US20170294567A1 - Led module - Google Patents
Led module Download PDFInfo
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- US20170294567A1 US20170294567A1 US15/634,602 US201715634602A US2017294567A1 US 20170294567 A1 US20170294567 A1 US 20170294567A1 US 201715634602 A US201715634602 A US 201715634602A US 2017294567 A1 US2017294567 A1 US 2017294567A1
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- led
- led unit
- viewed
- led module
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- 229910010293 ceramic material Inorganic materials 0.000 abstract description 5
- 239000000758 substrate Substances 0.000 description 21
- 239000004020 conductor Substances 0.000 description 18
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- 230000005496 eutectics Effects 0.000 description 6
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- 229910052737 gold Inorganic materials 0.000 description 4
- 229910052759 nickel Inorganic materials 0.000 description 4
- 229920005989 resin Polymers 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 239000004065 semiconductor Substances 0.000 description 3
- 229910052721 tungsten Inorganic materials 0.000 description 3
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- 238000010030 laminating Methods 0.000 description 1
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- 238000007747 plating Methods 0.000 description 1
- 239000012780 transparent material Substances 0.000 description 1
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- 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
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- H01L25/04—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers
- H01L25/075—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers the devices being of a type provided for in group H01L33/00
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Definitions
- the present invention relates to an LED module provided with an LED chip as the light source.
- FIG. 19 shows an example of conventional LED module (see e.g. Patent Document 1).
- the LED module X illustrated in the figure includes a case 91 , a sub-mount substrate 92 , a wiring pattern 93 , an LED chip 94 and a light-transmitting portion 95 .
- the case 91 is made of e.g. resin.
- the sub-mount substrate 92 is made of e.g. Si.
- the wiring pattern 93 is formed on the sub-mount substrate 92 and has an obverse surface made of e.g. Au or Ag.
- the LED chip 94 is the light source of the LED module X and emits light of a predetermined wavelength.
- the LED chip 94 is mounted to the sub-mount substrate 92 by eutectic bonding to the wiring pattern 93 .
- the light-transmitting portion 95 is made of a material that transmits light from the LED chip 94 , such as silicone resin, and covers the LED chip 94 .
- the material such as Ag that forms the obverse surface of the wiring pattern 93 is corroded and changes to a dark color.
- the wiring pattern 93 that has changed to a dark color in this way absorbs light emitted from the LED chip 94 .
- the amount of light emission from the LED module X may reduce with time.
- Patent Document 1 JP-A-2006-237141
- the present invention has been conceived in view of the above-described situation, and it is an object of the present invention to provide an LED module that is configured to suppress reduction of light emission with time.
- An LED module provided according to a first aspect of the present invention comprises: at least one LED unit including an LED chip; and a case including a main body made of a ceramic material and at least one pad for mounting the LED unit.
- the pad includes an outer edge that is positioned inward of the outer edge of the LED unit as viewed in plan.
- the pad in the LED module of the first aspect, includes an obverse surface made of Ag or Au.
- the main body is white.
- the LED module of anyone of the first through the third aspects further comprises at least one wire including an end bonded to the LED unit.
- the case further comprises at least one bonding pad to which another end of the wire is bonded and which is positioned on the outer side of the pad as viewed in plan.
- the main body further comprises a reflector surrounding the LED unit, and the reflector is provided with a recess that accommodates at least a part of the bonding pad as viewed in plan.
- the case further comprises: at least one mounting electrode provided on an opposite side from the pad; and a penetration conductor penetrating the main body and connecting one of the pads and one of the mounting electrodes to each other.
- the LED unit in the LED module of any one of the first through the sixth aspects, consists of the LED chip only.
- the LED unit further comprises a sub-mount substrate on which the LED chip is mounted.
- the above-mentioned pad comprises a plurality of pads arranged in a plurality of rows
- the above-mentioned LED unit comprises a plurality of LED units mounted on the plurality of pads, respectively.
- the LED unit and the pad are bonded to each other by eutectic bonding.
- the LED module of anyone of the first through the tenth aspects further comprises a light-transmitting portion covering the LED unit.
- the light-transmitting portion is made up of a resin material and a fluorescent substance, where the resin material is configured to transmit light from the LED unit, and the fluorescent substance is configured to be excited by the light from the LED unit, thereby emitting light of a wavelength different from that of the light from the LED unit.
- FIG. 1 is a plan view showing an LED module according to a first embodiment of the present invention
- FIG. 2 is a sectional view taken along lines II-II in FIG. 1 ;
- FIG. 3 is a sectional view taken along lines III-III in FIG. 1 ;
- FIG. 4 is an enlarged sectional view of a principal portion of the LED module according to the first embodiment of the present invention.
