index of 90% or more with respect to the light refractive index of the LED chip 14. Translucent layer of light refractive index. For example, when the LED chip 14 is an LED chip with a sapphire substrate, since the light refractive index n of the LED chip is 1.768, the light refractive index n of the first high refractive index layer 31 is set to 1.591 or more. That is, the light-transmitting resin of polysiloxane resin is usually used, and the optical refractive index is about 1.4 to 1.57. However, if the first high refractive index layer of the present embodiment uses a highly refractive resin with an optical refractive index n of 1.591 or more. Such highly refractive resins can be used, for example, LPL-1150 (Mitsubishi Gas Chemicals) with an optical refractive index n of 1.76, MR-174 (Mitsui Chemicals) with an optical refractive index n of 1.74, and OKP ( Osaka Gas Chemicals) etc.

再者,第1高折射率層31係如圖3所示,具備有:含螢光體的螢光體層311、及未含螢光體的非螢光體層312。換言之,螢光體層311與非螢光體層312一起構成相對於LED晶片14的光折射率,具有達90%以上光折射率的第1高折射率層31。另外,當LED晶片14本身便會照射紅色光、綠色光、或藍色光的LED晶片時,便不需要供照射紅色光、綠色光、或藍色光的螢光體層311,可僅由非螢光體層312構成第1高折射率層31。本實施形態,因為具備有照射藍色光的LED晶片14,因而為照射紅色或綠色光而設置螢光體層311。 Furthermore, as shown in FIG. 3, the first high refractive index layer 31 includes a phosphor layer 311 containing a phosphor, and a non-fluorescent layer 312 that does not contain a phosphor. In other words, the phosphor layer 311 and the non-phosphor layer 312 together constitute the first high refractive index layer 31 having an optical refractive index of 90% or more with respect to the optical refractive index of the LED chip 14. In addition, when the LED chip 14 itself irradiates red light, green light, or blue light, the phosphor layer 311 for irradiating red light, green light, or blue light is not needed, and only non-fluorescent light The bulk layer 312 constitutes the first high refractive index layer 31. In this embodiment, since the LED chip 14 for irradiating blue light is provided, the phosphor layer 311 is provided for irradiating red or green light.

螢光體層311係在供構成第1高折射率層31用的高折射樹脂中混入螢光體,依無空隙地鄰接於LED晶片14之方式,將已混入螢光體的高折射樹脂,在反射器20內填充至超過LED晶 片14上表面位置處而形成。另外,螢光體層311所含的螢光體並無特別的限定,可配合所需的光色再行適當設定。另外,本實施形態例示在高折射樹脂中混入螢光體而形成螢光體層311的構成,惟並不僅侷限於此構成,亦可例如藉由在LED晶片14的上表面貼附螢光體層311之片,而在LED晶片14上表面積層螢光體層311。 For the phosphor layer 311, a phosphor is mixed into the high refractive resin used to form the first high refractive index layer 31, and the high refractive resin mixed into the phosphor is made to adjoin the LED chip 14 without gaps. The reflector 20 is filled to exceed the LED crystal The sheet 14 is formed at the upper surface position. In addition, the phosphor contained in the phosphor layer 311 is not particularly limited, and can be appropriately set according to the required light color. In addition, this embodiment exemplifies a structure in which phosphor is mixed with a high-refractive resin to form the phosphor layer 311, but it is not limited to this structure. For example, the phosphor layer 311 may be attached to the upper surface of the LED chip 14. A phosphor layer 311 is layered on the surface of the LED chip 14.

在螢光體層311的上表面,積層著由未含螢光體、且高折射材料構成的非螢光體層312。非螢光體層312係上表面形成透鏡狀(曲面)。非螢光體層312的透鏡形狀係利用公知方法,設計成在非螢光體層312與低折射率層32的邊界面幾乎不會發生全反射的形狀。例如本實施形態,非螢光體層312的上表面形成半徑R:0.576mm狀態。非螢光體層312係使用具有對應於非螢光體層312上表面形狀之曲面的模具,將高折射率透光性樹脂填充於模具中,經硬化便可成形。又,亦可預先使用模具另行製作非螢光體層312,再依將所製造非螢光體層312積層於螢光體層311上的狀態下,使螢光體層311硬化,便形成非螢光體層312貼附於螢光體層311上表面(特別係非螢光體層312係由玻璃構成時,最好另行製造)。藉此,密接於LED晶片14,便可在與LED晶片14間沒有空隙狀態下,構成由螢光體層311與非螢光體層312構成的第1高折射率層31。另外,透光性樹脂硬化的方法亦可例如使用金屬模具進行加熱而使硬化的方法,亦可例如使用由透光性玻璃等構成的模具,從外面照射UV光而使硬化的方法。 On the upper surface of the phosphor layer 311, a non-phosphor layer 312 made of a high-refractive material without phosphor is laminated. The upper surface of the non-phosphor layer 312 is formed into a lens shape (curved surface). The lens shape of the non-fluorescent body layer 312 is designed by a known method so that the boundary surface between the non-fluorescent body layer 312 and the low refractive index layer 32 hardly causes total reflection. For example, in this embodiment, the upper surface of the non-phosphor layer 312 is in a state of radius R: 0.576 mm. The non-fluorescent body layer 312 is formed by using a mold having a curved surface corresponding to the shape of the upper surface of the non-fluorescent body layer 312, filling the mold with a high refractive index light-transmitting resin, and curing it. In addition, the non-phosphor layer 312 may be separately fabricated using a mold in advance, and then the non-phosphor layer 312 is hardened in the state where the manufactured non-phosphor layer 312 is laminated on the phosphor layer 311 to form the non-phosphor layer 312 It is attached to the upper surface of the phosphor layer 311 (especially when the non-fluorescent layer 312 is made of glass, it is better to manufacture separately). Thereby, the LED chip 14 is in close contact, and the first high refractive index layer 31 composed of the phosphor layer 311 and the non-phosphor layer 312 can be formed without a gap between the LED chip 14 and the LED chip 14. In addition, the method of curing the translucent resin may be, for example, a method of heating and curing using a metal mold, or a method of curing by irradiating UV light from the outside using a mold made of translucent glass or the like.

再者,本實施形態,在第1高折射率層31上表面無空隙地積層著低折射率層32。低折射率層32係由例如環氧系、聚矽氧系透明樹脂構成的透光性樹脂層,在反射器20內將低折射樹 脂填充至反射器20上表面的高度位置處,經使硬化而形成。又,低折射率層32係具有光折射率較低於第1高折射率層31之光折射率的透光性樹脂層。例如第1高折射率層31的光折射率n係1.76時,低折射率層32的折射率n便設為未滿1.74。此種低折射樹脂係可使用例如:光折射率n為1.54的OE6351(Toray‧Dow Corning股份有限公司)、光折射率n為1.51的KER6200(信越化學工業股份有限公司)等。 Furthermore, in this embodiment, the low refractive index layer 32 is laminated on the upper surface of the first high refractive index layer 31 without voids. The low refractive index layer 32 is a translucent resin layer made of, for example, epoxy-based, silicone-based transparent resin, and the low-refractive resin layer is formed in the reflector 20. Grease is filled up to the height of the upper surface of the reflector 20, and is formed by curing. In addition, the low refractive index layer 32 is a translucent resin layer having a light refractive index lower than that of the first high refractive index layer 31. For example, when the optical refractive index n of the first high refractive index layer 31 is 1.76, the refractive index n of the low refractive index layer 32 is less than 1.74. For such a low-refractive resin system, for example, OE6351 (Toray•Dow Corning Co., Ltd.) with an optical refractive index n of 1.54, KER6200 (Shin-Etsu Chemical Co., Ltd.) with an optical refractive index n of 1.51, etc. can be used.

