US20190348579A1 - Led package and method for manufacturing same - Google Patents
Led package and method for manufacturing same Download PDFInfo
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- US20190348579A1 US20190348579A1 US16/482,986 US201816482986A US2019348579A1 US 20190348579 A1 US20190348579 A1 US 20190348579A1 US 201816482986 A US201816482986 A US 201816482986A US 2019348579 A1 US2019348579 A1 US 2019348579A1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/44—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the coatings, e.g. passivation layer or anti-reflective coating
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
- H01L33/52—Encapsulations
- H01L33/54—Encapsulations having a particular shape
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L25/00—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof
- H01L25/03—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
- 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
- H01L25/0753—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 the devices being arranged next to each other
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
- H01L33/50—Wavelength conversion elements
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
- H01L33/50—Wavelength conversion elements
- H01L33/501—Wavelength conversion elements characterised by the materials, e.g. binder
- H01L33/502—Wavelength conversion materials
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
- H01L33/50—Wavelength conversion elements
- H01L33/507—Wavelength conversion elements the elements being in intimate contact with parts other than the semiconductor body or integrated with parts other than the semiconductor body
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2933/00—Details relating to devices covered by the group H01L33/00 but not provided for in its subgroups
- H01L2933/0008—Processes
- H01L2933/0025—Processes relating to coatings
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2933/00—Details relating to devices covered by the group H01L33/00 but not provided for in its subgroups
- H01L2933/0008—Processes
- H01L2933/0033—Processes relating to semiconductor body packages
- H01L2933/0041—Processes relating to semiconductor body packages relating to wavelength conversion elements
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2933/00—Details relating to devices covered by the group H01L33/00 but not provided for in its subgroups
- H01L2933/0008—Processes
- H01L2933/0033—Processes relating to semiconductor body packages
- H01L2933/005—Processes relating to semiconductor body packages relating to encapsulations
Definitions
- the present invention relates to an LED package and a method for manufacturing the same.
- LED packages Light-emitting devices (LED packages) are known in which a light-emitting diode (LED) element is mounted on a substrate and sealed with a translucent resin containing a phosphor. In such a light-emitting device, light emitted from the LED element is mixed with light generated by exciting the phosphor with the emitted light, thereby producing light of a desired color, such as white, according to the purpose.
- LED light-emitting diode
- Patent Literature 1 describes a method for manufacturing light-emitting diodes. This method includes coating multiple LED elements mounted on a substrate with a translucent resin, partially removing the cured translucent resin from space between the LED elements, filling a light-reflecting resin into grooves thus formed, and cutting the substrate so as to leave the cured light-reflecting resin around each LED element, thereby separating light-emitting diodes from each other.
- Patent Literature 2 describes a surface-light-emitter unit wherein surface light emitters formed by sealing light-emitting elements with a sealing light-transmitting member mixed with a phosphor are provided on a substrate, a scattering light-transmitting member is filled between adjacent surface light emitters on the substrate, and exposed surfaces of the surface light emitters and scattering light-transmitting member are coated with a translucent film.
- Patent Literature 1 Japanese Unexamined Patent Publication No. 2002-368281
- Patent Literature 2 Japanese Unexamined Patent Publication No. 2015-026778
- Particles of some phosphors have a coating layer, in order to prevent deterioration caused by external factors, such as heat, humidity and ultraviolet rays. If such phosphor particles are mixed in a sealing resin of LED elements and the sealing resin is cut or ground to manufacture LED packages, the coating layer of some phosphor particles is also cut by this cutting or grinding, causing broken surfaces of these particles to be exposed in the cut or ground surface of the sealing resin. Since this causes the effect of the coating layer preventing deterioration to be lost, phosphor particles in the cut surface deteriorate, which leads to partial discoloration of the sealing resin and deviation of the emission color from the designed color with the passage of time.
- a method for manufacturing an LED package including the steps of: mounting LED elements on a substrate; filling a first translucent resin on the substrate to seal the LED elements, the first translucent resin containing wavelength conversion particles configured by forming a coating layer on at least part of the surface of each phosphor particle which converts the wavelength of light emitted from the LED elements; cutting the first translucent resin; and forming a protective layer with a second translucent resin on a side surface of the first translucent resin which is an exposed cut surface, the second translucent resin not containing the wavelength conversion particles.