- FIG. 5 is a bottom view of the LED module according to the first embodiment of the present invention.
- FIG. 6 is a plan view showing an LED module according to a second embodiment of the present invention.
- FIG. 7 is a sectional view taken along lines VII-VII in FIG. 6 ;
- FIG. 8 is a sectional view taken along lines VIII-VIII in FIG. 6 ;
- FIG. 9 is an enlarged sectional view of a principal portion of the LED module according to the second embodiment of the present invention.
- FIG. 10 is a plan view showing an LED module according to a third embodiment of the present invention.
- FIG. 11 is a sectional view taken along lines XI-XI in FIG. 10 ;
- FIG. 12 is a sectional view taken along lines XII-XII in FIG. 10 ;
- FIG. 13 is an enlarged sectional view of a principal portion of the LED module according to the third embodiment of the present invention.
- FIG. 14 is a plan view showing an LED module according to a fourth embodiment of the present invention.
- FIG. 15 is a sectional view taken along lines XV-XV in FIG. 14 ;
- FIG. 16 is a sectional view taken along lines XVI-XVI in FIG. 14 ;
- FIG. 17 is an enlarged sectional view of a principal portion of the LED module according to the fourth embodiment of the present invention.
- FIG. 18 is a sectional view showing an LED module according to a fifth embodiment of the present invention.
- FIG. 19 is a sectional view showing an example of a conventional LED module.
- FIGS. 1-5 show an example of LED module according to the present invention.
- the LED module A 1 of this embodiment includes a case 1 , a plurality of LED units 2 , a Zener diode 3 , wires 4 and a light-transmitting portion 5 (not shown in FIG. 1 ).
- the LED module A 1 is an LED module of a high output type that provides a relatively high brightness and is about 5 mm ⁇ 5 mm as viewed in plan and about 0.9 mm in thickness.
- the case 1 includes a main body 11 , a plurality of pads 12 a and 12 b, a plurality of bonding pads 13 a and 13 b, a pad 16 , a pair of mounting electrodes 14 a and 14 b, and a plurality of penetration conductors 15 a, 15 b, 15 c and 15 d.
- the case 1 is made of a white ceramic material such as alumina.
- the main body 11 has a reflector 11 a and a bottom surface 11 c.
- the reflector 11 a reflects the light traveling generally horizontally from the LED chip 21 in FIG. 2 to direct the light upward in the figure.
- the reflector 11 a is provided with four recesses 11 b.
- Each of the four recesses 11 b has a triangular cross section as viewed in plan and reaches the bottom surface 11 c.
- the bottom surface 11 c is generally circular and connected to the bottom edge of the reflector 11 a.
- the pads 12 a and 12 b are formed on the bottom surface 11 c. In this embodiment, three pads 12 a and three pads 12 b are arranged in two rows. Each of the pads 12 a, 12 b is rectangular and made of a plurality of plated layers laminated from the bottom surface 11 c side in the order of e.g. Ag, Ni, Au or Ag, Ni, Ag or W, Ni, Ag or W, Ni, Au.
- the top layer is made of Ag
- the Ag layer is made to have a thickness of about 2.5 ⁇ m.
- the Au layer is made to have a thickness of about 0.1 ⁇ m.
- the bonding pads 13 a, 13 b are formed on the bottom surface 11 c.
- three bonding pads 13 a and three bonding pads 13 b are arranged in two rows.
- Each of the bonding pads 13 a, 13 b is rectangular and made of plated layers similar to those of the pads 12 a, 12 b.
- About one third of each of the four bonding pads 13 a, 13 b positioned at four corners is accommodated in a respective one of the four recesses 11 b.
- the pad 16 is arranged adjacent to the edge of the bottom surface 11 c and made of plated layers similar to those of the pads 12 and the bonding pads 13 .
- the paired mounting electrodes 14 a and 14 b are generally rectangular and formed on a surface of the main body 11 opposite from the surface provided with the reflector 11 a and the bottom surface 11 c. As shown in the figure, the mounting electrode 14 a is considerably larger than the mounting electrode 14 b and overlaps the LED chips 21 as viewed in plan.
- the penetration conductors 15 a, 15 b, 15 c and 15 d are made of e.g. Ag or W and penetrate the main body 11 .
- three penetration conductors 15 a connect the three bonding pads 13 a to the mounting electrode 14 a.
- Three penetration conductors 15 b connect the three pads 12 a to the mounting electrode 14 a.
- Three penetration conductors 15 c connect the three pads 12 b to the mounting electrode 14 a.
- the single penetration conductor 15 c connects the pad 16 to the mounting electrode 14 a.
- Three penetration conductors 15 d connect the three bonding pad 13 b to the mounting electrode 14 b and are in the form of a crank.