再者,本實施形態,在低折射率層32的上表面無空隙地積層著第2高折射率層33。第2高折射率層33係由例如環氧系、聚矽氧系透光性樹脂、玻璃等透光性材料構成的透光性層,如圖3所示,上表面形成透鏡狀。例如將具有對應於第2高折射率層33上表面形狀之曲面的模具,覆蓋在反射器20上,在該模具中填充高折射率透光性樹脂,經硬化,便可在低折射率層32的上表面無空隙地形成第2高折射率層33。另外,相關第2高折射率層33亦是與第1高折射率層31同樣,使用金屬模具,利用加熱便可使硬化,但亦可使用由透光性玻璃等構成的模具,從外面照射UV光而使硬化的方法。又,同第1高折射率層31,亦可預先使用模具另行製造第2高折射率層33,在所製造的第2高折射率層33積層於低折射率層32上的狀態下,使第2高折射率層33硬化,便可形成第2高折射率層33貼附於低折射率層32上表面(特別係第2高折射率層33係由玻璃構成時,最好另行製造)。 Furthermore, in this embodiment, the second high refractive index layer 33 is laminated on the upper surface of the low refractive index layer 32 without voids. The second high refractive index layer 33 is a translucent layer made of a translucent material such as epoxy-based, silicone-based translucent resin, glass, and the like, and as shown in FIG. 3, the upper surface is formed in a lens shape. For example, a mold having a curved surface corresponding to the shape of the upper surface of the second high refractive index layer 33 is covered on the reflector 20, and the mold is filled with a high refractive index light-transmitting resin, and after hardening, the low refractive index layer The second high refractive index layer 33 is formed on the upper surface of 32 without voids. In addition, the related second high refractive index layer 33 is also the same as the first high refractive index layer 31. A metal mold is used and can be cured by heating. However, a mold made of translucent glass can also be used to irradiate from the outside. The method of curing by UV light. Also, as with the first high refractive index layer 31, the second high refractive index layer 33 may be separately manufactured using a mold in advance, and the manufactured second high refractive index layer 33 may be laminated on the low refractive index layer 32. The second high refractive index layer 33 is hardened to form the second high refractive index layer 33 and attached to the upper surface of the low refractive index layer 32 (especially when the second high refractive index layer 33 is made of glass, it is better to manufacture separately) .

第2高折射率層33係光折射率較高於低折射率層32之光折射率的透光性層。例如與第1高折射率層31同樣使用透光性樹脂、玻璃便可形成第2高折射率層33。惟,並不僅侷限於此構 成,在光折射率較高於低折射率層32之前提下,亦可使用折射率較低於第1高折射率層31、或高折射率透光性樹脂或玻璃,形成第2高折射率層33。又,本實施形態中,第2高折射率層33係無間隙地鄰接反射器20的上表面21,形成覆蓋著較反射器20之開口部22(從上方觀看反射器20時,較上表面21更靠內側部分的開口)更寬廣範圍。 The second high refractive index layer 33 is a translucent layer whose optical refractive index is higher than that of the low refractive index layer 32. For example, it is possible to form the second high refractive index layer 33 by using translucent resin or glass as in the first high refractive index layer 31. However, it is not limited to this structure Therefore, before the light refractive index is higher than the low refractive index layer 32, the refractive index lower than the first high refractive index layer 31, or high refractive index translucent resin or glass can also be used to form the second high refractive index layer.率层33. Furthermore, in this embodiment, the second high refractive index layer 33 is adjacent to the upper surface 21 of the reflector 20 without a gap, and forms an opening 22 covering the lower reflector 20 (when the reflector 20 is viewed from above, the upper surface 21. The opening on the inner side) has a wider range.

如上述,本實施形態,第1高折射率層31係依無空隙地鄰接LED晶片14狀態積層,且低折射率層32與第2高折射率層33亦係依無空隙地分別鄰接第1高折射率層31與低折射率層32的狀態積層,藉此便可依密接於LED晶片14,在與LED晶片14間沒有空隙的狀態下,構成透光性構件30。 As described above, in this embodiment, the first high refractive index layer 31 is laminated in a state adjacent to the LED chip 14 without voids, and the low refractive index layer 32 and the second high refractive index layer 33 are also adjacent to the first without voids. The high-refractive index layer 31 and the low-refractive index layer 32 are laminated in a state where they can be closely attached to the LED chip 14 to form the light-transmitting member 30 without a gap between the LED chip 14 and the LED chip 14.

其次,針對本實施形態的LED光源裝置1與投影機裝置4之性能進行說明。實施例1,如圖4所示,具有1個寬W為1.0mm的LED晶片14,將反射器20的高度H1設為0.7mm,從LED晶片14的上表面距第2高折射率層33的頂點之高度H2設為2.5mm,第2高折射率層33的寬度L設為5mm,第2高折射率層33的透鏡半徑設為2.78mm,模擬LED光源裝置1的性能。又,實施例1,如圖4所示,亦針對在LED光源裝置1照射方向上安裝準直儀透鏡42的投影機裝置4進行模擬。模擬結果如下述。 Next, the performance of the LED light source device 1 and the projector device 4 of this embodiment will be described. Example 1, as shown in FIG. 4, has an LED chip 14 with a width W of 1.0 mm. The height H1 of the reflector 20 is set to 0.7 mm, and the distance from the upper surface of the LED chip 14 to the second high refractive index layer 33 The height H2 of the apex of is set to 2.5 mm, the width L of the second high refractive index layer 33 is set to 5 mm, and the lens radius of the second high refractive index layer 33 is set to 2.78 mm to simulate the performance of the LED light source device 1. In addition, in Embodiment 1, as shown in FIG. 4, simulation was also performed on the projector device 4 in which the collimator lens 42 was installed in the irradiation direction of the LED light source device 1. The simulation results are as follows.

下述表1所示係以下所說明的(A)~(E)構成中,在距準直儀透鏡42所配置位置離10mm處的受光面,受光時的光束量(lm)。此處,(A)係僅LED晶片14的構成(未設反射器20與透光性構件30的構成),(B)係圖4所示在LED光源裝置1中僅未設第2高折射率層33的構成(透光性構件30僅具有第1高折射率層31與 低折射率層32的構成),(C)係同圖3所示LED光源裝置1,但亦具有第2高折射率層33的構成之LED光源裝置模擬結果。又,(D)係如圖4所示,在LED光源裝置1前配置準直儀透鏡42的構成,(E)係(D)光束中,配光角在12°以下的光束之投影機裝置4模擬結果。 The following Table 1 shows the amount of light beam (lm) when receiving light on the light receiving surface 10 mm away from the position where the collimator lens 42 is arranged in the configurations (A) to (E) described below. Here, (A) is the structure of only the LED chip 14 (the reflector 20 and the translucent member 30 are not provided), and (B) is shown in FIG. 4 and only the second high refractive index is not provided in the LED light source device 1 The structure of the rate layer 33 (the translucent member 30 only has the first high refractive index layer 31 and The structure of the low refractive index layer 32), (C) is the same as the LED light source device 1 shown in FIG. 3, but also has a simulation result of the LED light source device having the structure of the second high refractive index layer 33. In addition, (D) is a configuration in which a collimator lens 42 is arranged in front of the LED light source device 1, as shown in FIG. 4, and (E) is a projector device with a beam with a light distribution angle of 12° or less in the beam of (D) 4 Simulation results.

Figure 108122144-A0101-12-0012-1
Figure 108122144-A0101-12-0012-1

如上述表1所示,相較於(A)之下,(B)的光束量成為約1.5倍。此現象係藉由將第1高折射率層31依無空隙地鄰接LED晶片14上表面的方式積層,而抑制在LED晶片14內所產生的光,於LED晶片14與第1高折射率層31的邊界面被全反射,便可取出於LED晶片14外面的緣故所致。又,藉由將第1高折射率層31的上表面設為透鏡狀,亦可抑制第1高折射率層31與低折射率層32之邊界面處的全反射,同時實施例1,藉由依被反射器20反射之從低折射率層32入射於外部的光束入射角變小方式,增加反射器20的傾斜角(急遽傾斜),亦能抑制在低折射率層32與外部空氣邊界面的全反射,便可將光束導向於外部。 As shown in Table 1 above, the beam volume of (B) is approximately 1.5 times lower than that of (A). This phenomenon is caused by laminating the first high-refractive index layer 31 in such a way that it is adjacent to the upper surface of the LED chip 14 without any gaps, thereby suppressing the light generated in the LED chip 14 and the LED chip 14 and the first high-refractive index layer The boundary surface of 31 is totally reflected and can be taken out of the LED chip 14 because of the reason. In addition, by making the upper surface of the first high refractive index layer 31 into a lens shape, it is also possible to suppress total reflection at the boundary surface of the first high refractive index layer 31 and the low refractive index layer 32. At the same time, in the first embodiment, By reducing the incident angle of the light beam incident from the low refractive index layer 32 to the outside by the reflector 20, increasing the inclination angle (a sharp tilt) of the reflector 20 can also suppress the boundary surface between the low refractive index layer 32 and the outside air. The total reflection can guide the beam to the outside.

再者,相較於(B)之下,(C)的光束量更增加約1.5倍。此現象係(B)在低折射率層32與外部空氣的邊界面發生全反射,部分光束未被放射至LED光源裝置1的外部,相對於此,(C)係因為低折射率層32上,因為上表面形成透鏡狀第2高折射率層33,因 而抑制第2高折射率層33與外部空氣邊界面的全反射,便可將更多的光束放射至LED光源裝置1的外部之緣故所致。 Furthermore, compared to (B), the beam volume of (C) is increased by about 1.5 times. This phenomenon is caused by (B) that total reflection occurs on the boundary surface between the low refractive index layer 32 and the outside air, and part of the light beam is not radiated to the outside of the LED light source device 1. In contrast, (C) is caused by the low refractive index layer 32 , Because the lenticular second high refractive index layer 33 is formed on the upper surface, By suppressing the total reflection of the boundary surface between the second high refractive index layer 33 and the outside air, more light beams can be radiated to the outside of the LED light source device 1.

