US20100032693A1 - Led reflecting plate and led device - Google Patents
Led reflecting plate and led device Download PDFInfo
- Publication number
- US20100032693A1 US20100032693A1 US12/581,828 US58182809A US2010032693A1 US 20100032693 A1 US20100032693 A1 US 20100032693A1 US 58182809 A US58182809 A US 58182809A US 2010032693 A1 US2010032693 A1 US 2010032693A1
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- United States
- Prior art keywords
- led
- reflecting plate
- wiring board
- printed wiring
- land
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- Abandoned
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- 229910052759 nickel Inorganic materials 0.000 description 4
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- 229910052802 copper Inorganic materials 0.000 description 2
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- 229910052709 silver Inorganic materials 0.000 description 2
- 239000004332 silver Substances 0.000 description 2
- 229910000906 Bronze Inorganic materials 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices having potential barriers 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
- H01L33/58—Optical field-shaping elements
- H01L33/60—Reflective elements
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L2224/42—Wire connectors; Manufacturing methods related thereto
- H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
- H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
- H01L2224/4805—Shape
- H01L2224/4809—Loop shape
- H01L2224/48091—Arched
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L2224/42—Wire connectors; Manufacturing methods related thereto
- H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
- H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
- H01L2224/481—Disposition
- H01L2224/48151—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive
- H01L2224/48221—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked
- H01L2224/48245—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being metallic
- H01L2224/48247—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being metallic connecting the wire to a bond pad of the item
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/01—Chemical elements
- H01L2924/01004—Beryllium [Be]
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/01—Chemical elements
- H01L2924/01078—Platinum [Pt]
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/01—Chemical elements
- H01L2924/01079—Gold [Au]
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/10—Details of semiconductor or other solid state devices to be connected
- H01L2924/11—Device type
- H01L2924/12—Passive devices, e.g. 2 terminal devices
- H01L2924/1204—Optical Diode
- H01L2924/12041—LED
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices having potential barriers 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
- H01L33/62—Arrangements for conducting electric current to or from the semiconductor body, e.g. lead-frames, wire-bonds or solder balls
Definitions
- the present invention relates to an LED reflecting plate and LED device and, more particularly, to an LED reflecting plate which improves the reflecting efficiency of an LED chip to be mounted on it, and an LED device using the same.
- LED chips having high luminance have been developed. Such LED chips are not only used as an illumination for the ten-key pad of a conventional cellular phone or the like or as spot illumination, but also becoming to be used as illumination for a comparatively wide range, e.g., a reading lamp. Accordingly, the LED chips require higher heat radiation properties.
- a through hole is formed in an insulating substrate.
- One opening of the through hole is covered with a metal plate.
- a metal film is formed on the wall surface of the through hole, the surface of the metal plate, and the surface of the insulating substrate by plating.
- An LED chip is mounted on the metal plate and is electrically connected to the metal film on the insulating film by wire bonding.
- FIG. 12 As the second example of the conventional LED device, one as shown in FIG. 12 is available in which a lead frame 102 formed of a thin metal plate is subjected to resin molding, and an LED chip 103 is mounted on the lead frame 102 . More specifically, a funnel-shaped recess 101 is formed in molded resin 100 . The lead frame 102 is buried in the bottom of the recess 101 . The LED chip 103 is mounted on the lead frame 102 and connected to a terminal portion 104 of the lead frame 102 through a thin metal wire by wire bonding.
- the metal film on the wall surface of the through hole formed in the insulating substrate is formed by plating. Accordingly, there is a limit to increasing the thickness of the metal film, and the heat radiation properties cannot be improved.
- the lead frame 102 improves the heat radiation properties.
- a mold to form the lead frame 102 and a mold to form the resin are required to increase the cost. It is difficult to perform uniform-thick metal plating on the surface of the molded resin 100 . Therefore, the reflecting efficiency of light emitted from the LED decreases.
- the present invention has been made in view of the conventional problems described above, and has as its object to improve the heat radiation properties of an LED device.
- an LED reflecting plate is characterized by comprising a plurality of lands each comprising a recess where an LED chip is to be mounted, a first bridging portion which connects the plurality of lands in series, a frame having a frame shape to surround the plurality of lands, and a second bridging portion which connects the frame to, of the plurality of lands, lands which are located at two ends, wherein the lands, the first bridging portion, the second bridging portion, and the frame are made of a metal.
- An LED device is characterized by comprising an LED chip, an LED reflecting plate made of a metal and having a recess where the LED chip is to be mounted, and a printed wiring board on which the LED reflecting plate is to be mounted, wherein the printed wiring board comprises a first through hole in which the recess of the LED reflecting plate is to be fitted, and a terminal portion to be electrically connected to the LED chip.
- the LED chip is mounted on the reflecting plate made of a metal plate, the heat radiation properties improve.
- the reflecting plate is made of the metal plate, the thickness of an underlying plating film formed on the reflecting plate can be made uniform.
- the mirror surface effect of a noble metal plating film formed on the underlying plating film, aluminum deposition, or the like can improve the reflecting efficiency.
- FIG. 1 is a perspective view showing the entire appearance of an LED reflecting plate according to the first embodiment of the present invention
- FIG. 2A is a plan view of the LED reflecting plate shown in FIG. 1 ;
- FIG. 2B is a sectional view taken along the line II(B)-II(B) of FIG. 2A ;
- FIGS. 3A to 3F are sectional views to explain a method of manufacturing an LED device according to the first embodiment of the present invention.
- FIGS. 4A to 4D are sectional views to explain the method of manufacturing the LED device according to the first embodiment of the present invention.
- FIG. 5A is a sectional view of the LED device according to the first embodiment of the present invention.