- the case 1 having this structure can be made by laminating a ceramic material, an Ag material or a W material in an appropriate order, then baking these materials, and then performing plating.
- the LED units 2 are the light source of the LED module A 1 and comprise a plurality of LED chips 21 in this embodiment.
- Each LED chip 21 includes an n-type semiconductor layer made of e.g. GaN-based semiconductor, a p-type semiconductor layer, and an active layer sandwiched between these layers, and emits blue light.
- the LED chips 21 are bonded to the pads 12 a, 12 b by eutectic bonding.
- the size of each LED chip 21 as viewed in plan is larger than that of each pad 12 a, 12 b. That is, as shown in FIG. 4 , the outer edge 121 a of each pad 12 a is positioned slightly inward of the outer edge 2 a of the LED unit 2 (LED chip 21 ) as viewed in plan. This holds true for the outer edge of each pad 12 b.
- the LED chips 21 are configured as a two-wire LED chip.
- the Zener diode 3 prevents application of excessive reverse voltage to the LED chips 21 and allows current to flow in a reverse direction only when an excessive reverse voltage above a certain value is applied.
- the Zener diode 3 is bonded to the pad 16 via e.g. Ag paste.
- the wires 4 are made of e.g. Au. Each of the wires 4 is bonded at one end to the bonding pad 13 a or 13 b and bonded at the other end to one of the LED chips 21 or the Zener diode 3 .
- the light-transmitting portion 5 fills the region surrounded by the reflector 11 a and the bottom surface 11 c and covers the LED chips 21 , the Zener diode 3 and the wires 4 .
- the light-transmitting portion 5 is made of e.g. transparent silicone resin with a fluorescent substance mixed in it.
- the fluorescent substance emits yellow light when excited by the blue light from the LED chips 21 .
- the yellow light mixes with the blue light from the LED chips 21 , whereby white light is emitted from the LED module A 1 .
- the pads 12 a, 12 b are covered by the LED chips 21 .
- the pads 12 a, 12 b change to a dark color with time, light from the LED chips 21 traveling toward the bottom surface 11 c is not absorbed by the pads 12 a, 12 b but reflected by the bottom surface 11 c.
- reduction of light emission amount of the LED module with time is suppressed, and the LED module A 1 offers high brightness.
- the bonding pads 13 a, 13 b are not completely covered by the LED chips 21 or the wires 4 , the bonding pads 13 a, 13 b are provided on the outer side of the LED chips 21 and spaced apart from the LED chips 21 . This prevents light from the LED chips 21 from being absorbed by the bonding pad 13 a, 13 b.
- the provision of the recesses 11 b in the reflector 11 a allows the reflector 11 a to be arranged relatively close to the LED chips 2 . Such an arrangement is suitable for increasing the brightness of the LED module A 1 .
- the main body 11 which is made of a ceramic material, can transmit light from the LED chips 21 , though the amount is small. Arranging the reflector 11 a relatively close to LED chips 21 allows the size of the portion of the main body 11 which is on the outer side of the reflector 11 a to be increased without changing the outer dimensions of the main body 11 . Thus, unfavorable leak of the light from the LED chips 21 to the sides through the main body 11 is prevented.
- the penetration conductors 15 b, 15 c do not carry out electrical function but conduct the heat generated at the LED chips 21 from the pads 12 a, 12 b to the mounting electrode 14 a. With this arrangement, heat is efficiently dissipated from the LED chips 21 , which makes it possible to apply high current to the LED chips 21 . This is advantageous for increasing the brightness of the LED module A 1 .
- FIGS. 6-18 show other embodiments of the present invention.
- the elements that are identical or similar to those of the foregoing embodiment are designated by the same reference signs as those used for the foregoing embodiment.
- FIGS. 6-9 show an LED module according to a second embodiment of the present invention.
- the LED module A 2 of this embodiment is different from the foregoing embodiment in structure of the LED units 2 .
- each LED unit 2 comprises an LED chip 21 and a sub-mount substrate 22 .
- the sub-mount substrate 22 is made of e.g. Si, and the LED chip 21 is mounted on the sub-mount substrate.
- the sub-mount substrate 22 has a wiring pattern formed on it.
- the wiring pattern is electrically connected to an electrode (not shown) of the LED chip 21 , and includes a portion extending into a region that is not covered by the LED chip 21 .
- wires 4 are bonded to the wiring pattern.
- the sub-mount substrate 22 is bonded to the pad 12 a or 12 b with e.g. Ag paste 17 . This bonding may be performed by eutectic bonding.
- each pad 12 a, 12 b as viewed in plan is smaller than that of the sub-mount substrate 22 .
- the outer edge 121 a of each pad 12 a is positioned slightly inward of the outer edge 2 a of the LED unit 2 (sub-mount substrate 22 ) as viewed in plan. This holds true for the outer edge of each pad 12 b.