依此,藉由將第1高折射率層31依無空隙地鄰接LED晶片14的方式積層,針對LED晶片14所產生的光,可抑制在LED晶片14與第1高折射率層31邊界面處的全反射,便能從LED晶片14取出。又,藉由將第1高折射率層31的上表面設為透鏡狀,便可抑制第1高折射率層31與低折射率層32邊界面的全反射,俾能將光束放射至LED光源裝置1的外部。又,藉由將第2高折射率層33的上表面設為透鏡狀,便可抑制第2高折射率層33與外部空氣邊界面的全反射,俾能將更多光束放射至LED光源裝置1的外部。另外,得知(D)、(E)受準直儀透鏡42的影響,光束量較低於(C),但光束量則較(B)增加。 Accordingly, by laminating the first high refractive index layer 31 so as to be adjacent to the LED chip 14 without voids, the light generated by the LED chip 14 can be suppressed on the boundary surface between the LED chip 14 and the first high refractive index layer 31 The total reflection at the position can be taken out from the LED chip 14. In addition, by making the upper surface of the first high refractive index layer 31 into a lens shape, it is possible to suppress the total reflection of the boundary surface between the first high refractive index layer 31 and the low refractive index layer 32, so that the light beam can be radiated to the LED light source. The exterior of the device 1. In addition, by making the upper surface of the second high refractive index layer 33 into a lens shape, the total reflection of the boundary surface between the second high refractive index layer 33 and the outside air can be suppressed, so that more light beams can be radiated to the LED light source device. 1 outside. In addition, it is known that (D) and (E) are affected by the collimator lens 42, and the beam volume is lower than (C), but the beam volume is larger than (B).

再者,圖5所示係距LED晶片14之光軸O的距離L、與光束密度(lm/mm2)的關係圖。如圖5所示,相較於(A)與(B)之下,(C)係無關距LED晶片14之光軸O的距離L,光束密度(lm/mm2)均有變大。由此現象得知藉由設置上表面形成透鏡狀的第2高折射率層33,被射出於LED光源裝置1外部的光之光束密度(lm/mm2)會變大。又,有設置準直儀透鏡42的投影機(D)、(E),因為從LED光源裝置1所照射的光束可利用準直儀透鏡42收束,因而相較於(A)~(C)之下,得知在LED晶片14的光軸O附近(距LED晶片14之光軸在3~4mm範圍內)的光束密度(lm/mm2)較高,若遠離LED晶片14的光軸O,則光束密度(lm/mm2)便急遽降低。即,得知可縮小LED晶片14的配光角。又,如圖5所示,得知(D)、(E)係即便利用準直儀透鏡42收束的情況,在LED晶片14的光軸O附近之 光束密度(lm/mm2)仍較穩定,可放射沒有不均情形的強度均勻光。 Furthermore, FIG. 5 shows the relationship between the distance L from the optical axis O of the LED chip 14 and the beam density (lm/mm 2 ). As shown in FIG. 5, compared with (A) and (B), (C) is independent of the distance L from the optical axis O of the LED chip 14, and the beam density (lm/mm 2 ) is increased. From this phenomenon, it is understood that by providing the second high refractive index layer 33 with a lens-like upper surface, the beam density (lm/mm 2 ) of the light emitted from the outside of the LED light source device 1 increases. In addition, there are projectors (D) and (E) equipped with a collimator lens 42. Because the light beam irradiated from the LED light source device 1 can be condensed by the collimator lens 42, it is compared with (A)~(C ), it is known that the beam density (lm/mm 2 ) near the optical axis O of the LED chip 14 (within the range of 3~4mm from the optical axis of the LED chip 14) is higher, if it is far away from the optical axis of the LED chip 14 O, the beam density (lm/mm 2 ) is drastically reduced. That is, it is found that the light distribution angle of the LED chip 14 can be reduced. Furthermore, as shown in FIG. 5, it is known that even if the beams (D) and (E) are condensed by the collimator lens 42, the beam density (lm/mm 2 ) near the optical axis O of the LED chip 14 is still relatively high. It is stable and can emit uniform intensity light without unevenness.

再者,實施例2,設有1個寬W為1.0mm之LED晶片14,並將反射器20之高度H1設為0.75mm、LED晶片14上表面距第2高折射率層33頂點的高度H2設為2.45mm、第2高折射率層33的寬度D設為3.64mm、第2高折射率層33的透鏡曲率半徑R設為1.85mm,模擬LED光源裝置1的性能。又,實施例2亦是如圖4所示,亦針對在LED光源裝置1的照射方向上有安裝準直儀透鏡42的投影機裝置4施行模擬。模擬結果如下述。 Furthermore, in Example 2, an LED chip 14 with a width W of 1.0 mm is provided, and the height H1 of the reflector 20 is set to 0.75 mm, and the height of the upper surface of the LED chip 14 from the apex of the second high refractive index layer 33 H2 is set to 2.45 mm, the width D of the second high refractive index layer 33 is set to 3.64 mm, and the lens curvature radius R of the second high refractive index layer 33 is set to 1.85 mm, which simulates the performance of the LED light source device 1. In addition, the second embodiment is also shown in FIG. 4, and simulation is also performed on the projector device 4 with the collimator lens 42 installed in the irradiation direction of the LED light source device 1. The simulation results are as follows.

下述表2所示係實施例2,針對以下所說明(F)~(J)的構成,在距準直儀透鏡42所配置位置離10mm處的受光面,受光時的光束量(lm)。此處,(F)係僅LED晶片14的構成(未設反射器20與透光性構件30的構成),(G)係圖4所示在LED光源裝置1中僅未設第2高折射率層33的構成(透光性構件30僅具有第1高折射率層31與低折射率層32的構成),(H)係同圖3所示LED光源裝置1,但亦具有第2高折射率層33的構成之LED光源裝置模擬結果。又,(I)係如圖4所示,在LED光源裝置1前配置準直儀透鏡42的構成,(J)係(I)光束中,配光角在15°以下的光束之投影機裝置4模擬結果。 The following Table 2 shows the second embodiment. For the configurations (F) to (J) described below, the light-receiving surface at a position 10mm away from the collimator lens 42 is the amount of light (lm) . Here, (F) is the structure of only the LED chip 14 (the reflector 20 and the translucent member 30 are not provided), and (G) is shown in FIG. 4 and only the second high refractive index is not provided in the LED light source device 1. The structure of the high-efficiency layer 33 (the translucent member 30 has only the first high-refractive-index layer 31 and the low-refractive-index layer 32), (H) is the same as the LED light source device 1 shown in FIG. 3, but also has a second high The LED light source device simulation result of the composition of the refractive index layer 33. In addition, (I) is a configuration in which a collimator lens 42 is arranged in front of the LED light source device 1, as shown in FIG. 4, and (J) is a projector device for a beam with a light distribution angle of 15° or less among the beams of (I) 4 Simulation results.

Figure 108122144-A0101-12-0014-2
Figure 108122144-A0101-12-0014-2

如上述表2所示,未設有第2高折射率層33的構成 (G),係與僅設有LED晶片14的(F)幾乎相同程度的光束量。理由係(G)藉由第1高折射率層31依無空隙地鄰接LED晶片14的上表面方式積層,便可將LED晶片14內所產生的光取出於LED晶片14外,但實施例2,因為反射器20形成較小的傾斜角(傾斜緩和),因而由反射器20反射並從低折射率層32入射於外部空氣的光束,入射角將大於臨界角,導致在低折射率層32與外部空氣邊界面發生全反射,造成光束未被放射至LED光源裝置1外部的緣故所致。 As shown in Table 2 above, the structure without the second high refractive index layer 33 (G) is almost the same amount of light beam as (F) in which only the LED chip 14 is provided. The reason is (G) by laminating the first high refractive index layer 31 in such a way that it is adjacent to the upper surface of the LED chip 14 without voids, the light generated in the LED chip 14 can be taken out of the LED chip 14, but the second embodiment Since the reflector 20 forms a small tilt angle (tilt relaxation), the light beam reflected by the reflector 20 and incident on the outside air from the low refractive index layer 32 will have an incident angle greater than the critical angle, resulting in the low refractive index layer 32 The total reflection occurs on the boundary surface with the outside air, and the light beam is not emitted to the outside of the LED light source device 1.