- FIG. 5B is a perspective view showing the appearance of the LED device shown in FIG. 5A ;
- FIG. 6 is a perspective view showing the array of LED reflecting plates to cope with a case wherein a printed wiring board is formed to be larger than an LED reflecting plate;
- FIG. 7 is a perspective view showing an LED reflecting plate according to the second embodiment of the present invention.
- FIG. 8 is a plan view showing the arrangement of lands in an LED reflecting plate according to the third embodiment of the present invention.
- FIG. 9 is a perspective view showing a land in an LED reflecting plate according to the fourth embodiment of the present invention.
- FIG. 10A is a sectional view of an LED device according to the fifth embodiment of the present invention.
- FIG. 10B is a perspective view showing the outer appearance of the LED device shown in FIG. 10A ;
- FIG. 11 is a sectional view of an LED device according to the sixth embodiment of the present invention.
- FIG. 12 is a sectional view of a conventional LED device.
- An LED reflecting plate 1 shown in FIGS. 1 and 2A comprises a plurality of lands 2 on which LED chips 27 are to be mounted, first bridging portions 3 which connect the plurality of lands 2 in series, a frame 4 having a frame shape to surround the plurality of lands 2 , and second bridging portions 5 which connect, of the plurality of lands 2 , the lands at the two ends to the frame 4 .
- the LED reflecting plate 1 is formed from a thin phosphor bronze plate (with a thickness of 50 ⁇ m to 200 ⁇ m) by punching so that one metal plate forms the lands 2 , first bridging portions 3 , second bridging portions 5 , and frame 4 integrally.
- the LED reflecting plate 1 is provided with four land groups 6 , each comprising three lands 2 that are linearly connected in series with the first bridging portions 3 , to be parallel to each other.
- the 12 lands 2 are arranged in a matrix of 4 columns ⁇ 3 rows. Alternatively, a plurality of (to or more) land groups 6 may be provided.
- the LED reflecting plate 1 is provided with positioning holes 11 , at its two vertices located on a diagonal of the frame 4 , to be aligned with a printed wiring board 25 (to be described later).
- the land 2 of the LED reflecting plate 1 has a recess formed by drawing and a flat flange 9 around the recess.
- the recess comprises a flat bottom and a side wall inclined to form an obtuse angle with respect to the bottom.
- the bottom of the recess forms an LED chip mounting portion 7 where the LED chip 27 is to be mounted, and the side wall of the recess forms a reflecting portion 8 which reflects forward light from an LED.
- a space 10 surrounded by the LED chip mounting portion 7 and reflecting portion 8 is frustoconical.
- a height T 1 (the height from the lower surface of the flange 9 to the lower surface of the LED chip mounting portion 7 ) of the space 10 is slightly larger than a thickness T 2 of the printed wiring board 25 .
- drawing is performed.
- drawing may be performed, and after that punching may be performed, or drawing and punching may be performed simultaneously.
- the LED reflecting plate 1 formed in this manner is subjected to nickel plating to form an underlying plating film, and then to silver plating to form a noble metal plating film on the underlying plating film.
- a nickel plating film serving as the underlying plating film formed on the surface of the land 2 has a uniform thickness entirely.
- the surface of the silver plating film formed on the nickel plating film accordingly forms a mirror surface having very few steps entirely.
- the reflecting efficiency of the surface of the reflecting portion 8 can be improved.
- FIGS. 3A to 3F show only one LED device for descriptive convenience, actually, a plurality of LED devices are arranged in a matrix.
- FIG. 3A shows a double-side copper-clad board 15 obtained by adhering copper foils 17 to the two surfaces of an insulating substrate 16 .
- the double-side copper-clad board 15 is subjected to boring with a drill to form a first through hole 18 and third through holes 19 which intervene between the first through hole 18 , as shown in FIG. 3B .
- a diameter R 2 of the first through hole 18 is slightly larger than an outer diameter (an outer diameter added with the thickness of the land 2 ) R 1 at the upper end of the space 10 formed above the land 2 of the reflecting plate 1 (described above).
- the double-side copper-clad board 15 is subjected to panel plating by electrolytic copper plating to form a plating film 20 to cover the two surfaces of the insulating substrate 16 and the hole walls of the first and second through holes 18 and 19 , as shown in FIG. 3C .
- a circuit is formed by etching, as shown in FIG. 3D , to form a land placing portion 21 , where the land 2 described above is to be placed, at the upper edge of the first through hole 18 .
- Terminal portions 22 for wire bonding are formed at portions away from the land placing portion 21 .
- a solder resist 23 is applied to an unnecessary circuit. Then, as shown in FIG. 3F , the land placing portion 21 and terminal portions 22 are subjected to noble metal plating using nickel and gold to form the printed wiring board 25 .
- a cream solder is applied to the land placing portion 21 of the printed wiring board 25 .
- positioning pins either is shown
- the printed wiring board 25 and LED reflecting plate 1 are heated in a heating furnace to fuse the cream solder again, so that the flange 9 of each land 2 is bonded on the land placing portion 21 of the printed wiring board 25 and that the LED reflecting plate 1 is bonded on the printed wiring board 25 , as shown in FIG. 4B .
- the LED chip 27 is bonded on the LED chip mounting portion 7 of the LED reflecting plate 1 by die bonding, and thin metal wires (wires) 28 of the LED chip 27 are electrically connected to the terminal portions 22 of the printed wiring board 25 by wire bonding.
- the land 2 of the LED reflecting plate 1 and the terminal portions 22 of the printed wiring board 25 are resin-sealed with a transparent molding resin 29 .
- FIG. 4C shows that the LED chip 27 is bonded on the LED chip mounting portion 7 of the LED reflecting plate 1 by die bonding, and thin metal wires (wires) 28 of the LED chip 27 are electrically connected to the terminal portions 22 of the printed wiring board 25 by wire bonding.