- FIGS. 10-13 show an LED module according to a third embodiment of the present invention.
- the LED module A 3 of this embodiment is different from the foregoing embodiments in structure of the LED units 2 .
- each LED unit 2 consists of an LED chip 21 only and is structured as a single-wire LED unit. Since each LED unit 2 is a single-wire LED unit, the bonding pads 13 a and the penetration conductors 15 , which are provided in the cases 1 of the LED modules A 1 and A 2 , are not provided in this embodiment.
- electrodes are formed on the upper surface and the lower surface of each LED chip 21 .
- a wire 4 To the electrode on the upper surface is bonded a wire 4 .
- the electrode on the lower surface is bonded to the pad 12 a or 12 b by e.g. eutectic bonding.
- each pad 12 a, 12 b as viewed in plan is smaller than that of each LED chip 21 .
- the outer edge 121 b of each pad 12 b is positioned slightly inward of the outer edge 2 a of the LED unit 2 (LED chip 21 ) as viewed in plan.
- FIGS. 14-17 show an LED module according to a fourth embodiment of the present invention.
- the LED module A 4 of this embodiment is different from the foregoing embodiments in structure of the LED units 2 .
- each LED unit 2 is made up of an LED chip 21 and a sub-mount substrate 22 and structured as a single-wire LED unit.
- the sub-mount substrate 22 is made of e.g. Si, and the LED chip 21 is mounted on the sub-mount substrate.
- the sub-mount substrate 22 has a wiring pattern formed on it via an insulating film.
- the wiring pattern is electrically connected to an electrode (not shown) of the LED chip 21 , and includes a portion extending into a region that is not covered by the LED chip 21 .
- a wire 4 is bonded to the wiring pattern.
- the sub-mount substrate 22 is made a conductor by e.g. doping. Another electrode (not shown) of the LED chip 21 is held in contact with and electrically connected to the sub-mount substrate 22 .
- the sub-mount substrate 22 is bonded to the pad 12 a or 12 b with e.g. Ag paste 17 . This bonding may be performed by eutectic bonding.
- each pad 12 a, 12 b as viewed in plan is smaller than that of the sub-mount substrate 22 .
- the outer edge 121 b of each pad 12 b is positioned slightly inward of the outer edge 2 a of the LED unit 2 (sub-mount substrate 22 ) as viewed in plan.
- FIG. 18 shows an LED module according to a fifth embodiment of the present invention.
- the LED module A 5 of this embodiment has the same structure as that of the LED module A 1 except that the structure of the penetration conductors 15 a, 15 b, 15 c, 15 d are different.
- penetration conductor 15 b is not shown in this figure, the penetration conductor 15 b has the same structure as that of the penetration conductor 15 c.
- the penetration conductor 15 c is provided at a position that avoids the LED unit 2 (LED chip 21 ) as viewed in plan.
- the pad 12 b and the penetration conductor 15 c are electrically connected to each other via a plated layer extending from the pad 12 b.
- the penetration conductors 15 a, 15 d are provided at positions that avoid bonded portions of the wires as viewed in plan.
- the LED module according to the present invention is not limited to the foregoing embodiments.
- the specific structure of each part of the LED module according to the present invention can be varied in design in many ways.
- the plurality of LED chips 21 may emit light of different wavelengths.
- the shape of the bottom surface 11 c is not limited to a circular shape.
- the light-transmitting portion 5 may be made of a transparent material only.
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Abstract
An LED module according to the present invention includes an LED unit 2 and a case 1, where the LED unit includes an LED chip 21, and the case 1 includes a main body 11 made of a ceramic material and a pad 12 a on which the LED unit 2 is mounted. The outer edge 121 a of the pad 12 a is positioned inward of the outer edge 2 a of the LED unit 2 as viewed in plan. These arrangements prevent the light emission amount of the LED module A1 from reducing with time.
Description
- The present invention relates to an LED module provided with an LED chip as the light source.
-
FIG. 19 shows an example of conventional LED module (see e.g. Patent Document 1). The LED module X illustrated in the figure includes acase 91, asub-mount substrate 92, awiring pattern 93, anLED chip 94 and a light-transmittingportion 95. Thecase 91 is made of e.g. resin. Thesub-mount substrate 92 is made of e.g. Si. Thewiring pattern 93 is formed on thesub-mount substrate 92 and has an obverse surface made of e.g. Au or Ag. TheLED chip 94 is the light source of the LED module X and emits light of a predetermined wavelength. TheLED chip 94 is mounted to thesub-mount substrate 92 by eutectic bonding to thewiring pattern 93. The light-transmittingportion 95 is made of a material that transmits light from theLED chip 94, such as silicone resin, and covers theLED chip 94. - After long use of the LED module X, the material such as Ag that forms the obverse surface of the
wiring pattern 93 is corroded and changes to a dark color. Thewiring pattern 93 that has changed to a dark color in this way absorbs light emitted from theLED chip 94. Thus, the amount of light emission from the LED module X may reduce with time. - Patent Document 1: JP-A-2006-237141
- The present invention has been conceived in view of the above-described situation, and it is an object of the present invention to provide an LED module that is configured to suppress reduction of light emission with time.