另一方面,相較於(G)之下,(H)的光束量成為約2倍。理由係(H)係在低折射率層32上,形成由上表面呈透鏡狀的第2高折射率層33,覆蓋著反射器20之開口部22(從上方觀看反射器20時,較上表面21更靠內側部分處的開口)狀態,因而抑制第2高折射率層33與外部空氣邊界面處的全反射,俾能將更多光束放射至LED光源裝置1外部的緣故所致。 On the other hand, compared to (G), the beam volume of (H) is approximately doubled. The reason is that (H) is on the low-refractive index layer 32, and the second high-refractive index layer 33 whose upper surface is lenticular is formed to cover the opening 22 of the reflector 20 (when the reflector 20 is viewed from above, the upper The surface 21 has an opening at the inner side), thereby suppressing total reflection at the boundary surface between the second high refractive index layer 33 and the outside air, so that more light beams can be radiated to the outside of the LED light source device 1.

依此,藉由將第1高折射率層31依無空隙地鄰接LED晶片14的方式積層,針對LED晶片14所產生的光,可抑制在LED晶片14與第1高折射率層31邊界面處的全反射,便能從LED晶片14取出。又,藉由將第1高折射率層31的上表面設為透鏡狀,便可抑制第1高折射率層31與低折射率層32邊界面的全反射,俾能將光束放射至LED光源裝置1的外部。又,藉由將第2高折射率層33的上表面設為透鏡狀,便可抑制第2高折射率層33與外部空氣邊界面的全反射,俾能將更多光束放射至LED光源裝置1的外部。另外,得知(I)、(J)受準直儀透鏡42的影響,光束量較低於(H),但光束量較(G)增加。 Accordingly, by laminating the first high refractive index layer 31 so as to be adjacent to the LED chip 14 without voids, the light generated by the LED chip 14 can be suppressed on the boundary surface between the LED chip 14 and the first high refractive index layer 31 The total reflection at the position can be taken out from the LED chip 14. In addition, by making the upper surface of the first high refractive index layer 31 into a lens shape, it is possible to suppress the total reflection of the boundary surface between the first high refractive index layer 31 and the low refractive index layer 32, so that the light beam can be radiated to the LED light source. The exterior of the device 1. In addition, by making the upper surface of the second high refractive index layer 33 into a lens shape, the total reflection of the boundary surface between the second high refractive index layer 33 and the outside air can be suppressed, so that more light beams can be radiated to the LED light source device. 1 outside. In addition, it is known that (I) and (J) are affected by the collimator lens 42, and the beam volume is lower than (H), but the beam volume is larger than (G).

再者,圖6所示係距LED晶片14之光軸O的距離L、 與光束密度(lm/mm2)的關係圖。如圖6所示,相較於(F)與(G)之下,(H)係無關距LED晶片14之光軸O的距離L,光束密度(lm/mm2)均有變大。由此現象得知藉由設置上表面形成透鏡狀的第2高折射率層33,被射出於LED光源裝置1外部的光之光束密度(lm/mm2)會變大。又,有設置準直儀透鏡42的投影機(I)、(J),因為從LED光源裝置1所照射的光束可利用準直儀透鏡42收束,因而相較於(F)~(H)之下,得知在LED晶片14的光軸O附近(距LED晶片14之光軸在3~4mm範圍內)的光束密度(lm/mm2)較高,若遠離LED晶片14的光軸O,則光束密度(lm/mm2)便急遽降低。即,得知可縮小LED晶片14的配光角。又,如圖6所示,得知(I)、(J)係即便利用準直儀透鏡42收束的情況,在LED晶片14的光軸O附近之光束密度(lm/mm2)仍較穩定,可放射沒有不均情形的強度均勻光。 Furthermore, FIG. 6 shows the relationship between the distance L from the optical axis O of the LED chip 14 and the beam density (lm/mm 2 ). As shown in FIG. 6, compared with (F) and (G), (H) is independent of the distance L from the optical axis O of the LED chip 14, and the beam density (lm/mm 2 ) is increased. From this phenomenon, it is understood that by providing the second high refractive index layer 33 with a lens-like upper surface, the beam density (lm/mm 2 ) of the light emitted from the outside of the LED light source device 1 increases. In addition, there are projectors (I) and (J) equipped with a collimator lens 42. Because the light beam irradiated from the LED light source device 1 can be condensed by the collimator lens 42, compared to (F)~(H ), it is known that the beam density (lm/mm 2 ) near the optical axis O of the LED chip 14 (within the range of 3~4mm from the optical axis of the LED chip 14) is higher, if it is far away from the optical axis of the LED chip 14 O, the beam density (lm/mm 2 ) is drastically reduced. That is, it is found that the light distribution angle of the LED chip 14 can be reduced. Furthermore, as shown in FIG. 6, it is known that even if the beams (I) and (J) are condensed by the collimator lens 42, the beam density (lm/mm 2 ) near the optical axis O of the LED chip 14 is still relatively high. It is stable and can emit uniform intensity light without unevenness.

如上述,本實施形態的LED光源裝置1,透光性構件30係在與LED晶片14間無空隙地密接積層於LED晶片14上。特別係本實施形態的透光性構件30,具有相對於LED晶片14之光折射率,達90%以上折射率的第1高折射率層31,係依無空隙地鄰接LED晶片14的方式形成。藉此,可抑制LED晶片14與第1高折射率層31邊界面的全反射,便可從LED晶片14中取出更多由LED晶片14所產生的光,結果可更增加由LED光源裝置1放射的光束量。又,本實施形態的LED光源裝置1,因為具有反射器20,且透光性構件30的上表面(第2高折射率層33的上表面)形成透鏡狀(曲面),因而從LED晶片14取出的光束便可在反射器20與透光性構件30的透鏡面處收束,便可照射放射角小且強度均勻的光。 As described above, in the LED light source device 1 of the present embodiment, the light-transmitting member 30 is laminated on the LED chip 14 in close contact with the LED chip 14 without a gap. In particular, the light-transmitting member 30 of this embodiment has a first high refractive index layer 31 having a refractive index of 90% or more with respect to the light refractive index of the LED chip 14, and is formed so as to be adjacent to the LED chip 14 without voids. . As a result, the total reflection of the boundary surface between the LED chip 14 and the first high refractive index layer 31 can be suppressed, and more light generated by the LED chip 14 can be extracted from the LED chip 14, and as a result, the LED light source device 1 can be further increased. The amount of beam emitted. In addition, the LED light source device 1 of the present embodiment has the reflector 20, and the upper surface of the translucent member 30 (the upper surface of the second high refractive index layer 33) is formed into a lens shape (curved surface). The extracted light beam can be condensed at the lens surface of the reflector 20 and the translucent member 30, and light with a small radiation angle and uniform intensity can be irradiated.

再者,本實施形態的透光性構件30,具有光折射率 較低於第1高折射率層31的低折射率層32,且低折射率層32係依無空隙地鄰接方式積層於第1高折射率層31的上表面。一般因為高折射樹脂相較於低折射樹脂之下屬高價位,因而利用在由透光性樹脂所構成第1高折射率層31的上表面,積層著低折射率層32,而減少高折射樹脂的使用量,便可降低LED光源裝置1的製造成本。另外,在第1高折射率層31的上表面積層低折射率層32的情況,亦是因為第1高折射率層31的上表面形成透鏡狀,因而在第1高折射率層31與低折射率層32的邊界面處,可有效地抑制光束全反射。結果,相較於透光性構件30僅由高折射率透光性樹脂、透鏡構成的情況,不會使LED光源裝置1的光束量大幅降低。 Furthermore, the translucent member 30 of this embodiment has a light refractive index The low refractive index layer 32 is lower than the first high refractive index layer 31, and the low refractive index layer 32 is laminated on the upper surface of the first high refractive index layer 31 in an adjacent manner without voids. Generally, because high refractive resin is more expensive than low refractive resin, the low refractive index layer 32 is laminated on the upper surface of the first high refractive index layer 31 made of translucent resin to reduce the high refractive index resin. The amount of usage can reduce the manufacturing cost of the LED light source device 1. In addition, in the case where the low refractive index layer 32 is layered on the upper surface of the first high refractive index layer 31, the reason is that the upper surface of the first high refractive index layer 31 is formed into a lens shape. At the boundary surface of the refractive index layer 32, the total reflection of the light beam can be effectively suppressed. As a result, compared with the case where the light-transmitting member 30 is composed of only a high-refractive-index light-transmitting resin and a lens, the light beam quantity of the LED light source device 1 is not significantly reduced.