- the land 2 of the LED reflecting plate 1 and the terminal portions 22 of the printed wiring board 25 are resin-sealed with a transparent molding resin 29 .
- LED devices 30 each forming one unit as shown in FIGS. 5A and 5B are formed.
- a heat sink 31 serving as a cooling member which cools the land 2 of the LED reflecting plate 1 is attached to the bottom of the LED device 30 .
- the height T 1 of the space 10 of the land 2 is slightly larger than the thickness T 2 of the printed wiring board 25 , the bottom of the recess of the land 2 comes into contact with the heat sink 31 .
- heat generated by the LED chip 27 is dissipated from the land 2 outside the LED device 30 through the heat sink 31 .
- the land 2 on which the LED chip 27 is mounted is formed of the metal plate, the land 2 can be formed to have a predetermined thickness or more and uniformly, to improve heat radiation properties.
- one plating process by masking the printed wiring board 25 suffices. Therefore, when compared to a conventional example that requires plating twice by masking in order to form a reflecting portion and the remaining portions with different plating films, the manufacturing cost can be decreased. Since only a mold to form the LED reflecting plate 1 must be prepared, the cost required by the mold can be decreased.
- the LED device 30 described above, cutting at the lines C 1 , C 2 , and C 3 forms the LED device 30 as one unit.
- the printed wiring board 25 need not be cut, but may be used with the plurality of LED reflecting plates 1 being mounted on it.
- the printed wiring board 25 is formed to be larger than the LED reflecting plate 1 .
- the LED reflecting plate 1 is formed of a very thin metal plate, from the viewpoint of the strength, there is a limit to forming the LED reflecting plate 1 to have a large outer size.
- the printed wiring board 25 may be formed to have a larger outer size than that of the LED reflecting plate 1 .
- the outer size of the plurality of LED reflecting plates 1 as a whole can be set to coincide with the outer size of the large printed wiring board 25 .
- LED devices 30 each serving as one unit may be formed by cutting.
- the printed wiring board 25 need not be cut, but may be used with the plurality of LED reflecting plates 1 being mounted on it.
- an LED device which is suitably employed in a display device, illumination device, or the like which requires high luminance can be provided.
- the array of the LED reflecting plates 1 is not limited to the matrix described above to match the outer shape of the printed wiring board 25 , but may be a horizontal array or vertical array.
- An LED reflecting plate 40 shown in FIG. 7 is different from the first embodiment described above in that a land group 6 comprising three lands 2 which are linearly connected in series through first bridging portions 3 comprises only one group.
- the array of first through holes 18 formed in a printed wiring board 25 can also cope with arrays other than 4 arrays or 4 ⁇ n (n is an integer) arrays, unlike the first embodiment described above.
- An LED reflecting plate 50 shown in FIG. 8 is characterized in that lands 2 are not formed in a matrix but are in a staggered manner. With this arrangement, the density of the lands 2 can be increased. Therefore, an LED device which is suitably employed in a display device, illumination device, or the like which requires high luminance and uses LED devices as an aggregate can be provided.
- This embodiment is characteristic in that an LED chip mounting portion 7 of a land 2 is square and that a space 10 is frustopyramidal, as shown in FIG. 9 .
- an LED chip having a square section is mounted on the LED chip mounting portion 7 of the land 2 , so that the LED chip mounting portion 7 can be formed relatively small.
- first bridging portions 3 and second bridging portions 5 are arranged on one straight line in the embodiments descried above, they need not always be arranged on one straight line. It suffices as far as the lands 2 , and the lands 2 and frame 4 are connected integrally.
- An LED device 80 shown in FIGS. 10A and 10B is characterized in that a plurality of LED chips 27 A to 27 D are mounted in the recess of each land 2 of an LED reflecting plate and that the land 2 is arranged in a printed wiring board 75 and integrated with it. This arrangement will be described in more detail.
- the printed wiring board 75 has a lower-layer substrate 75 A serving as the first substrate and an upper-layer substrate 75 B serving as the second substrate. Both the lower-layer substrate 75 A and upper-layer substrate 75 B are formed of insulating substrates.
- a first through hole 68 A to fit with the recess of the land 2 is formed in the lower-layer substrate 75 A.
- a second through hole 68 B from which thin metal wires 28 to be connected to the LED chips 27 A to 27 D on the land 2 are extended is formed in the upper-layer substrate 75 B.
- the first through hole 68 A and second through hole 68 B have the same shape and the same size to form one through hole.
- the upper surface of the lower-layer substrate 75 A is bonded to the lower surface of the upper-layer substrate 75 B. This forms a structure in which the land 2 is incorporated in the printed wiring board 75 .
- a plurality of terminal portions 72 are formed around the second through hole 68 B.
- Two terminal portions 72 correspond to each one of the LED chips 27 A to 27 D to be mounted on the land 2 .
- one is a positive terminal and the other is a negative terminal.
- Two thin metal wires 28 are connected to each one of the LED chips 27 A to 27 D.
- the thin metal wires 28 are extended from the second through hole 68 B.
- one is electrically connected to the positive terminal portion 72
- the other is connected to the negative terminal portion 72 .
- Side-surface terminal portions 72 A are formed on the side surfaces of the upper-layer substrate 75 B and lower-layer substrate 75 A that are bonded to each other.
- Lower-surface terminal portions 72 B are formed on the lower surface of the lower-layer substrate 75 A.
- the terminal portions 72 A and 72 B are electrically connected to the terminal portions 72 .
- the terminal portions 72 and lower-surface terminal portions 72 B are formed by etching copper foils adhered to the upper and lower surfaces of the upper- and lower-layer substrates 75 B and 75 A, respectively.