- the second translucent resin is applied to the side surface of the first translucent resin of each LED package having diced in the cutting step.
- the substrate is left uncut in the cutting step, and the forming step includes filling the second translucent resin into a groove of the first translucent resin formed by cutting, curing the second translucent resin, and entirely cutting the cured second translucent resin and the substrate in the thickness direction thereof, thereby obtaining diced LED packages wherein the side surface of the first translucent resin is coated with the second translucent resin.
- the protective layer may also be formed on an upper surface of the first translucent resin in the forming step.
- an LED package including: a substrate; an LED element mounted on the substrate; a first translucent resin filled on the substrate to seal the LED element, the first translucent resin containing wavelength conversion particles configured by forming a coating layer on at least part of the surface of each phosphor particle which converts the wavelength of light emitted from the LED element, the first translucent resin having a side surface which is a cut surface including the wavelength conversion particles whose coating layers are cut; and a protective layer covering the cut surface of the first translucent resin and made of a second translucent resin not containing the wavelength conversion particles.
- a method for manufacturing an LED package including the steps of: mounting LED elements on a substrate; filling a first resin on the substrate to seal the LED elements, the first resin being transparent or translucent and containing wavelength conversion particles configured by forming a coating layer on at least part of the surface of each phosphor particle which converts the wavelength of light emitted from the LED elements; cutting or grinding the first resin; and forming a protective layer with a second resin on a cut surface of the first resin exposed as a result of the cutting or on a ground surface of the first resin, the second resin not containing the wavelength conversion particles.
- the first resin is cut in the cutting or grinding step, the cut surface is a side surface of the first resin, and the second resin is applied to the side surface of the first resin in the forming step.
- the first resin is cut while the substrate is left uncut, the cut surface is a side surface of the first resin, and the forming step includes filling the second resin into a groove of the first resin formed by cutting the first resin, curing the second resin, and entirely cutting the cured second resin and the substrate in the thickness direction thereof, thereby obtaining diced LED packages wherein the side surface of the first resin is coated with the second resin.
- An upper surface of the first resin may be ground in the cutting or grinding step, and the protective layer may be formed on the upper surface of the first resin in the forming step.
- the LED elements are blue LED elements emitting blue light
- the phosphor particles are particles of KSF phosphor absorbing part of the blue light to emit red light.
- an LED package including: a substrate; an LED element mounted on the substrate; a first resin filled on the substrate to seal the LED element, the first resin being transparent or translucent and containing wavelength conversion particles configured by forming a coating layer on at least part of the surface of each phosphor particle which converts the wavelength of light emitted from the LED element; and a protective layer covering a surface of the first resin and made of a second resin not containing the wavelength conversion particles, wherein the surface of the first resin includes broken surfaces of the wavelength conversion particles whose coating layers are cut.
- the second resin contains a scattering agent.
- the second resin is a transparent or translucent resin.
- FIG. 1 is a perspective view of an LED package 1 .
- FIGS. 2(A) to 2(C) are diagrams for explaining manufacturing steps of the LED package 1 .
- FIG. 3 is a cross-sectional view of the LED package 1 taken along line III-III in FIG. 1 .
- FIG. 4 is a perspective view of an LED package 2 .
- FIGS. 5(C) to 5(E) are diagrams for explaining manufacturing steps of the LED package 2 .
- FIG. 6 is a cross-sectional view of an LED package 3 .
- FIG. 7 is a cross-sectional view of an LED package 4 .
- FIG. 8 is a cross-sectional view of an LED package 5 .
- FIG. 1 is a perspective view of an LED package 1 .
- the LED package 1 is a light-emitting device including an LED element as a light-emitting element and utilizing wavelength conversion of a phosphor for emitting white light, for example, and is used as an LED light source for various kinds of lighting equipment, for example.
- Major components of the LED package 1 include a mounting substrate 10 , an LED element 20 , a sealing resin 30 and a transparent resin coat 40 .