又,本實施形態的LED光源裝置1係在低折射率層32的上表面依無空隙地鄰接方式積層第2高折射率層33,且第2高折射率層33的上表面亦形成透鏡狀(曲面)。藉此,可抑制第2高折射率層33與外部(空氣)間之邊界面的全反射,亦可增加照射於LED光源裝置1外部的光束之光束量。又,本實施形態的LED光源裝置1,如圖3所示,第2高折射率層33係無間隙地鄰接於反射器20的上表面21,形成依較反射器20之開口部22更廣範圍覆蓋狀態。依此,藉由第2高折射率層33形成無間隙地鄰接於反射器20的上表面21,便可由第2高折射率層33覆蓋反射器20的全體開口部22,便可消除低折射率層32會接觸到外部空氣的部分。藉此,可有效防止因低折射率層32與外部空氣間之邊界面處的全反射,導致光束量降低情形,可使LED光源裝置1全體提高光束量。 In the LED light source device 1 of this embodiment, the second high-refractive index layer 33 is laminated on the upper surface of the low-refractive index layer 32 in a non-voided manner, and the upper surface of the second high-refractive index layer 33 is also lenticular. (Surface). Thereby, the total reflection of the boundary surface between the second high refractive index layer 33 and the outside (air) can be suppressed, and the amount of the light beam irradiated to the outside of the LED light source device 1 can be increased. Furthermore, in the LED light source device 1 of this embodiment, as shown in FIG. 3, the second high refractive index layer 33 is adjacent to the upper surface 21 of the reflector 20 without a gap, and is formed to be wider than the opening 22 of the reflector 20 Range coverage status. Accordingly, by forming the second high refractive index layer 33 adjacent to the upper surface 21 of the reflector 20 without gaps, the entire opening 22 of the reflector 20 can be covered by the second high refractive index layer 33, thereby eliminating low refraction. The part of the rate layer 32 that will contact the outside air. Thereby, it is possible to effectively prevent the total reflection at the boundary surface between the low refractive index layer 32 and the outside air from reducing the amount of light beam, and the total amount of light beam of the LED light source device 1 can be increased.

《第2實施形態》 "Second Embodiment"

其次,針對第2實施形態的LED光源裝置1a進行說明。圖7所示係第2實施形態的LED光源裝置1a之剖視圖。第2實施形態的LED光源裝置1a係如圖7所示,由第1實施形態的LED光源裝置1積層於金屬製金屬基板17的上表面,除以下所說明之外,其餘均與第1實施形態的LED光源裝置1同樣構成且產生動作。 Next, the LED light source device 1a of the second embodiment will be described. Fig. 7 shows a cross-sectional view of the LED light source device 1a according to the second embodiment. The LED light source device 1a of the second embodiment is shown in FIG. 7, and the LED light source device 1 of the first embodiment is laminated on the upper surface of a metal metal substrate 17. Except for the following description, the rest are the same as those of the first embodiment The LED light source device 1 of the form is similarly configured and operates.

第2實施形態,金屬基板17之導熱性與電氣特性均優異的表面係由金屬構成的板材,例如表面係由銅、鋁所構成水冷構造的均熱片(由上板、中板、下板等3種銅板構成的積層構造體)、或者由銅、鋁所構成金屬板(例如厚0.5~2.00mm)構成。如玻璃環氧樹脂之類導熱性較低的材料,因為會發生散熱性差的發光中心部之光量,出現特別降低的甜甜圈化現象,故最好避免。 In the second embodiment, the surface of the metal substrate 17 having excellent thermal conductivity and electrical properties is a plate made of metal, for example, the surface is made of copper and aluminum with a water-cooling structure (composed of upper plate, middle plate, and lower plate). A layered structure composed of three types of copper plates), or a metal plate composed of copper and aluminum (for example, a thickness of 0.5 to 2.00 mm). Materials with low thermal conductivity, such as glass epoxy resin, have poor heat dissipation properties in the center of the light emitting area, and a particularly reduced donutization phenomenon, so it is best avoided.

在金屬基板17上形成絕緣層15。絕緣層15係為將金屬基板17與佈線層12予以電氣絕緣的層,主要成分為玻璃環氧樹脂、聚醯亞胺樹脂構成。 An insulating layer 15 is formed on the metal substrate 17. The insulating layer 15 is a layer that electrically insulates the metal substrate 17 and the wiring layer 12, and the main component is composed of glass epoxy resin and polyimide resin.

第2實施形態,藉由將公知具銅箔絕緣樹脂片(例如預先將成為絕緣層15的玻璃環氧樹脂、與成為佈線層12a的銅箔進行積層之薄片),積層於金屬基板17上,便可在金屬基板17上積層絕緣層15與佈線層12a。另外,因為玻璃環氧樹脂的導熱性低(例如1W/mk程度),因而藉由添加填料便可提高導熱性(例如10~20W/mk程度)。 In the second embodiment, a known insulating resin sheet with copper foil (for example, a sheet in which glass epoxy resin used as the insulating layer 15 and copper foil used as the wiring layer 12a are laminated in advance) is laminated on the metal substrate 17. The insulating layer 15 and the wiring layer 12a can be laminated on the metal substrate 17. In addition, because the thermal conductivity of glass epoxy resin is low (for example, about 1 W/mk), the thermal conductivity (for example, about 10 to 20 W/mk) can be improved by adding fillers.

再者,第2實施形態,如圖7所示,在反射器20的下側設計凹部24,在凹部24中,將靠安裝基板11側的佈線層12、與靠金屬基板17側的佈線層12a之間,利用導線18予以電氣式耦接。又,為能配設導線18,防焊層亦是在靠安裝基板11側的防焊 層13、與靠金屬基板17側的防焊層13a上開設間隙,分別積層於各佈線層12、12a上。 Furthermore, in the second embodiment, as shown in FIG. 7, a recessed portion 24 is provided on the lower side of the reflector 20. In the recessed portion 24, the wiring layer 12 on the side of the mounting substrate 11 and the wiring layer on the side of the metal substrate 17 are combined. Between 12a, the wire 18 is used for electrical coupling. Also, in order to be able to arrange the lead 18, the solder mask is also the solder mask on the side of the mounting board 11. A gap is opened between the layer 13 and the solder resist layer 13a on the side of the metal substrate 17, and they are laminated on the wiring layers 12 and 12a, respectively.

再者,第2實施形態,隔著接著層16,在金屬基板17上積層高散熱性安裝基板11。為將安裝基板11接著於金屬基板17用的接著層16,亦是使用高熱導率接著劑。接著層16係在屬於高熱導率前提下,其餘並無特別的限定,可使用例如熱導率200W/mk銀膏之CT2700R7S(京瓷股份有限公司)。 Furthermore, in the second embodiment, the mounting substrate 11 with high heat dissipation is laminated on the metal substrate 17 with the adhesive layer 16 interposed therebetween. In order to bond the mounting substrate 11 to the adhesive layer 16 for the metal substrate 17, a high thermal conductivity adhesive is also used. The subsequent layer 16 is under the premise of high thermal conductivity, and the rest is not particularly limited. For example, CT2700R7S (Kyocera Corporation) with a thermal conductivity of 200W/mk silver paste can be used.

如上述,第2實施形態的LED光源裝置1a,相較於第1實施形態的LED光源裝置1,雖基板部的構成不同,但與第1實施形態的LED光源裝置1同樣,均由反射器20與透光性構件30構成。所以,如同第1實施形態,可照射光束量多、放射角小、且強度均勻的光。 As described above, the LED light source device 1a of the second embodiment is different from the LED light source device 1 of the first embodiment in the structure of the substrate, but it is the same as the LED light source device 1 of the first embodiment in that it is composed of a reflector. 20 and a translucent member 30 are formed. Therefore, as in the first embodiment, it is possible to irradiate light with a large beam volume, a small radiation angle, and a uniform intensity.

《第3實施形態》 "The third embodiment"

其次,針對第3實施形態的LED光源裝置1b進行說明。圖8所示係第3實施形態的LED光源裝置1b之剖視圖。第3實施形態的LED光源裝置1b,如圖8所示,除透光性構件30a僅由第1高折射率層31構成之外,其餘均與第1實施形態的LED光源裝置1同樣構成且進行動作。 Next, the LED light source device 1b of the third embodiment will be described. Fig. 8 shows a cross-sectional view of the LED light source device 1b according to the third embodiment. The LED light source device 1b of the third embodiment, as shown in FIG. 8, has the same configuration as the LED light source device 1 of the first embodiment except that the light-transmitting member 30a is composed of only the first high refractive index layer 31. Take action.

第3實施形態的LED光源裝置1b中,透光性構件30a係僅設有第1高折射率層31。此情況,僅在螢光體層311的上表面填充非螢光體層312並使硬化,便可形成透光性構件30a。故,相較於第1實施形態的LED光源裝置1之下,可較輕易且簡單地製造LED光源裝置。 In the LED light source device 1b of the third embodiment, the translucent member 30a is provided with only the first high refractive index layer 31. In this case, only the upper surface of the phosphor layer 311 is filled with the non-phosphor layer 312 and cured to form the translucent member 30a. Therefore, compared with the LED light source device 1 of the first embodiment, the LED light source device can be manufactured more easily and simply.