- the side-surface terminal portions 72 A are formed of plating films in the third through holes that extend through the substrates 75 A and 75 B.
- the plurality of third through holes are formed, around the first and second through holes 68 A and 68 B, along the lines C 1 , C 2 , and C 3 shown in FIG. 2A .
- a space 10 surrounded by an LED chip mounting portion 7 and reflecting portion 8 of the land 2 is resin-molded with a transparent molding resin 29 .
- a dome-like lens 81 is arranged on the upper-layer substrate 75 B.
- a plurality of LED devices arranged in a matrix may be cut along the lines C 1 , C 2 , and C 3 shown in FIG. 2A , in the same manner as in the first embodiment.
- LED devices When LED devices are to be used as an aggregate, they need not be cut.
- a material to form the lower-layer substrate 75 A and a material for the upper-layer substrate 75 B may be adhered, heated, and hardened.
- the upper surface of the lower-layer substrate 75 A and the lower surface of the upper-layer substrate 75 B sandwich a flange 9 of the land 2 . Therefore, according to this embodiment, bonding with an adhesive or by welding is not necessary to bond the land 2 to the printed wiring board 75 .
- Each terminal portion 72 on the printed wiring board 75 has a thickness of about several ten ⁇ m, whereas the flange 9 has a thickness of about several hundred ⁇ m. If the land 2 appears on the surface of the printed wiring board 25 , as in the first embodiment, the entire LED device 30 becomes thicker by an amount corresponding to the thickness of the flange 9 . In contrast to this, according to this embodiment, since the land 2 is arranged in the printed wiring board 75 and does not appear on the surface of the printed wiring board 75 , the LED device 80 can be made thinner than in the first embodiment.
- the flange 9 of the land 2 and the terminal portions 22 are arranged on the surface of one printed wiring board 25 , as in the first embodiment, the flange 9 of the land 2 and the terminal portions 22 must be set apart by a sufficient distance between them so they will not come into contact with each other. In contrast to this, according to this embodiment, the flange 9 of the land 2 and the terminal portions 22 are arranged on the different layers of the printed wiring board 75 . Thus, the area of the LED device 80 can be decreased when compared to the first embodiment.
- the plurality of LED chips 27 A to 27 D are mounted on one land 2 .
- one LED chip may be mounted on one land 2 .
- An LED device 90 shown in FIG. 11 is characterized in that power is supplied to an LED chip 27 E mounted on a land 2 via one thin metal wire 28 and the land 2 made of a metal.
- the LED chip 27 E is connected to terminal portions 72 on an upper-layer substrate 75 C through the thin metal wires 28 . This arrangement is the same as that of the fifth embodiment described above.
- an electrical connection hole 91 is formed in that portion of the land 2 of the upper-layer substrate 75 C which is above a flange 9 .
- a plating film 92 is formed on the hole wall of the electrical connection hole 91 .
- An interconnection 93 which extends from the electrical connection hole 91 to the corresponding terminal portion 72 is formed on the upper surface of the upper-layer substrate 75 C.
- the electrical connection hole 91 and plating film 92 can be formed in the following manner. First, a lower-layer substrate 75 A is bonded to an upper-layer substrate 75 C, and the electrical connection hole 91 is formed by boring with a drill or a laser. After that, panel plating with electrolytic copper plating is performed to form the plating film 92 on the hole wall of the electrical connection hole 91 .
- a plurality of LED chips may be mounted on one land 2 , in the same manner as in the fifth embodiment.
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Abstract
A recess is formed in a land (2) of an LED reflecting plate (1) formed of a metal plate. The recess comprises a flat LED chip mounting portion (7) and a reflecting portion (8) inclined with respect to the LED chip mounting portion (7). The LED reflecting plate (1) is mounted on a printed wiring board (25) such that the land (2) is fitted in a first through hole (18). An LED chip (27) mounted on the LED chip mounting portion (7) is connected to a terminal portion (22) formed on the printed wiring board (25). The printed wiring board (25) is diced along a third through hole (19) to form an LED device (30) as one unit. With this arrangement, heat radiation properties and reflecting efficiency of the LED device (30) can be improved, and the manufacturing cost can be decreased.
Description
- The present invention relates to an LED reflecting plate and LED device and, more particularly, to an LED reflecting plate which improves the reflecting efficiency of an LED chip to be mounted on it, and an LED device using the same.
- In recent years, LED chips having high luminance have been developed. Such LED chips are not only used as an illumination for the ten-key pad of a conventional cellular phone or the like or as spot illumination, but also becoming to be used as illumination for a comparatively wide range, e.g., a reading lamp. Accordingly, the LED chips require higher heat radiation properties.
- As the first example of a conventional LED device, one described in reference 1 (Japanese Patent Laid-Open No. 7-235696) is available. In this LED device, a through hole is formed in an insulating substrate. One opening of the through hole is covered with a metal plate. A metal film is formed on the wall surface of the through hole, the surface of the metal plate, and the surface of the insulating substrate by plating. An LED chip is mounted on the metal plate and is electrically connected to the metal film on the insulating film by wire bonding.
- As the second example of the conventional LED device, one as shown in
FIG. 12 is available in which alead frame 102 formed of a thin metal plate is subjected to resin molding, and anLED chip 103 is mounted on thelead frame 102. More specifically, a funnel-shaped recess 101 is formed inmolded resin 100. Thelead frame 102 is buried in the bottom of therecess 101. TheLED chip 103 is mounted on thelead frame 102 and connected to aterminal portion 104 of thelead frame 102 through a thin metal wire by wire bonding. - In the first example of the conventional LED devices described above, the metal film on the wall surface of the through hole formed in the insulating substrate is formed by plating. Accordingly, there is a limit to increasing the thickness of the metal film, and the heat radiation properties cannot be improved.