- the LED package need not include only one LED element 20 , but may include multiple LED elements 20 mounted on the mounting substrate 10 .
- the mounting substrate 10 includes two connecting electrodes (not shown) for connecting the LED element 20 to an external power source, and has an upper surface on which the LED element 20 is mounted.
- the mounting substrate 10 may be a ceramic substrate, or a substrate constructed by bonding a metal board made of aluminum or copper, which excels in heat resistance and heat dissipation, to an insulating circuit board on which conductive patterns and connecting electrodes are formed for the LED element 20 .
- the mounting substrate 10 may be a base of the LED package including a concave portion in which the LED element 20 is mounted and the sealing resin 30 is filled and two lead electrodes for connecting the LED element 20 to an external power source.
- the LED element 20 is made of a gallium nitride compound semiconductor which emits light having a wavelength in the ultraviolet to blue regions, for example.
- the LED element 20 is assumed to be a blue LED element which emits blue light having a wavelength in the range of about 450 to 460 nm, but may be an element which emits light having another wavelength.
- the LED element 20 is die-bonded on the upper surface of the mounting substrate 10 , and has positive and negative electrodes electrically connected to the connecting electrodes on the mounting substrate 10 via two bonding wires (hereinafter, simply referred to as “wires”) 21 . If the LED package includes multiple LED elements 20 , the LED elements 20 are also electrically connected via the wires 21 with each other.
- the sealing resin 30 is an example of the first resin (or first translucent resin), and is transparent or translucent. “Translucent” means being not completely transparent but semitransparent and allowing light to pass through.
- the sealing resin 30 contains phosphor particles (wavelength conversion particles) for converting the wavelength of light emitted from the LED element 20 , and is filled on the mounting substrate 10 to integrally seal the LED element 20 and wires 21 .
- the phosphor particles may be uniformly dispersed in the sealing resin 30 , or deposited near the upper surface of the mounting substrate 10 so that the density thereof increases downward in the sealing resin 30 .
- the sealing resin 30 is an epoxy or silicone resin, for example.
- the sealing resin 30 may contain only one phosphor, or two or more phosphors.
- the sealing resin 30 contains KSF and YAG phosphors, which are a yellow and a red phosphor, respectively.
- KSF phosphor K 2 SiF 6 :Mn 4+
- the LED package 1 mixes blue light emitted from the LED element 20 and yellow and red light generated by exciting the yellow and red phosphors with the blue light, thereby emitting white light.
- the transparent resin coat 40 is an example of the protective layer made of the second resin (or second translucent resin), contains no phosphor particles, and covers the four side surfaces of the sealing resin 30 . As described later, the side surfaces of the sealing resin 30 are cut surfaces formed during manufacture of the LED package 1 .
- the transparent resin coat 40 is a dampproof coating applied to these cut surfaces. Since the upper surface of the sealing resin 30 (surface opposite to the mounting substrate 10 ) is not a cut surface, the transparent resin coat 40 is not provided on the upper surface thereof.
- the transparent resin coat 40 is also an epoxy or silicone resin, for example.
- the material of the sealing resin 30 may be the same as or different from that of the transparent resin coat 40 .
- the sealing resin 30 and transparent resin coat 40 have a light transmittance of 80% or more, and a water absorption of 1% or less.
- FIGS. 2(A) to 2(C) are diagrams for explaining manufacturing steps of the LED package 1 .
- LED elements 20 are first die-bonded on the upper surface of the mounting substrate 10 , and then the positive and negative electrodes of the LED elements 20 are connected to the connecting electrodes on the mounting substrate 10 via bonding wires (mounting step).
- the sealing resin 30 containing the above-mentioned phosphors is filled on the upper surface of the mounting substrate 10 , to integrally seal the LED elements 20 and wires 21 (sealing step).
- the sealing resin 30 may be kept uncured for several hours, for example, thereby causing the phosphors in the sealing resin 30 to be naturally deposited on the upper surfaces of the mounting substrate 10 and LED elements 20 , and then the sealing resin 30 may be cured.