- An LED module provided according to a first aspect of the present invention comprises: at least one LED unit including an LED chip; and a case including a main body made of a ceramic material and at least one pad for mounting the LED unit. The pad includes an outer edge that is positioned inward of the outer edge of the LED unit as viewed in plan.
- According to a second aspect of the present invention, in the LED module of the first aspect, the pad includes an obverse surface made of Ag or Au.
- According to a third aspect of the present invention, in the LED module of the first or the second aspect, the main body is white.
- According to a fourth aspect of the present invention, the LED module of anyone of the first through the third aspects further comprises at least one wire including an end bonded to the LED unit. The case further comprises at least one bonding pad to which another end of the wire is bonded and which is positioned on the outer side of the pad as viewed in plan.
- According to a fifth aspect of the present invention, in the LED module of anyone of the first through the fourth aspects, the main body further comprises a reflector surrounding the LED unit, and the reflector is provided with a recess that accommodates at least a part of the bonding pad as viewed in plan.
- According to a sixth aspect of the present invention, in the LED module of any one of the first through the fifth aspects, the case further comprises: at least one mounting electrode provided on an opposite side from the pad; and a penetration conductor penetrating the main body and connecting one of the pads and one of the mounting electrodes to each other.
- According to a seventh aspect of the present invention, in the LED module of any one of the first through the sixth aspects, the LED unit consists of the LED chip only.
- According to an eighth aspect of the present invention, in the LED module of any one of the first through the sixth aspects, the LED unit further comprises a sub-mount substrate on which the LED chip is mounted.
- According to a ninth aspect of the present invention, in the LED module of any one of the first through the eighth aspects, the above-mentioned pad comprises a plurality of pads arranged in a plurality of rows, and the above-mentioned LED unit comprises a plurality of LED units mounted on the plurality of pads, respectively.
- According to a tenth aspect of the present invention, in the LED module of anyone of the first through the ninth aspects, the LED unit and the pad are bonded to each other by eutectic bonding.
- According to an eleventh aspect of the present invention, the LED module of anyone of the first through the tenth aspects further comprises a light-transmitting portion covering the LED unit. The light-transmitting portion is made up of a resin material and a fluorescent substance, where the resin material is configured to transmit light from the LED unit, and the fluorescent substance is configured to be excited by the light from the LED unit, thereby emitting light of a wavelength different from that of the light from the LED unit. Other features and advantages of the present invention will become more apparent from detailed description given below with reference to the accompanying drawings.
-
FIG. 1 is a plan view showing an LED module according to a first embodiment of the present invention; -
FIG. 2 is a sectional view taken along lines II-II inFIG. 1 ; -
FIG. 3 is a sectional view taken along lines III-III inFIG. 1 ; -
FIG. 4 is an enlarged sectional view of a principal portion of the LED module according to the first embodiment of the present invention; -
FIG. 5 is a bottom view of the LED module according to the first embodiment of the present invention; -
FIG. 6 is a plan view showing an LED module according to a second embodiment of the present invention; -
FIG. 7 is a sectional view taken along lines VII-VII inFIG. 6 ; -
FIG. 8 is a sectional view taken along lines VIII-VIII inFIG. 6 ; -
FIG. 9 is an enlarged sectional view of a principal portion of the LED module according to the second embodiment of the present invention; -
FIG. 10 is a plan view showing an LED module according to a third embodiment of the present invention; -
FIG. 11 is a sectional view taken along lines XI-XI inFIG. 10 ; -
FIG. 12 is a sectional view taken along lines XII-XII inFIG. 10 ; -
FIG. 13 is an enlarged sectional view of a principal portion of the LED module according to the third embodiment of the present invention; -
FIG. 14 is a plan view showing an LED module according to a fourth embodiment of the present invention; -
FIG. 15 is a sectional view taken along lines XV-XV inFIG. 14 ; -
FIG. 16 is a sectional view taken along lines XVI-XVI inFIG. 14 ; -
FIG. 17 is an enlarged sectional view of a principal portion of the LED module according to the fourth embodiment of the present invention; -
FIG. 18 is a sectional view showing an LED module according to a fifth embodiment of the present invention; and -
FIG. 19 is a sectional view showing an example of a conventional LED module. - Preferred embodiments of the present invention are described below with reference to the accompanying drawings.