- In contrast to this, in the second example, the
lead frame 102 improves the heat radiation properties. However, a mold to form thelead frame 102 and a mold to form the resin are required to increase the cost. It is difficult to perform uniform-thick metal plating on the surface of the moldedresin 100. Therefore, the reflecting efficiency of light emitted from the LED decreases. - The present invention has been made in view of the conventional problems described above, and has as its object to improve the heat radiation properties of an LED device.
- It is another object of the present invention to improve the reflecting efficiency of light emitted from the LED.
- It is still another object of the present invention to decrease the manufacturing cost of the LED device.
- In order to achieve the above object, an LED reflecting plate according to the present invention is characterized by comprising a plurality of lands each comprising a recess where an LED chip is to be mounted, a first bridging portion which connects the plurality of lands in series, a frame having a frame shape to surround the plurality of lands, and a second bridging portion which connects the frame to, of the plurality of lands, lands which are located at two ends, wherein the lands, the first bridging portion, the second bridging portion, and the frame are made of a metal.
- An LED device according to the present invention is characterized by comprising an LED chip, an LED reflecting plate made of a metal and having a recess where the LED chip is to be mounted, and a printed wiring board on which the LED reflecting plate is to be mounted, wherein the printed wiring board comprises a first through hole in which the recess of the LED reflecting plate is to be fitted, and a terminal portion to be electrically connected to the LED chip.
- According to the present invention, since the LED chip is mounted on the reflecting plate made of a metal plate, the heat radiation properties improve.
- Since the reflecting plate is made of the metal plate, the thickness of an underlying plating film formed on the reflecting plate can be made uniform. Thus, the mirror surface effect of a noble metal plating film formed on the underlying plating film, aluminum deposition, or the like can improve the reflecting efficiency.
- Only a mold to form the reflecting plate must be prepared. Thus, the cost of the mold can be decreased, and accordingly the manufacturing cost of an LED device can be decreased.
-
FIG. 1 is a perspective view showing the entire appearance of an LED reflecting plate according to the first embodiment of the present invention; -
FIG. 2A is a plan view of the LED reflecting plate shown inFIG. 1 ; -
FIG. 2B is a sectional view taken along the line II(B)-II(B) ofFIG. 2A ; -
FIGS. 3A to 3F are sectional views to explain a method of manufacturing an LED device according to the first embodiment of the present invention; -
FIGS. 4A to 4D are sectional views to explain the method of manufacturing the LED device according to the first embodiment of the present invention; -
FIG. 5A is a sectional view of the LED device according to the first embodiment of the present invention; -
FIG. 5B is a perspective view showing the appearance of the LED device shown inFIG. 5A ; -
FIG. 6 is a perspective view showing the array of LED reflecting plates to cope with a case wherein a printed wiring board is formed to be larger than an LED reflecting plate; -
FIG. 7 is a perspective view showing an LED reflecting plate according to the second embodiment of the present invention; -
FIG. 8 is a plan view showing the arrangement of lands in an LED reflecting plate according to the third embodiment of the present invention; -
FIG. 9 is a perspective view showing a land in an LED reflecting plate according to the fourth embodiment of the present invention; -
FIG. 10A is a sectional view of an LED device according to the fifth embodiment of the present invention; -
FIG. 10B is a perspective view showing the outer appearance of the LED device shown inFIG. 10A ; -
FIG. 11 is a sectional view of an LED device according to the sixth embodiment of the present invention; and -
FIG. 12 is a sectional view of a conventional LED device. - The embodiments of the present invention will be described with reference to the drawings.
- The first embodiment of the present invention will be described with reference to
FIGS. 1 to 6 . - An
LED reflecting plate 1 shown inFIGS. 1 and 2A comprises a plurality oflands 2 on whichLED chips 27 are to be mounted,first bridging portions 3 which connect the plurality oflands 2 in series, a frame 4 having a frame shape to surround the plurality oflands 2, andsecond bridging portions 5 which connect, of the plurality oflands 2, the lands at the two ends to the frame 4. TheLED reflecting plate 1 is formed from a thin phosphor bronze plate (with a thickness of 50 μm to 200 μm) by punching so that one metal plate forms thelands 2,first bridging portions 3,second bridging portions 5, and frame 4 integrally. - The
LED reflecting plate 1 is provided with fourland groups 6, each comprising threelands 2 that are linearly connected in series with thefirst bridging portions 3, to be parallel to each other. The 12lands 2 are arranged in a matrix of 4 columns×3 rows. Alternatively, a plurality of (to or more)land groups 6 may be provided. - The
LED reflecting plate 1 is provided withpositioning holes 11, at its two vertices located on a diagonal of the frame 4, to be aligned with a printed wiring board 25 (to be described later). - As shown in
FIG. 2B , theland 2 of theLED reflecting plate 1 has a recess formed by drawing and aflat flange 9 around the recess. The recess comprises a flat bottom and a side wall inclined to form an obtuse angle with respect to the bottom. The bottom of the recess forms an LEDchip mounting portion 7 where theLED chip 27 is to be mounted, and the side wall of the recess forms a reflectingportion 8 which reflects forward light from an LED. Aspace 10 surrounded by the LEDchip mounting portion 7 and reflectingportion 8 is frustoconical. A height T1 (the height from the lower surface of theflange 9 to the lower surface of the LED chip mounting portion 7) of thespace 10 is slightly larger than a thickness T2 of the printedwiring board 25. - To manufacture the
LED reflecting plate 1, after punching as described above, drawing is performed. Alternatively, drawing may be performed, and after that punching may be performed, or drawing and punching may be performed simultaneously. - The