- the mounting substrate 10 and sealing resin 30 are cut lengthwise and crosswise along cutting lines L to divide the LED elements 20 (cutting step). Then, for each diced LED package, the transparent resin coat 40 is applied to the side surfaces of the sealing resin 30 , which are exposed cut surfaces, by spraying or vapor deposition, for example (forming step of the protective layer). In this way, the LED package 1 shown in FIG. 1 is completed.
- FIG. 3 is a cross-sectional view of the LED package 1 taken along lines III-III in FIG. 1 .
- KSF phosphor particles are exaggerated in order to illustrate the cut surface of the sealing resin 30 , and thus the proportions of the illustrated elements are not necessarily correct.
- a coating layer (dampproof coating) 62 is formed on each phosphor particle 61 as shown in enlarged form in FIG. 3 .
- phosphor particles 61 each having a coating layer 62 are also referred to as “wavelength conversion particles 60 ” for convenience sake.
- the coating layer 62 of the wavelength conversion particles 60 are cut and their broken surfaces are exposed in the side surfaces of the sealing resin 30 , as shown in FIG. 3 .
- KSF phosphor has lower resistance to moisture, and cutting the wavelength conversion particles 60 in this way causes the effect of the coating layers 62 to be lost.
- the phosphor included in the cut surface deteriorates due to moisture in the air, causing the color of emitted light to differ from the designed color.
- phosphor particles are deposited in the sealing resin 30 , these particles are crowded near the upper surface of the mounting substrate 10 and that portion is cut; thus, deterioration of KSF phosphor may occur more conspicuously.
- the transparent resin coat 40 applied to the cut surfaces of the sealing resin 30 covers the broken surfaces and thus prevent them from being exposed to the air. Since the upper surface of the sealing resin 30 is not a cut surface, broken surfaces of the wavelength conversion particles 60 are not exposed there. Accordingly, in the LED package 1 , even if KSF phosphor, which easily deteriorates over time, is used, deterioration of the phosphor and discoloration of the emitted light are prevented. Since the transparent resin coat 40 is made of a resin having a high light transmittance, brightness of the LED package 1 hardly decreases even with the transparent resin coat 40 .
- FIG. 4 is a perspective view of an LED package 2 .
- Major components of the LED package 2 include a mounting substrate 10 , an LED element 20 , a sealing resin 30 and a transparent resin wall 50 .
- the LED package 2 is identical in structure to the LED package 1 of FIG. 1 , except that the transparent resin coat 40 of the LED package 1 is replaced with the transparent resin wall 50 .
- the transparent resin wall 50 is an example of the protective layer made of the second resin (or second translucent resin), contains no phosphor particles, and covers the four side surfaces of the sealing resin 30 , similarly to the transparent resin coat 40 .
- the transparent resin wall 50 is made of the same resin as the transparent resin coat 40 of the LED package 1 , for example, but laterally thicker than the transparent resin coat 40 , and corresponds to a resin frame enclosing the sealing resin 30 .
- the transparent resin wall 50 also has a light transmittance of 80% or more, and a water absorption of 1% or less.
- FIGS. 5(C) to 5(E) are diagrams for explaining manufacturing steps of the LED package 2 .
- LED elements 20 are first mounted on the upper surface of the mounting substrate 10 , and sealed with the sealing resin 30 containing the above-mentioned phosphors, together with wires 21 . Since figures corresponding to these step are the same as FIGS. 2(A) and 2(B) for the LED package 1 , they are omitted from illustration.
- the sealing resin 30 is entirely cut in the thickness direction while the mounting substrate 10 is left uncut, for example, thereby forming grooves 31 .
- a transparent resin is filled into the grooves 31 of the sealing resin 30 , and cured to form the transparent resin wall 50 .
- the transparent resin wall 50 and mounting substrate 10 are entirely cut in the thickness direction along cutting lines L to divide the LED elements 20 . In this way, the LED package 2 shown in FIG. 4 is completed.
- the LED package 2 even if KSF phosphor, which easily deteriorates over time, is used, deterioration of the phosphor and discoloration of the emitted light are prevented, similarly to the LED package 1 . Since the transparent resin wall 50 is made of a resin having a high light transmittance, the LED package 2 can emit light even from its side surfaces, which ensures wide-ranging emission.