如上述,第3實施形態的LED光源裝置1b,因為透光性構件30a係僅由第1高折射率層31構成,因而如第1實施形態的LED光源裝置1,沒有第1高折射率層31與低折射率層32的邊界面、及低折射率層32與第2高折射率層33的邊界面,除第1實施形態的LED光源裝置1之效果外,尚可將更多的光照射於外部。又,亦可輕易且簡單地製造LED光源裝置。 As described above, in the LED light source device 1b of the third embodiment, since the translucent member 30a is composed of only the first high refractive index layer 31, the LED light source device 1 of the first embodiment does not have the first high refractive index layer. The boundary surface between the low refractive index layer 32 and the low refractive index layer 32, and the boundary surface between the low refractive index layer 32 and the second high refractive index layer 33, in addition to the effect of the LED light source device 1 of the first embodiment, can provide more light Expose to the outside. Moreover, the LED light source device can also be manufactured easily and simply.

《第4實施形態》 "Fourth Embodiment"

其次,針對第4實施形態的LED光源裝置1c進行說明。圖9所示係第4實施形態的LED光源裝置1c之剖視圖。第4實施形態的LED光源裝置1c係除以下所說明事項外,其餘均與第3實施形態的LED光源裝置1b同樣構成。 Next, the LED light source device 1c of the fourth embodiment will be described. Fig. 9 shows a cross-sectional view of the LED light source device 1c according to the fourth embodiment. The LED light source device 1c of the fourth embodiment has the same configuration as the LED light source device 1b of the third embodiment except for the matters described below.

即,第4實施形態的LED光源裝置1c中,透光性構件30b僅由高折射率層31a單層構成。高折射率層31a係例如由環氧系、聚矽氧系樹脂構成的透明樹脂、或由玻璃構成的透光性層,但不同於第1~第3實施形態的第1高折射率層31,只要相對於LED晶片14的光折射率,具有達80%以上的光折射率便可。例如LED晶片14係藍寶石基板的LED晶片時,因為LED晶片的光折射率n係1.768,因而高折射率層31a的光折射率n便成為1.414以上。 That is, in the LED light source device 1c of the fourth embodiment, the light-transmitting member 30b is composed of only a single layer of the high refractive index layer 31a. The high refractive index layer 31a is, for example, a transparent resin composed of epoxy-based, silicone-based resin, or a translucent layer composed of glass, but is different from the first high-refractive index layer 31 of the first to third embodiments. , As long as the light refractive index of the LED chip 14 is above 80%. For example, when the LED chip 14 is an LED chip with a sapphire substrate, since the light refractive index n of the LED chip is 1.768, the light refractive index n of the high refractive index layer 31a becomes 1.414 or more.

此處,圖10所示係使用不同折射率之透光性構件時,光束量的模擬結果圖。圖10所示例,如下示,針對(K)~(M)等3個LED光源裝置,模擬距光軸O的距離L(mm)之各距離光束密度(lm/mm2)。具體而言,(K)係如圖8所示,使用屬於第3實施形態的透光性構件30a,對LED晶片14的折射率為93%、光折射率 n為1.65的透光性構件之模擬結果。又,(L)係使用屬於第4實施形態的透光性構件30b,對LED晶片14的折射率為89%、光折射率n為1.57的透光性構件之模擬結果。又,(M)係使用屬於第4實施形態的透光性構件30b,對LED晶片14的折射率為81%、光折射率n為1.44的透光性構件之模擬結果。 Here, FIG. 10 shows a simulation result diagram of the beam volume when using translucent members with different refractive indexes. As shown in the example of FIG. 10, the beam density (lm/mm 2 ) of each distance L (mm) from the optical axis O is simulated for three LED light source devices (K) to (M) as shown below. Specifically, (K) is one of the translucent members having a refractive index of 93% for the LED chip 14 and a light refractive index n of 1.65 as shown in FIG. 8 using a translucent member 30a belonging to the third embodiment. Simulation results. In addition, (L) is a simulation result of a translucent member having a refractive index of 89% for the LED chip 14 and a light refractive index n of 1.57 using the translucent member 30b belonging to the fourth embodiment. In addition, (M) is a simulation result of a translucent member having a refractive index of 81% for the LED chip 14 and a light refractive index n of 1.44 using the translucent member 30b belonging to the fourth embodiment.

如圖10所示,使用第4實施形態透光性構件30b的(L)、(M),相較於折射率高於其之透光性構件的(K),雖光束量降低,但使用第4實施形態透光性構件30b的(L),光束量積分值成為0.81流明,且就連(M)的光束量積分值亦達0.67流明,得知具有當作投影機使用的充分亮度與指向性。 As shown in Fig. 10, (L) and (M) of the translucent member 30b of the fourth embodiment are used. Compared with (K) of the translucent member with a higher refractive index, the beam quantity is lower, but the The (L) of the light-transmitting member 30b of the fourth embodiment has a beam volume integral value of 0.81 lumens, and even the beam volume integral value of (M) has reached 0.67 lumens. It is known that it has sufficient brightness and brightness for use as a projector. Directivity.

再者,第4實施形態的LED光源裝置1c,如圖9所示,在反射器20上表面21的周緣部形成壩部23。此處,當透光性構件30b係形成無空隙地鄰接反射器20上表面21的情況,便必需將屬於透光性材料的透光性樹脂填充至反射器20的上表面21,但此情況會有透光性材料流出於反射器20外側的可能性。本實施形態,藉由在反射器20的上表面21形成壩部23,即便透光性材料填充至反射器20上表面21的情況,便可在防止透光性材料流出於外部情況下,將透光性構件30b形成無空隙地鄰接反射器20上表面21的狀態。而,如圖9所示,依埋藏反射器20內側空間、與反射器20上表面21因壩部23所形成空間的方式,形成透光性構件30b(高折射率層31a)。 Furthermore, in the LED light source device 1c of the fourth embodiment, as shown in FIG. 9, a dam portion 23 is formed on the periphery of the upper surface 21 of the reflector 20. Here, when the translucent member 30b is formed to be adjacent to the upper surface 21 of the reflector 20 without voids, it is necessary to fill the upper surface 21 of the reflector 20 with a translucent resin which is a translucent material, but in this case There is a possibility that the light-transmitting material flows out of the reflector 20. In this embodiment, by forming the dam 23 on the upper surface 21 of the reflector 20, even when the translucent material is filled on the upper surface 21 of the reflector 20, it is possible to prevent the translucent material from flowing out to the outside. The light-transmitting member 30b is in a state where it abuts the upper surface 21 of the reflector 20 without a gap. However, as shown in FIG. 9, the light-transmitting member 30b (high refractive index layer 31a) is formed in such a manner that the space inside the reflector 20 is buried and the space formed by the dam 23 on the upper surface 21 of the reflector 20.

其次,針對第4實施形態的LED光源裝置1c之製造方法進行說明。LED光源裝置1c係首先在已描繪佈線層12的安裝基板11上配置LED晶片14,並與佈線層12耦接。又,在佈線層 12上形成防焊層13,依包圍LED晶片14周圍的方式,在該防焊層13上形成反射器20。又,第4實施形態係在反射器20的上表面21形成壩部23。 Next, a method of manufacturing the LED light source device 1c of the fourth embodiment will be described. In the LED light source device 1c, the LED chip 14 is first arranged on the mounting substrate 11 on which the wiring layer 12 has been drawn, and is coupled to the wiring layer 12. Also, on the wiring layer A solder resist layer 13 is formed on 12, and a reflector 20 is formed on the solder resist layer 13 in a manner surrounding the LED chip 14. In the fourth embodiment, a dam 23 is formed on the upper surface 21 of the reflector 20.

再者,第4實施形態,透光性構件30b並未如第1實施形態般,分開形成第1高折射率層31與低折射率層32的不同雙層,而是一體成形。所以,第4實施形態,例如藉由在反射器20內側、與反射器20的壩部23內側空間內,填充屬於透光性材料的透光性樹脂,便如圖9所示,可依覆蓋反射器20的開口部22方式,一體成形透光性構件30b。另外,透光性構件30b係在可一體成形之前提下,就成形方法並無限定,例如可利用轉移鑄模、樹脂注入、壓縮成形等方法進行成形。又,第4實施形態亦是依透光性構件30b無間隙地鄰接反射器20上表面21的方式,形成透光性構件30b。 In addition, in the fourth embodiment, the light-transmitting member 30b is not formed separately into two different layers of the first high refractive index layer 31 and the low refractive index layer 32 as in the first embodiment, but is integrally molded. Therefore, in the fourth embodiment, for example, by filling the space inside the reflector 20 and the inner space of the dam 23 of the reflector 20 with a light-transmitting resin, as shown in FIG. In the opening 22 of the reflector 20, the translucent member 30b is integrally molded. In addition, the light-transmitting member 30b is removed before being integrally molded, and the molding method is not limited. For example, it can be molded by a method such as transfer molding, resin injection, and compression molding. In the fourth embodiment, the light-transmitting member 30b is also formed so that the light-transmitting member 30b is adjacent to the upper surface 21 of the reflector 20 without a gap.