-
FIGS. 1-5 show an example of LED module according to the present invention. The LED module A1 of this embodiment includes acase 1, a plurality ofLED units 2, a Zenerdiode 3,wires 4 and a light-transmitting portion 5 (not shown inFIG. 1 ). The LED module A1 is an LED module of a high output type that provides a relatively high brightness and is about 5 mm×5 mm as viewed in plan and about 0.9 mm in thickness. - The
case 1 includes amain body 11, a plurality ofpads bonding pads pad 16, a pair ofmounting electrodes penetration conductors case 1 is made of a white ceramic material such as alumina. Themain body 11 has areflector 11 a and abottom surface 11 c. Thereflector 11 a reflects the light traveling generally horizontally from theLED chip 21 inFIG. 2 to direct the light upward in the figure. In this embodiment, thereflector 11 a is provided with fourrecesses 11 b. Each of the fourrecesses 11 b has a triangular cross section as viewed in plan and reaches thebottom surface 11 c. Thebottom surface 11 c is generally circular and connected to the bottom edge of thereflector 11 a. - The
pads bottom surface 11 c. In this embodiment, threepads 12 a and threepads 12 b are arranged in two rows. Each of thepads bottom surface 11 c side in the order of e.g. Ag, Ni, Au or Ag, Ni, Ag or W, Ni, Ag or W, Ni, Au. When the top layer is made of Ag, the Ag layer is made to have a thickness of about 2.5 μm. When the top layer is made of Au, the Au layer is made to have a thickness of about 0.1 μm. - The
bonding pads bottom surface 11 c. In this embodiment, threebonding pads 13 a and threebonding pads 13 b are arranged in two rows. Each of thebonding pads pads bonding pads recesses 11 b. - The
pad 16 is arranged adjacent to the edge of thebottom surface 11 c and made of plated layers similar to those of the pads 12 and the bonding pads 13. - As shown in
FIG. 4 , the paired mountingelectrodes main body 11 opposite from the surface provided with thereflector 11 a and thebottom surface 11 c. As shown in the figure, the mountingelectrode 14 a is considerably larger than the mountingelectrode 14 b and overlaps the LED chips 21 as viewed in plan. - The
penetration conductors main body 11. In this embodiment, threepenetration conductors 15 a connect the threebonding pads 13 a to the mountingelectrode 14 a. Threepenetration conductors 15 b connect the threepads 12 a to the mountingelectrode 14 a. Threepenetration conductors 15 c connect the threepads 12 b to the mountingelectrode 14 a. Thesingle penetration conductor 15 c connects thepad 16 to the mountingelectrode 14 a. Threepenetration conductors 15 d connect the threebonding pad 13 b to the mountingelectrode 14 b and are in the form of a crank. - The
case 1 having this structure can be made by laminating a ceramic material, an Ag material or a W material in an appropriate order, then baking these materials, and then performing plating. - The
LED units 2 are the light source of the LED module A1 and comprise a plurality ofLED chips 21 in this embodiment. EachLED chip 21 includes an n-type semiconductor layer made of e.g. GaN-based semiconductor, a p-type semiconductor layer, and an active layer sandwiched between these layers, and emits blue light. The LED chips 21 are bonded to thepads LED chip 21 as viewed in plan is larger than that of eachpad FIG. 4 , theouter edge 121 a of eachpad 12 a is positioned slightly inward of theouter edge 2 a of the LED unit 2 (LED chip 21) as viewed in plan. This holds true for the outer edge of eachpad 12 b. In this embodiment, the LED chips 21 are configured as a two-wire LED chip. - The
Zener diode 3 prevents application of excessive reverse voltage to the LED chips 21 and allows current to flow in a reverse direction only when an excessive reverse voltage above a certain value is applied. TheZener diode 3 is bonded to thepad 16 via e.g. Ag paste. - The
wires 4 are made of e.g. Au. Each of thewires 4 is bonded at one end to thebonding pad Zener diode 3. - The light-transmitting
portion 5 fills the region surrounded by thereflector 11 a and thebottom surface 11 c and covers the LED chips 21, theZener diode 3 and thewires 4. The light-transmittingportion 5 is made of e.g. transparent silicone resin with a fluorescent substance mixed in it. For instance, the fluorescent substance emits yellow light when excited by the blue light from the LED chips 21. The yellow light mixes with the blue light from the LED chips 21, whereby white light is emitted from the LED module A1. Instead of such a fluorescent substance, use may be made of a fluorescent substance that emits red light when excited by blue light and a fluorescent material that emits green light when excited by blue light. - The advantages of the LED module A1 are described below.