LED reflecting plate 1 formed in this manner is subjected to nickel plating to form an underlying plating film, and then to silver plating to form a noble metal plating film on the underlying plating film. In this case, since the surface of theland 2 formed of a metal plate is subjected to plating, a nickel plating film serving as the underlying plating film formed on the surface of theland 2 has a uniform thickness entirely. The surface of the silver plating film formed on the nickel plating film accordingly forms a mirror surface having very few steps entirely. Thus, the reflecting efficiency of the surface of the reflectingportion 8 can be improved. - A method of manufacturing the printed
wiring board 25 serving as an intermediate member of the LED device according to the present invention will be described with reference toFIGS. 3A to 3F . AlthoughFIGS. 3A to 3F show only one LED device for descriptive convenience, actually, a plurality of LED devices are arranged in a matrix. -
FIG. 3A shows a double-side copper-cladboard 15 obtained by adhering copper foils 17 to the two surfaces of an insulatingsubstrate 16. The double-side copper-cladboard 15 is subjected to boring with a drill to form a first throughhole 18 and third throughholes 19 which intervene between the first throughhole 18, as shown inFIG. 3B . A diameter R2 of the first throughhole 18 is slightly larger than an outer diameter (an outer diameter added with the thickness of the land 2) R1 at the upper end of thespace 10 formed above theland 2 of the reflecting plate 1 (described above). - Subsequently, the double-side copper-clad
board 15 is subjected to panel plating by electrolytic copper plating to form aplating film 20 to cover the two surfaces of the insulatingsubstrate 16 and the hole walls of the first and second throughholes FIG. 3C . Furthermore, a circuit is formed by etching, as shown inFIG. 3D , to form aland placing portion 21, where theland 2 described above is to be placed, at the upper edge of the first throughhole 18.Terminal portions 22 for wire bonding are formed at portions away from theland placing portion 21. - In
FIG. 3E , a solder resist 23 is applied to an unnecessary circuit. Then, as shown inFIG. 3F , theland placing portion 21 andterminal portions 22 are subjected to noble metal plating using nickel and gold to form the printedwiring board 25. - A method of manufacturing the LED device using the printed
wiring board 25 formed in this manner and theLED reflecting plate 1 described above will be described with reference toFIGS. 4A to 4D . - Referring to
FIG. 4A , a cream solder is applied to theland placing portion 21 of the printedwiring board 25. After that, positioning pins (neither is shown) are inserted in the positioning holes 11 of the printedwiring board 25 and the positioning holes of the printedwiring board 25 to place theLED reflecting plate 1 on the printedwiring board 25 such that thelands 2 of theLED reflecting plate 1 are respectively fitted in the plurality of first throughholes 18 of the printedwiring board 25. In this state, the printedwiring board 25 andLED reflecting plate 1 are heated in a heating furnace to fuse the cream solder again, so that theflange 9 of eachland 2 is bonded on theland placing portion 21 of the printedwiring board 25 and that theLED reflecting plate 1 is bonded on the printedwiring board 25, as shown inFIG. 4B . - Subsequently, as shown in
FIG. 4C , theLED chip 27 is bonded on the LEDchip mounting portion 7 of theLED reflecting plate 1 by die bonding, and thin metal wires (wires) 28 of theLED chip 27 are electrically connected to theterminal portions 22 of the printedwiring board 25 by wire bonding. As shown inFIG. 4D , theland 2 of theLED reflecting plate 1 and theterminal portions 22 of the printedwiring board 25 are resin-sealed with atransparent molding resin 29. As shown inFIG. 2A , lines C1 which are parallel to the first andsecond bridging portions holes 19, lines C2 which are perpendicular to the lines C1 and cross thefirst bridging portions 3, and lines C3 which cross thesecond bridging portions 5 are cut by dicing. Thus,LED devices 30 each forming one unit as shown inFIGS. 5A and 5B are formed. - A
heat sink 31 serving as a cooling member which cools theland 2 of theLED reflecting plate 1 is attached to the bottom of theLED device 30. As the height T1 of thespace 10 of theland 2 is slightly larger than the thickness T2 of the printedwiring board 25, the bottom of the recess of theland 2 comes into contact with theheat sink 31. Thus, heat generated by theLED chip 27 is dissipated from theland 2 outside theLED device 30 through theheat sink 31. At this time, as theland 2 on which theLED chip 27 is mounted is formed of the metal plate, theland 2 can be formed to have a predetermined thickness or more and uniformly, to improve heat radiation properties. - In this embodiment, one plating process by masking the printed
wiring board 25 suffices. Therefore, when compared to a conventional example that requires plating twice by masking in order to form a reflecting portion and the remaining portions with different plating films, the manufacturing cost can be decreased. Since only a mold to form theLED reflecting plate 1 must be prepared, the cost required by the mold can be decreased. - In the
LED device 30 described above, cutting at the lines C1, C2, and C3 forms theLED device 30 as one unit. When a plurality ofLED chips 27 are to be used as an aggregation as in a display device or illumination device, the printedwiring board 25 need not be cut, but may be used with the plurality ofLED reflecting plates 1 being mounted on it. - A case will be described with reference to
FIG. 6 wherein the printedwiring board 25 is formed to be larger than theLED reflecting plate 1. As theLED reflecting plate 1 is formed of a very thin metal plate, from the viewpoint of the strength, there is a limit to forming theLED reflecting plate 1 to have a large outer size. For this reason, the printedwiring board 25 may be formed to have a larger outer size than that of theLED reflecting plate 1. In this case, if a plurality ofLED reflecting plates 1 are arrayed in a matrix, the outer size of the plurality ofLED reflecting plates 1 as a whole can be set to coincide with the outer size of the large printedwiring board 25. - In this case,