- manufacturing steps of the LED package include cutting the sealing resin 30 or grinding a surface thereof, the protective layer formed on the cut or ground surface of the sealing resin 30 has the same effect of preventing deterioration of the phosphor and discoloration of the emitted light; the cutting is not limited to the step for dividing the elements into pieces.
- FIG. 6 is a cross-sectional view of an LED package 3 .
- FIG. 6 shows a vertical cross section of the LED package 3 , similarly to FIG. 3 .
- Major components of the LED package 3 include a mounting substrate 10 , an LED element 20 , a sealing resin 30 and a transparent resin coat 40 ′.
- the LED package 3 differs from the LED package 1 of FIG. 1 in that the upper surface of the sealing resin 30 is also provided with the transparent resin coat 40 ′, but is otherwise identical thereto.
- the transparent resin coat 40 ′ is an example of the protective layer made of the second resin (or second translucent resin), contains no phosphor particles, and covers the four side surfaces and upper surface of the sealing resin 30 .
- the protective layer for preventing deterioration of the phosphor may be formed to cover not only the side surfaces but all of the exposed surfaces of the sealing resin 30 .
- the transparent resin coat 40 ′ may also he formed on the upper surface of the sealing resin 30 .
- the transparent resin wail 50 of the LED package 2 which is thicker than the transparent resin coat 40 , may also be formed to cover the four side surfaces and upper surface of the sealing resin 30 .
- FIG. 7 is a cross-sectional view of an LED package 4 .
- FIG. 7 also shows a vertical cross section of the LED package 4 , similarly to FIG. 3 .
- the LED package 4 differs from the LED packages 1 , 3 of FIGS. 1, 6 in that the transparent resin coat 40 , 40 ′ of the LED package 1 , 3 is replaced with a transparent resin coat 40 ′′, but is otherwise identical thereto.
- the transparent resin coat 40 ′′ of the LED package 4 is an example of the protective layer made of the second resin (or second translucent resin), and is provided only on the upper surface of the sealing resin 30 .
- the transparent resin coat 40 ′′ may be formed only on the upper surface of the sealing resin 30 where broken surfaces of the wavelength conversion particles 60 are exposed, as in the LED package 4 .
- FIG. 8 is a cross-sectional view of an LED package 5 .
- FIG. 8 also shows a vertical cross section of the LED package 5 , similarly to FIG. 3 .
- the LED package 5 differs from the LED package 4 of FIG. 7 in that the mounting substrate 10 of the LED package 4 is replaced with a lead frame 10 ′, but is otherwise identical thereto.
- the lead frame 10 ′ includes a die pad 11 on which the LED element 20 is mounted, and terminals 12 , 13 separated from the die pad 11 . Space between the die pad 11 and the terminals 12 , 13 is filled with an insulating resin 35 , which electrically insulates the die pad 11 from the terminals 12 , 13 .
- the cross sections of the terminals 12 , 13 are substantially J-shaped. Edges of the terminals 12 , 13 correspond to outer leads 14 , 15 , respectively.
- the LED element 20 is mounted on a mounting surface 11 a of the die pad 11 , and electrically connected to the terminals 12 , 13 via wires 21 .
- Manufacturing steps of the LED package 5 do not include cutting the side surfaces of the sealing resin 30 , but may include grinding the upper surface thereof.
- the upper surface of the sealing resin 30 where broken surfaces of the wavelength conversion particles 60 are exposed is provided with a transparent resin coat 40 ′′. If not only the upper surface but also the side surfaces of the sealing resin 30 are ground, the transparent resin coat may also be formed similarly on these ground surfaces.
- the transparent resin coats 40 , 40 ′, 40 ′′ and transparent resin wall 50 need not be completely transparent, but may be a translucent and semitransparent resin.
- the transparent resin wall 50 of the LED package 2 may be replaced with a white resin wall, if it is desired to emit light upward.