- According to this embodiment, the
pads pads bottom surface 11 c is not absorbed by thepads bottom surface 11 c. Thus, reduction of light emission amount of the LED module with time is suppressed, and the LED module A1 offers high brightness. - Although the
bonding pads wires 4, thebonding pads bonding pad - The provision of the
recesses 11 b in thereflector 11 a allows thereflector 11 a to be arranged relatively close to theLED chips 2. Such an arrangement is suitable for increasing the brightness of the LED module A1. Themain body 11, which is made of a ceramic material, can transmit light from the LED chips 21, though the amount is small. Arranging thereflector 11 a relatively close toLED chips 21 allows the size of the portion of themain body 11 which is on the outer side of thereflector 11 a to be increased without changing the outer dimensions of themain body 11. Thus, unfavorable leak of the light from the LED chips 21 to the sides through themain body 11 is prevented. - The
penetration conductors pads electrode 14 a. With this arrangement, heat is efficiently dissipated from the LED chips 21, which makes it possible to apply high current to the LED chips 21. This is advantageous for increasing the brightness of the LED module A1. -
FIGS. 6-18 show other embodiments of the present invention. In these figures, the elements that are identical or similar to those of the foregoing embodiment are designated by the same reference signs as those used for the foregoing embodiment. -
FIGS. 6-9 show an LED module according to a second embodiment of the present invention. The LED module A2 of this embodiment is different from the foregoing embodiment in structure of theLED units 2. Specifically, in this embodiment, eachLED unit 2 comprises anLED chip 21 and asub-mount substrate 22. - The
sub-mount substrate 22 is made of e.g. Si, and theLED chip 21 is mounted on the sub-mount substrate. Thesub-mount substrate 22 has a wiring pattern formed on it. The wiring pattern is electrically connected to an electrode (not shown) of theLED chip 21, and includes a portion extending into a region that is not covered by theLED chip 21. In this embodiment,wires 4 are bonded to the wiring pattern. As shown inFIG. 9 , thesub-mount substrate 22 is bonded to thepad e.g. Ag paste 17. This bonding may be performed by eutectic bonding. - The size of each
pad sub-mount substrate 22. As shown inFIG. 9 , theouter edge 121 a of eachpad 12 a is positioned slightly inward of theouter edge 2 a of the LED unit 2 (sub-mount substrate 22) as viewed in plan. This holds true for the outer edge of eachpad 12 b. - According to this embodiment again, reduction of light emission amount of the LED module with time is suppressed, and the LED module A2 offers high brightness.
-
FIGS. 10-13 show an LED module according to a third embodiment of the present invention. The LED module A3 of this embodiment is different from the foregoing embodiments in structure of theLED units 2. Specifically, in this embodiment, eachLED unit 2 consists of anLED chip 21 only and is structured as a single-wire LED unit. Since eachLED unit 2 is a single-wire LED unit, thebonding pads 13 a and the penetration conductors 15, which are provided in thecases 1 of the LED modules A1 and A2, are not provided in this embodiment. - In this embodiment, electrodes (not shown) are formed on the upper surface and the lower surface of each
LED chip 21. To the electrode on the upper surface is bonded awire 4. The electrode on the lower surface is bonded to thepad - The size of each
pad LED chip 21. As shown inFIG. 13 , theouter edge 121 b of eachpad 12 b is positioned slightly inward of theouter edge 2 a of the LED unit 2 (LED chip 21) as viewed in plan. - According to this embodiment again, reduction of light emission amount of the LED module A3 with time is suppressed, and the LED module A3 offers high brightness.
-
FIGS. 14-17 show an LED module according to a fourth embodiment of the present invention. The LED module A4 of this embodiment is different from the foregoing embodiments in structure of theLED units 2. In this embodiment, eachLED unit 2 is made up of anLED chip 21 and asub-mount substrate 22 and structured as a single-wire LED unit. - The
sub-mount substrate 22 is made of e.g. Si, and theLED chip 21 is mounted on the sub-mount substrate. Thesub-mount substrate 22 has a wiring pattern formed on it via an insulating film. The wiring pattern is electrically connected to an electrode (not shown) of theLED chip 21, and includes a portion extending into a region that is not covered by theLED chip 21. In this embodiment, awire 4 is bonded to the wiring pattern. Thesub-mount substrate 22 is made a conductor by e.g. doping. Another electrode (not shown) of theLED chip 21 is held in contact with and electrically connected to thesub-mount substrate 22. Thesub-mount substrate 22 is bonded to thepad e.g. Ag paste 17. This bonding may be performed by eutectic bonding. - In this embodiment again, the size of each
pad sub-mount substrate 22. As shown inFIG. 17 , theouter edge 121 b of eachpad 12 b is positioned slightly inward of theouter edge 2 a of the LED unit 2 (sub-mount substrate 22) as viewed in plan. - According to this embodiment again, reduction of light emission amount of the LED module A4 with time is suppressed, and the LED module A4 offers high brightness.