如上述,第4實施形態的LED光源裝置1c,因為透光性構件30b亦係無空隙地鄰接於反射器20的上表面21,因而可提高透光性構件30b的接黏性。又,因為透光性構件30b具有相對於LED晶片14之光折射率達80%以上的光折射率,因而藉由與反射器20組合便可抑制全反射,可將更多的光束放射至LED光源裝置1c的外部,便能提供具有當作投影機使用時的充分亮度與指向性之LED光源裝置1c。 As described above, in the LED light source device 1c of the fourth embodiment, since the translucent member 30b is also adjacent to the upper surface 21 of the reflector 20 without a gap, the adhesion of the translucent member 30b can be improved. In addition, because the translucent member 30b has a light refractive index of 80% or more with respect to the light refractive index of the LED chip 14, the total reflection can be suppressed by combining with the reflector 20, and more light beams can be radiated to the LED. The outside of the light source device 1c can provide an LED light source device 1c with sufficient brightness and directivity when used as a projector.

再者,第4實施形態的透光性構件30b,相較於第3實施形態的透光性構件30a之下,因為可使用較低折射率原料形成,因而可將較廣範圍的透光性材料使用為原料,亦能達降低成本與提升設計性。又,第4實施形態的LED光源裝置1c,因為與第3實施形態的LED光源裝置1b同樣,透光性構件30b均僅由單一 層構成,因而可防止因將第1高折射率層31與低折射率層32等不同的二層接著時所造成的問題,且亦可輕易地製造LED光源裝置1c。 Furthermore, the translucent member 30b of the fourth embodiment can be formed using a lower refractive index material than the translucent member 30a of the third embodiment, so that a wider range of translucent properties can be obtained. The use of materials as raw materials can also reduce costs and improve design. In addition, the LED light source device 1c of the fourth embodiment is similar to the LED light source device 1b of the third embodiment, because the light-transmitting member 30b is composed of only a single The layer structure can prevent problems caused by bonding two different layers such as the first high refractive index layer 31 and the low refractive index layer 32, and the LED light source device 1c can also be easily manufactured.

以上,針對本揭示簡單例示數個實施形態並詳細說明,惟在不致實質脫逸本發明新穎揭示與有利效果之範疇內,該實施形態亦可進行多種變化例。 Above, several embodiments are simply exemplified and explained in detail for the present disclosure. However, within the scope of the novel disclosure and advantageous effects of the present invention, this embodiment can be modified in many ways.

例如上述實施形態,LED晶片14係例示具備藍寶石基板的LED晶片,惟並不僅侷限於該構成,亦可使用例如:氮化鎵系(GaN、AlGaN、InGaN)的LED晶片、照射紫外線(特別係UVA)LED晶片。此情況,透光性構件30中,第1高折射率層31係使用相對於該等LED晶片14之光折射率,具有達90%或80%以上之折射率者。另外,使用具有達80%以上折射率的透光性構件時,為能獲得較多的光束量,最好適當設定反射器20、透鏡形狀。又,因為LED晶片14係在藍寶石SiC、GaN基板等上沉積磊晶層而製造,因而所使用第1高折射率層31的折射率便配合該等基板材料的折射率。例如因為GaN系LED晶片的折射率n係2.6,因而若相對於LED晶片14的光折射率設為90%以上時,第1高折射率層31便使用折射率達2.34以上的樹脂層。 For example, in the above embodiment, the LED chip 14 exemplifies an LED chip equipped with a sapphire substrate, but it is not limited to this configuration. For example, gallium nitride-based (GaN, AlGaN, InGaN) LED chips and irradiated with ultraviolet light (especially UVA) LED chip. In this case, in the light-transmitting member 30, the first high refractive index layer 31 uses a refractive index of 90% or more with respect to the light refractive index of the LED chips 14. In addition, when a translucent member having a refractive index of 80% or more is used, it is preferable to appropriately set the reflector 20 and lens shape in order to obtain a large amount of light beam. In addition, since the LED chip 14 is manufactured by depositing an epitaxial layer on a sapphire SiC, GaN substrate, etc., the refractive index of the first high refractive index layer 31 used matches the refractive index of these substrate materials. For example, since the refractive index n of the GaN-based LED chip is 2.6, if the light refractive index with respect to the LED chip 14 is 90% or more, the first high refractive index layer 31 uses a resin layer with a refractive index of 2.34 or more.

再者,上述實施形態例示第1高折射率層31係由螢光體層311與非螢光體層312構成、或僅由非螢光體層312構成,惟並不僅侷限於該構成,例如第1高折射率層31亦可僅由螢光體層311構成。但,若第1高折射率層31僅由螢光體層311構成時,因為螢光體會被激發並朝全方向再發光、或因再發光所生成的熱不易散熱,因而第1高折射率層31最好由螢光體層311與非螢光體 層312構成,或僅由非螢光體層312構成。 Furthermore, the above-mentioned embodiment exemplifies that the first high refractive index layer 31 is composed of the phosphor layer 311 and the non-phosphor layer 312, or is composed only of the non-phosphor layer 312, but it is not limited to this configuration, such as the first high The refractive index layer 31 may also be composed of only the phosphor layer 311. However, if the first high refractive index layer 31 is composed only of the phosphor layer 311, the phosphor will be excited and re-emit in all directions, or the heat generated by the re-emission will not easily dissipate, so the first high refractive index layer 31 is preferably composed of a phosphor layer 311 and a non-fluorescent body The layer 312 is composed of, or is composed of only the non-phosphor layer 312.

再者,上述第1實施形態中,透光性構件30係可設為由未含硫的透光性材料形成。具高折射率的透光性材料多數均含有硫,當併用聚矽氧樹脂時,會有阻礙聚矽氧樹脂硬化的情況。所以,藉由透光性構件30係由未硫的透光性材料形成,設為未硫的構成,便可解決此種問題,可提供更高品質的LED光源裝置1。另外,未含硫的透光性構件30係可使用例如OKP(Osaka Gas Chemicals)。又,為提高第1高折射率層31與低折射率層32的接黏性,亦可如圖11所示,將第1高折射率層31的底面313形成透鏡狀。藉此,將第2高折射率層33接著於低折射率層32上之時,可使第2高折射率層33與低折射率層32的界面不會有空氣殘留。 In addition, in the first embodiment described above, the translucent member 30 may be formed of a translucent material that does not contain sulfur. Most light-transmitting materials with high refractive index contain sulfur. When silicone resin is used in combination, it may hinder the curing of silicone resin. Therefore, by forming the light-transmitting member 30 with a non-sulfurized light-transmitting material and having a non-sulfurized structure, this problem can be solved, and a higher-quality LED light source device 1 can be provided. In addition, OKP (Osaka Gas Chemicals) can be used as the translucent member 30 which does not contain sulfur. In addition, in order to improve the adhesion between the first high refractive index layer 31 and the low refractive index layer 32, as shown in FIG. 11, the bottom surface 313 of the first high refractive index layer 31 may be formed into a lens shape. Thereby, when the second high refractive index layer 33 is attached to the low refractive index layer 32, no air remains at the interface between the second high refractive index layer 33 and the low refractive index layer 32.

除此之外,上述第1實施形態與第2實施形態例示由高折射率層31、33、與低折射率層32等不同的2以上層積層之構成,但依此將不同層積層時,最好烘烤至透光性材料(透光性樹脂材料)呈液狀的溫度(50℃左右)為止、或經施行真空脫泡後才施行硬化烘烤。藉此,可抑制樹脂內部產生氣泡。又,如第3實施形態或第4實施形態的LED光源裝置1a、1b,當透光性構件30a、30b係僅由同一透光性材料形成的情況,亦可設為將由同一透光性材料構成的層施行雙層重疊的構成。此情況亦是為能抑制樹脂內部生成氣泡,最好烘烤至透光性材料呈液狀的溫度(50℃左右)為止、或經施行真空脫泡後才施行硬化烘烤。 In addition, the above-mentioned first embodiment and the second embodiment exemplified the configuration of two or more laminated layers different from the low refractive index layer 32 and the high refractive index layers 31 and 33. However, when different layers are laminated accordingly, It is best to bake to the temperature (about 50°C) at which the light-transmitting material (light-transmitting resin material) is in a liquid state, or to perform curing and baking after vacuum degassing. This can suppress the generation of bubbles in the resin. In addition, as in the LED light source devices 1a and 1b of the third embodiment or the fourth embodiment, when the translucent members 30a and 30b are formed of only the same translucent material, they can also be made of the same translucent material. The composition layer is a double-layered structure. In this case too, in order to suppress the formation of bubbles in the resin, it is best to bake it to the temperature (about 50°C) at which the light-transmitting material is liquid, or to perform curing and bake after vacuum degassing.