- the transparent resin coats 40 ′, 40 ′′, which cover the upper surface of the sealing resin 30 may contain a scattering agent. The scattering agent diffuses light in the transparent resin coat, allowing all the upper surface of the sealing resin 30 to emit light uniformly.
- the transparent resin coat 40 , 40 ′, 40 ′′ or transparent resin wall 50 may be formed similarly to the LED packages 1 to 5 . If each particle of the phosphor has a coating layer for preventing deterioration and manufacturing steps of the LED package include cutting or grinding the sealing resin 30 , the effect of preventing deterioration of the phosphor and discoloration of the emitted light may be produced.
- the LED element 20 need not be mounted by wire bonding, but may be flip-chip mounted. Unlike the LED packages 1 to 5 , even if a phosphor board for wavelength conversion is placed on the upper surface of the LED element 20 , for example, a transparent resin coat or wall may be formed similarly on that board. If the phosphor board has a cut or ground surface, the effect of preventing deterioration of the phosphor and discoloration of the emitted light may be produced.
Abstract
Description
- The present invention relates to an LED package and a method for manufacturing the same.
- Light-emitting devices (LED packages) are known in which a light-emitting diode (LED) element is mounted on a substrate and sealed with a translucent resin containing a phosphor. In such a light-emitting device, light emitted from the LED element is mixed with light generated by exciting the phosphor with the emitted light, thereby producing light of a desired color, such as white, according to the purpose.
-
Patent Literature 1 describes a method for manufacturing light-emitting diodes. This method includes coating multiple LED elements mounted on a substrate with a translucent resin, partially removing the cured translucent resin from space between the LED elements, filling a light-reflecting resin into grooves thus formed, and cutting the substrate so as to leave the cured light-reflecting resin around each LED element, thereby separating light-emitting diodes from each other. - Patent Literature 2 describes a surface-light-emitter unit wherein surface light emitters formed by sealing light-emitting elements with a sealing light-transmitting member mixed with a phosphor are provided on a substrate, a scattering light-transmitting member is filled between adjacent surface light emitters on the substrate, and exposed surfaces of the surface light emitters and scattering light-transmitting member are coated with a translucent film.
- Patent Literature 1: Japanese Unexamined Patent Publication No. 2002-368281
- Patent Literature 2: Japanese Unexamined Patent Publication No. 2015-026778
- Particles of some phosphors have a coating layer, in order to prevent deterioration caused by external factors, such as heat, humidity and ultraviolet rays. If such phosphor particles are mixed in a sealing resin of LED elements and the sealing resin is cut or ground to manufacture LED packages, the coating layer of some phosphor particles is also cut by this cutting or grinding, causing broken surfaces of these particles to be exposed in the cut or ground surface of the sealing resin. Since this causes the effect of the coating layer preventing deterioration to be lost, phosphor particles in the cut surface deteriorate, which leads to partial discoloration of the sealing resin and deviation of the emission color from the designed color with the passage of time.
- It is an object of the present invention to provide an LED package and a method for manufacturing the same wherein, if its sealing resin containing phosphor particles each having a coating layer is cut or ground, age deterioration of the phosphor particles in the cut or ground surface is prevented.
- Provided is a method for manufacturing an LED package, including the steps of: mounting LED elements on a substrate; filling a first translucent resin on the substrate to seal the LED elements, the first translucent resin containing wavelength conversion particles configured by forming a coating layer on at least part of the surface of each phosphor particle which converts the wavelength of light emitted from the LED elements; cutting the first translucent resin; and forming a protective layer with a second translucent resin on a side surface of the first translucent resin which is an exposed cut surface, the second translucent resin not containing the wavelength conversion particles.
- Preferably, in the forming step, the second translucent resin is applied to the side surface of the first translucent resin of each LED package having diced in the cutting step.
- Preferably, the substrate is left uncut in the cutting step, and the forming step includes filling the second translucent resin into a groove of the first translucent resin formed by cutting, curing the second translucent resin, and entirely cutting the cured second translucent resin and the substrate in the thickness direction thereof, thereby obtaining diced LED packages wherein the side surface of the first translucent resin is coated with the second translucent resin.
- The protective layer may also be formed on an upper surface of the first translucent resin in the forming step.