LED devices 30 each serving as one unit may be formed by cutting. Alternatively, the printedwiring board 25 need not be cut, but may be used with the plurality ofLED reflecting plates 1 being mounted on it. In the latter case, an LED device which is suitably employed in a display device, illumination device, or the like which requires high luminance can be provided. The array of theLED reflecting plates 1 is not limited to the matrix described above to match the outer shape of the printedwiring board 25, but may be a horizontal array or vertical array. - The second embodiment of the present invention will be described with reference to
FIG. 7 . - An
LED reflecting plate 40 shown inFIG. 7 is different from the first embodiment described above in that aland group 6 comprising threelands 2 which are linearly connected in series throughfirst bridging portions 3 comprises only one group. With this arrangement, the array of first throughholes 18 formed in a printedwiring board 25 can also cope with arrays other than 4 arrays or 4×n (n is an integer) arrays, unlike the first embodiment described above. - The third embodiment of the present invention will be described with reference to
FIG. 8 . - An
LED reflecting plate 50 shown inFIG. 8 is characterized in that lands 2 are not formed in a matrix but are in a staggered manner. With this arrangement, the density of thelands 2 can be increased. Therefore, an LED device which is suitably employed in a display device, illumination device, or the like which requires high luminance and uses LED devices as an aggregate can be provided. - The fourth embodiment of the present invention will be described with reference to
FIG. 9 . - This embodiment is characteristic in that an LED
chip mounting portion 7 of aland 2 is square and that aspace 10 is frustopyramidal, as shown inFIG. 9 . In this arrangement, an LED chip having a square section is mounted on the LEDchip mounting portion 7 of theland 2, so that the LEDchip mounting portion 7 can be formed relatively small. - Although the
first bridging portions 3 andsecond bridging portions 5 are arranged on one straight line in the embodiments descried above, they need not always be arranged on one straight line. It suffices as far as thelands 2, and thelands 2 and frame 4 are connected integrally. - The fifth embodiment of the present invention will be described with reference to
FIGS. 10A and 10B . - An
LED device 80 shown inFIGS. 10A and 10B is characterized in that a plurality ofLED chips 27A to 27D are mounted in the recess of eachland 2 of an LED reflecting plate and that theland 2 is arranged in a printedwiring board 75 and integrated with it. This arrangement will be described in more detail. - The printed
wiring board 75 has a lower-layer substrate 75A serving as the first substrate and an upper-layer substrate 75B serving as the second substrate. Both the lower-layer substrate 75A and upper-layer substrate 75B are formed of insulating substrates. A first throughhole 68A to fit with the recess of theland 2 is formed in the lower-layer substrate 75A. A second throughhole 68B from whichthin metal wires 28 to be connected to theLED chips 27A to 27D on theland 2 are extended is formed in the upper-layer substrate 75B. The first throughhole 68A and second throughhole 68B have the same shape and the same size to form one through hole. - With the recess of the
land 2 being fitted in the first throughhole 68A, the upper surface of the lower-layer substrate 75A is bonded to the lower surface of the upper-layer substrate 75B. This forms a structure in which theland 2 is incorporated in the printedwiring board 75. - On the upper surface of the upper-
layer substrate 75B, a plurality ofterminal portions 72 are formed around the second throughhole 68B. Twoterminal portions 72 correspond to each one of theLED chips 27A to 27D to be mounted on theland 2. Of the twoterminal portions 72, one is a positive terminal and the other is a negative terminal. Twothin metal wires 28 are connected to each one of theLED chips 27A to 27D. Thethin metal wires 28 are extended from the second throughhole 68B. Of the twothin metal wires 28, one is electrically connected to the positiveterminal portion 72, and the other is connected to thenegative terminal portion 72. - Side-
surface terminal portions 72A are formed on the side surfaces of the upper-layer substrate 75B and lower-layer substrate 75A that are bonded to each other. Lower-surface terminal portions 72B are formed on the lower surface of the lower-layer substrate 75A. Theterminal portions terminal portions 72. Theterminal portions 72 and lower-surface terminal portions 72B are formed by etching copper foils adhered to the upper and lower surfaces of the upper- and lower-layer substrates surface terminal portions 72A are formed of plating films in the third through holes that extend through thesubstrates holes FIG. 2A . - A
space 10 surrounded by an LEDchip mounting portion 7 and reflectingportion 8 of theland 2 is resin-molded with atransparent molding resin 29. A dome-like lens 81 is arranged on the upper-layer substrate 75B. - To form the
LED device 80 which forms one unit as shown inFIGS. 10A and 10B , a plurality of LED devices arranged in a matrix may be cut along the lines C1, C2, and C3 shown inFIG. 2A , in the same manner as in the first embodiment. When LED devices are to be used as an aggregate, they need not be cut. - According to this embodiment, to bond the lower-
layer substrate 75A to the upper-layer substrate 75B, a material to form the lower-layer substrate 75A and a material for the upper-layer substrate 75B may be adhered, heated, and hardened. At this time, as the recess of theland 2 is fitted in the first throughhole 68A, the upper surface of the lower-layer substrate 75A and the lower surface of the upper-layer substrate 75B sandwich aflange 9 of theland 2. Therefore, according to this embodiment, bonding with an adhesive or by welding is not necessary to bond theland 2 to the printedwiring board 75. - Each
terminal portion 72 on the printedwiring board 75 has a thickness of about several ten μm, whereas theflange 9 has a thickness of about several hundred μm. If theland 2 appears on the surface of the printedwiring board 25, as in the first embodiment, theentire LED device 30 becomes thicker by an amount corresponding to the thickness of theflange 9. In contrast to this, according to this embodiment, since theland 2 is arranged in the printedwiring board 75 and does not appear on the surface of the printedwiring board 75, theLED device 80 can be made thinner than in the first embodiment. - If the