再者,上述第4實施形態例示為在透光性材料填充至反射器20的上表面21為止時,防止透光性材料流出於反射器20的外部,便在反射器20的上表面21設置壩部23(防流出部),惟並 不僅侷限於該構成,例如藉由在反射器20的上表面21設置當作防流出部之溝或凹部,藉由該溝或凹部,即便透光性材料填充至反射器20的上表面21為止時,仍可有效地防止透光性材料流出於反射器20的外部。又,藉由使用模具,亦可未在反射器20的上部設置防流出部情況下,一體成形透光性構件30b。另外,第1~3實施形態的LED光源裝置1~1b亦同樣地可設置壩部23等防流出部。 Furthermore, in the fourth embodiment described above, when the translucent material is filled to the upper surface 21 of the reflector 20, to prevent the translucent material from flowing out of the reflector 20, it is provided on the upper surface 21 of the reflector 20. Dam section 23 (outflow prevention section), only combined It is not limited to this configuration. For example, by providing a groove or a concave portion serving as an outflow prevention portion on the upper surface 21 of the reflector 20, the groove or the concave portion can fill up to the upper surface 21 of the reflector 20 with a light-transmitting material. At this time, the translucent material can still be effectively prevented from flowing out of the reflector 20. In addition, by using a mold, the light-transmitting member 30b may be integrally molded without providing an outflow prevention portion on the upper portion of the reflector 20. In addition, the LED light source devices 1 to 1b of the first to third embodiments can also be provided with outflow prevention portions such as the dam portion 23 in the same manner.

4‧‧‧投影機裝置 4‧‧‧Projector device

1R、1G、1B‧‧‧LED光源裝置 1R, 1G, 1B‧‧‧LED light source device

41‧‧‧雙色稜鏡 41‧‧‧Two-color 稜鏡

42R、42G、42B‧‧‧準直儀透鏡 42R, 42G, 42B‧‧‧Collimator lens

43R、43G、43B‧‧‧液晶光閥 43R, 43G, 43B‧‧‧LCD light valve

44‧‧‧投射光學系統 44‧‧‧Projection optical system

L‧‧‧投射光 L‧‧‧Projection light

Claims (14)

一種LED光源裝置,係具備有: An LED light source device is provided with: LED晶片; LED chip; 反射器,其係包圍上述LED晶片周圍;以及 A reflector, which surrounds the LED chip; and 透光性構件,其係由透光性材料構成且上表面形成透鏡狀; Translucent member, which is composed of translucent material and the upper surface is formed into a lens shape; 其中,上述透光性構件係具有第1高折射率層,該第1高折射率層係無空隙地鄰接於上述LED晶片之層,且相對於上述LED晶片的光折射率,具有達90%以上光折射率的層。 Wherein, the translucent member has a first high refractive index layer, and the first high refractive index layer is adjacent to the layer of the LED chip without voids and has a refractive index of 90% relative to the light refractive index of the LED chip. The above light refractive index layer. 如請求項1之LED光源裝置,其中,上述透光性構件係更進一步具備有:光折射率較低於上述第1高折射率層的低折射率層; The LED light source device according to claim 1, wherein the translucent member is further provided with: a low refractive index layer having a light refractive index lower than that of the first high refractive index layer; 上述低折射率層係構成為無空隙地積層於上述第1高折射率層的上表面。 The low refractive index layer is configured to be laminated on the upper surface of the first high refractive index layer without voids. 如請求項2之LED光源裝置,其中,上述透光性構件係更進一步具備有:光折射率較高於上述低折射率層的第2高折射率層; The LED light source device of claim 2, wherein the translucent member is further provided with: a second high refractive index layer having a higher light refractive index than the low refractive index layer; 上述第2高折射率層係構成為無空隙地積層於上述低折射率層的上表面,且上表面形成透鏡狀。 The second high refractive index layer is configured to be laminated on the upper surface of the low refractive index layer without voids, and the upper surface is formed into a lens shape. 如請求項3之LED光源裝置,其中,上述第1高折射率層係由透光性樹脂或玻璃構成; The LED light source device of claim 3, wherein the first high refractive index layer is composed of light-transmitting resin or glass; 上述低折射率層係由透光性樹脂構成; The low refractive index layer is made of light-transmitting resin; 上述第2高折射率層係由透光性樹脂或玻璃構成。 The second high refractive index layer is made of translucent resin or glass. 如請求項3或4之LED光源裝置,其中,上述第2高折射率層係上表面與底面形成透鏡狀。 The LED light source device according to claim 3 or 4, wherein the upper surface and the bottom surface of the second high refractive index layer are formed in a lens shape. 如請求項1至4中任一項之LED光源裝置,其中,上述第1高折射率層係上表面形成透鏡狀。 The LED light source device according to any one of claims 1 to 4, wherein the upper surface of the first high refractive index layer is formed into a lens shape. 如請求項1至4中任一項之LED光源裝置,其中,上述第1高折射率層係設有含螢光體之螢光體層。 The LED light source device according to any one of claims 1 to 4, wherein the first high refractive index layer is provided with a phosphor layer containing a phosphor. 如請求項1至4中任一項之LED光源裝置,其中,上述透光性構件係未含硫。 The LED light source device according to any one of claims 1 to 4, wherein the light-transmitting member does not contain sulfur. 一種LED光源裝置,係具備有: An LED light source device is provided with: LED晶片; LED chip; 反射器,其係包圍上述LED晶片周圍;以及 A reflector, which surrounds the LED chip; and 透光性構件,其係由透光性材料構成且上表面形成透鏡狀; Translucent member, which is composed of translucent material and the upper surface is formed into a lens shape; 其中,上述透光性構件係無空隙地鄰接於上述LED晶片,且亦無空隙地鄰接於上述反射器的上表面。 Wherein, the translucent member is adjacent to the LED chip without a gap, and also adjacent to the upper surface of the reflector without a gap. 如請求項9之LED光源裝置,其中,上述透光性構件係相對於上述LED晶片的光折射率,具有達80%以上的光折射率。 The LED light source device according to claim 9, wherein the translucent member has a light refractive index of 80% or more with respect to the light refractive index of the LED chip. 如請求項9或10之LED光源裝置,其中,上述透光性構件係一體成形。 The LED light source device of claim 9 or 10, wherein the light-transmitting member is integrally formed. 如請求項11之LED光源裝置,其中,更進一步具備有:防流出部,該防流出部係將上述透光性材料填充於上述反射器內部而一體成形上述透光性構件時,供防止上述透光性材料流出於外部用。 The LED light source device according to claim 11, further comprising: an outflow prevention portion for preventing the above-mentioned when the above-mentioned translucent material is filled in the reflector to integrally form the above-mentioned translucent member The light-transmitting material flows out for external use. 如請求項9或10之LED光源裝置,其中,上述透光性構件係未含硫。 The LED light source device of claim 9 or 10, wherein the light-transmitting member does not contain sulfur. 一種投影機,係具備有: A projector that has: 紅色光用LED光源裝置; LED light source device for red light; 紅色光用穿透式液晶面板,其係將從上述紅色光用LED光源裝置放射出的光進行調變; A transmissive liquid crystal panel for red light, which modulates the light emitted from the above-mentioned LED light source device for red light; 綠色光用LED光源裝置; LED light source device for green light; 綠色光用穿透式液晶面板,其係將從上述綠色光用LED光源裝置放射出的光進行調變; A transmissive liquid crystal panel for green light, which modulates the light emitted from the above-mentioned LED light source device for green light; 藍色光用LED光源裝置; LED light source device for blue light; 紅色光用穿透式液晶面板,其係將從上述紅色光用LED光源裝置放射出的光進行調變; A transmissive liquid crystal panel for red light, which modulates the light emitted from the above-mentioned LED light source device for red light; 雙色稜鏡,其係將紅色光、綠色光及藍色光進行合成;以及 Two-color 鏡, which combines red light, green light and blue light; and 投影光學系統,其係將來自雙色稜鏡的合成光進行投影; Projection optical system, which projects the synthetic light from the two-color beam; 其中,上述紅色光用LED光源裝置、上述綠色光用LED光源裝置及上述藍色光用LED光源裝置,係由請求項1至4中任一項之LED光源裝置構成。 Wherein, the LED light source device for red light, the LED light source device for green light, and the LED light source device for blue light are constituted by the LED light source device of any one of claims 1 to 4.
TW108122144A 2018-07-25 2019-06-25 Led light source device having directivity, method for manufacturing led light source device, and projector TW202028848A (en)

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