-
FIG. 18 shows an LED module according to a fifth embodiment of the present invention. The LED module A5 of this embodiment has the same structure as that of the LED module A1 except that the structure of thepenetration conductors penetration conductor 15 b is not shown in this figure, thepenetration conductor 15 b has the same structure as that of thepenetration conductor 15 c. - In this embodiment, the
penetration conductor 15 c is provided at a position that avoids the LED unit 2 (LED chip 21) as viewed in plan. Thepad 12 b and thepenetration conductor 15 c are electrically connected to each other via a plated layer extending from thepad 12 b. Thepenetration conductors - According to this embodiment again, reduction of light emission amount of the LED module A5 with time is suppressed, and the LED module A5 offers high brightness.
- The LED module according to the present invention is not limited to the foregoing embodiments. The specific structure of each part of the LED module according to the present invention can be varied in design in many ways.
- The plurality of
LED chips 21 may emit light of different wavelengths. The shape of thebottom surface 11 c is not limited to a circular shape. The light-transmittingportion 5 may be made of a transparent material only.
Claims (14)
1-11. (canceled)
12. An LED module comprising:
a base portion;
a first LED unit located on the base portion, the first LED unit including a first end and a second end that are located at opposite sides of the first LED unit as viewed in plan, the first end facing in a first direction, and the second end facing in a second direction that is opposite to the first direction;
a first electrode located at the first direction side relative to the first end of the first LED, and exposed from the base portion;
a first wire bonded to the first LED unit and the first electrode;
a second LED unit located on the base portion, the second LED unit being overlapped with the first LED unit as viewed in a third direction that is perpendicular to the first direction;
a third LED unit located on the base portion, the third LED unit being offset in the second direction from the first end of the first LED unit; and
a second wire bonded to the third LED unit and the first electrode, the second wire including a part that is located between the first LED unit and the second LED unit as viewed in plan.
13. An LED module of claim 12 , further comprising:
a second electrode located at the second direction side relative to the second end of the first LED, and exposed from the base portion; and
a third wire bonded to the first LED unit and the second electrode.
14. An LED module of claim 13 , further comprising a fourth wire bonded to the third LED unit and the second electrode, the fourth wire extending to the second direction side from the third LED unit toward the second electrode as viewed in plan.
15. Aft LED module of claim 12 , wherein the third LED unit is spaced apart from the first LED unit as viewed in the third direction.
16. An LED module of claim 12 , wherein a part of the third LED unit is overlapped with the second LED unit as viewed in the second direction.
17. An LED module of claim 12 , wherein the second LED unit includes a first end and a second end that are located at opposite sides of the second LED unit as viewed in plan,
the first end of the first LED unit is located at a substantially same position as the first end of the second LED unit as viewed in the third direction, and
the second end of the first LED unit is located at a substantially same position as the second end of the second LED unit as viewed in the third direction.
18. An LED module of claim 12 , further comprising a surrounding portion located on the base portion, the surrounding portion surrounding the first LED unit, the second LED unit, and the third LED unit as viewed in plan.
19. An LED module of claim 18 , wherein the surrounding portion includes a curved surface and a first recess that is recessed from the curved surface as viewed in plan, and the curved surface is spaced apart from each of the first LED unit, the second LED unit, and the third LED unit.
20. An LED module of claim 19 , wherein the surrounding portion includes a second recess that is recessed from the curved surface as viewed in plan, and the second recess is spaced apart from the first recess as viewed in plan.
21. An LED module of claim 19 , wherein the curved surface of the surrounding portion is made of an insulating material.
22. An LED module of claim 12 , wherein each of the first LED unit and the third LED unit has a centerline that extends along the third direction, and the center line of the third LED unit is offset in the second direction from the center line of the first LED unit.
23. An LED module of claim 12 , wherein the first LED unit is spaced apart from the first electrode as viewed in plan.
24. An LED module of claim 12 , wherein the first LED unit is spaced apart from the second electrode as viewed in plan.
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Also Published As
Publication number | Publication date |
---|---|
CN102834942A (en) | 2012-12-19 |
US20190386190A1 (en) | 2019-12-19 |
US11605765B2 (en) | 2023-03-14 |
WO2011126135A1 (en) | 2011-10-13 |
JPWO2011126135A1 (en) | 2013-07-11 |
CN105720180B (en) | 2018-05-29 |
US20130020605A1 (en) | 2013-01-24 |
US9722157B2 (en) | 2017-08-01 |
CN105720180A (en) | 2016-06-29 |
JP5939977B2 (en) | 2016-06-29 |
CN102834942B (en) | 2016-04-13 |
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