flange 9 of theland 2 and theterminal portions 22 are arranged on the surface of one printedwiring board 25, as in the first embodiment, theflange 9 of theland 2 and theterminal portions 22 must be set apart by a sufficient distance between them so they will not come into contact with each other. In contrast to this, according to this embodiment, theflange 9 of theland 2 and theterminal portions 22 are arranged on the different layers of the printedwiring board 75. Thus, the area of theLED device 80 can be decreased when compared to the first embodiment. - In the
LED device 90 described above, the plurality ofLED chips 27A to 27D are mounted on oneland 2. Alternatively, one LED chip may be mounted on oneland 2. - The sixth embodiment of the present invention will be described with reference to
FIG. 11 . - An
LED device 90 shown inFIG. 11 is characterized in that power is supplied to anLED chip 27E mounted on aland 2 via onethin metal wire 28 and theland 2 made of a metal. TheLED chip 27E is connected toterminal portions 72 on an upper-layer substrate 75C through thethin metal wires 28. This arrangement is the same as that of the fifth embodiment described above. - In the
LED device 90, anelectrical connection hole 91 is formed in that portion of theland 2 of the upper-layer substrate 75C which is above aflange 9. Aplating film 92 is formed on the hole wall of theelectrical connection hole 91. Aninterconnection 93 which extends from theelectrical connection hole 91 to the correspondingterminal portion 72 is formed on the upper surface of the upper-layer substrate 75C. Thus, theLED chip 27E is electrically connected to theterminal portion 72 through themetal land 2, platingfilm 92 in theelectrical connection hole 91, and theinterconnection 93 on the upper-layer substrate 75C. - For example, the
electrical connection hole 91 andplating film 92 can be formed in the following manner. First, a lower-layer substrate 75A is bonded to an upper-layer substrate 75C, and theelectrical connection hole 91 is formed by boring with a drill or a laser. After that, panel plating with electrolytic copper plating is performed to form theplating film 92 on the hole wall of theelectrical connection hole 91. - In this embodiment, a plurality of LED chips may be mounted on one
land 2, in the same manner as in the fifth embodiment.
Claims (3)
1. An LED device comprising:
an LED chip;
an LED reflecting plate made of a metal and having a recess where said LED chip is to be mounted; and
a printed wiring board on which said LED reflecting plate is to be mounted,
said printed wiring board comprising
a first through hole in which the recess of said LED reflecting plate is to be fitted, and
a terminal portion formed on a surface of said printed wiring board to be electrically connected to said LED chip,
said LED reflecting plate comprising
a flat LED chip mounting portion which forms a bottom of the recess, and
a reflecting portion which forms a side wall of the recess and is inclined with respect to said LED chip mounting portion,
said LED device further comprising
a thin metal wire which electrically connects said LED chip and said terminal portion of said printed wiring board,
said LED reflecting plate further comprising
a flat flange around the recess, and
said printed wiring board further comprising
a first substrate formed with the first through hole,
a second substrate which sandwiches, together with said first substrate, said flange of said LED reflecting plate the recess of which is fitted in the first through hole, and
a second through hole which is formed in said second substrate and through which said thin metal wire connected to said LED chip on said LED reflecting plate is extended.
2. An LED device according to claim 1 , wherein a plurality of LED chips are mounted on each recess of said LED reflecting plate.
3. An LED device according to claim 1 , wherein said printed wiring board further comprises
an electrical connection hole formed in a portion of said second substrate which is above said flange, and
a wiring line which is formed on a surface of said second substrate and electrically connects the electrical connection hole to said terminal portion.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US12/581,828 US20100032693A1 (en) | 2004-09-16 | 2009-10-19 | Led reflecting plate and led device |
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
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JP2004269513 | 2004-09-16 | ||
JP269513/2004 | 2004-09-16 | ||
PCT/JP2005/016407 WO2006030671A1 (en) | 2004-09-16 | 2005-09-07 | Reflector for led and led device |
US57416006A | 2006-03-28 | 2006-03-28 | |
US12/581,828 US20100032693A1 (en) | 2004-09-16 | 2009-10-19 | Led reflecting plate and led device |
Related Parent Applications (2)
Application Number | Title | Priority Date | Filing Date |
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PCT/JP2005/016407 Division WO2006030671A1 (en) | 2004-09-16 | 2005-09-07 | Reflector for led and led device |
US57416006A Division | 2004-09-16 | 2006-03-28 |
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US20100032693A1 true US20100032693A1 (en) | 2010-02-11 |
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US10/574,160 Expired - Fee Related US7626211B2 (en) | 2004-09-16 | 2005-09-07 | LED reflecting plate and LED device |
US12/581,828 Abandoned US20100032693A1 (en) | 2004-09-16 | 2009-10-19 | Led reflecting plate and led device |
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US10/574,160 Expired - Fee Related US7626211B2 (en) | 2004-09-16 | 2005-09-07 | LED reflecting plate and LED device |
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JP (1) | JP4062358B2 (en) |
KR (1) | KR100723618B1 (en) |
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TW (1) | TW200629596A (en) |
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Also Published As
Publication number | Publication date |
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KR100723618B1 (en) | 2007-06-04 |
TWI313937B (en) | 2009-08-21 |
US20070063209A1 (en) | 2007-03-22 |
CN100403565C (en) | 2008-07-16 |
WO2006030671A1 (en) | 2006-03-23 |
JPWO2006030671A1 (en) | 2008-07-31 |
KR20060085928A (en) | 2006-07-28 |
TW200629596A (en) | 2006-08-16 |
JP4062358B2 (en) | 2008-03-19 |
US7626211B2 (en) | 2009-12-01 |
CN1898809A (en) | 2007-01-17 |
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