- Provided is an LED package including: a substrate; an LED element mounted on the substrate; a first translucent resin filled on the substrate to seal the LED element, the first translucent resin containing wavelength conversion particles configured by forming a coating layer on at least part of the surface of each phosphor particle which converts the wavelength of light emitted from the LED element, the first translucent resin having a side surface which is a cut surface including the wavelength conversion particles whose coating layers are cut; and a protective layer covering the cut surface of the first translucent resin and made of a second translucent resin not containing the wavelength conversion particles.
- Provided is a method for manufacturing an LED package, including the steps of: mounting LED elements on a substrate; filling a first resin on the substrate to seal the LED elements, the first resin being transparent or translucent and containing wavelength conversion particles configured by forming a coating layer on at least part of the surface of each phosphor particle which converts the wavelength of light emitted from the LED elements; cutting or grinding the first resin; and forming a protective layer with a second resin on a cut surface of the first resin exposed as a result of the cutting or on a ground surface of the first resin, the second resin not containing the wavelength conversion particles.
- Preferably, the first resin is cut in the cutting or grinding step, the cut surface is a side surface of the first resin, and the second resin is applied to the side surface of the first resin in the forming step.
- Preferably, in the cutting or grinding step, the first resin is cut while the substrate is left uncut, the cut surface is a side surface of the first resin, and the forming step includes filling the second resin into a groove of the first resin formed by cutting the first resin, curing the second resin, and entirely cutting the cured second resin and the substrate in the thickness direction thereof, thereby obtaining diced LED packages wherein the side surface of the first resin is coated with the second resin.
- An upper surface of the first resin may be ground in the cutting or grinding step, and the protective layer may be formed on the upper surface of the first resin in the forming step.
- Preferably, the LED elements are blue LED elements emitting blue light, and the phosphor particles are particles of KSF phosphor absorbing part of the blue light to emit red light.
- Provided is an LED package including: a substrate; an LED element mounted on the substrate; a first resin filled on the substrate to seal the LED element, the first resin being transparent or translucent and containing wavelength conversion particles configured by forming a coating layer on at least part of the surface of each phosphor particle which converts the wavelength of light emitted from the LED element; and a protective layer covering a surface of the first resin and made of a second resin not containing the wavelength conversion particles, wherein the surface of the first resin includes broken surfaces of the wavelength conversion particles whose coating layers are cut.
- Preferably, the second resin contains a scattering agent.
- Preferably, the second resin is a transparent or translucent resin.
- According to the above LED package and method, if its sealing resin containing phosphor particles each having a coating layer is cut or ground, age deterioration of the phosphor particles in the cut or ground surface can be prevented.
-
FIG. 1 is a perspective view of anLED package 1. -
FIGS. 2(A) to 2(C) are diagrams for explaining manufacturing steps of theLED package 1. -
FIG. 3 is a cross-sectional view of theLED package 1 taken along line III-III inFIG. 1 . -
FIG. 4 is a perspective view of an LED package 2. -
FIGS. 5(C) to 5(E) are diagrams for explaining manufacturing steps of the LED package 2. -
FIG. 6 is a cross-sectional view of anLED package 3. -
FIG. 7 is a cross-sectional view of anLED package 4. -
FIG. 8 is a cross-sectional view of anLED package 5. - Hereinafter, with reference to the accompanying drawings, an LED package and a method for manufacturing the same will be explained in detail. However, note that the present invention is not limited to the drawings or the embodiments described below.
-
FIG. 1 is a perspective view of anLED package 1. TheLED package 1 is a light-emitting device including an LED element as a light-emitting element and utilizing wavelength conversion of a phosphor for emitting white light, for example, and is used as an LED light source for various kinds of lighting equipment, for example. Major components of theLED package 1 include amounting substrate 10, anLED element 20, asealing resin 30 and atransparent resin coat 40. The LED package need not include only oneLED element 20, but may includemultiple LED elements 20 mounted on themounting substrate 10. - The
mounting substrate 10 includes two connecting electrodes (not shown) for connecting theLED element 20 to an external power source, and has an upper surface on which theLED element 20 is mounted. For example, themounting substrate 10 may be a ceramic substrate, or a substrate constructed by bonding a metal board made of aluminum or copper, which excels in heat resistance and heat dissipation, to an insulating circuit board on which conductive patterns and connecting electrodes are formed for theLED element 20. Alternatively, themounting substrate 10 may be a base of the LED package including a concave portion in which theLED element 20 is mounted and the sealingresin 30 is filled and two lead electrodes for connecting theLED element 20 to an external power source. - The
LED element 20 is made of a gallium nitride compound semiconductor which emits light having a wavelength in the ultraviolet to blue regions, for example. In the following description, theLED element 20 is assumed to be a blue LED element which emits blue light having a wavelength in the range of about 450 to 460 nm, but may be an element which emits light having another wavelength. TheLED element 20 is die-bonded on the upper surface of themounting substrate 10, and has positive and negative electrodes electrically connected to the connecting electrodes on themounting substrate 10 via two bonding wires (hereinafter, simply referred to as “wires”) 21. If the LED package includesmultiple LED elements 20, theLED elements 20 are also electrically connected via thewires 21 with each other. - The
sealing resin 30 is an example of the first resin (or first translucent resin), and is transparent or translucent. “Translucent” means being not completely transparent but semitransparent and allowing light to pass through. The sealingresin 30 contains phosphor particles (wavelength conversion particles) for converting the wavelength of light emitted from theLED element 20, and is filled on themounting substrate 10 to integrally seal theLED element 20 andwires 21. The phosphor particles may be uniformly dispersed in the sealingresin 30, or deposited near the upper surface of themounting substrate 10 so that the density thereof increases downward in the sealingresin 30. Thesealing resin 30 is an epoxy or silicone resin, for example. - The sealing
resin 30 may contain only one phosphor, or two or more phosphors. For example, thesealing resin 30 contains KSF and YAG phosphors, which are a yellow and a red phosphor, respectively. Of these, KSF phosphor (K2SiF6:Mn4+) absorbs part of blue light emitted by theLED element 20 to emit red light having a peak in the wavelength range of 610 to 650 nm. In this case, theLED package 1 mixes blue light emitted from theLED element 20 and yellow and red light generated by exciting the yellow and red phosphors with the blue light, thereby emitting white light. - The
transparent resin coat 40 is an example of the protective layer made of the second resin (or second translucent resin), contains no phosphor particles, and covers the four side surfaces of thesealing resin 30. As described later, the side surfaces of the sealingresin 30 are cut surfaces formed during manufacture of theLED package 1. Thetransparent resin coat 40 is a dampproof coating applied to these cut surfaces. Since the upper surface of the sealing resin 30 (surface opposite to the mounting substrate 10) is not a cut surface, thetransparent resin coat 40 is not provided on the upper surface thereof. Thetransparent resin coat 40 is also an epoxy or silicone resin, for example. The material of the sealingresin 30 may be the same as or different from that of thetransparent resin coat 40. Preferably, the sealingresin 30 andtransparent resin coat 40 have a light transmittance of 80% or more, and a water absorption of 1% or less. -
FIGS. 2(A) to 2(C) are diagrams for explaining manufacturing steps of theLED package 1. In manufacturing theLED package 1, as shown inFIG. 2(A) ,LED elements 20 are first die-bonded on the upper surface of the mountingsubstrate 10, and then the positive and negative electrodes of theLED elements 20 are connected to the connecting electrodes on the mountingsubstrate 10 via bonding wires (mounting step). Subsequently, as shown inFIG. 2(B) , the sealingresin 30 containing the above-mentioned phosphors is filled on the upper surface of the mountingsubstrate 10, to integrally seal theLED elements 20 and wires 21 (sealing step). At this time, the sealingresin 30 may be kept uncured for several hours, for example, thereby causing the phosphors in the sealingresin 30 to be naturally deposited on the upper surfaces of the mountingsubstrate 10 andLED elements 20, and then the sealingresin 30 may be cured. - Thereafter, as shown in
FIG. 2(C) , the mountingsubstrate 10 and sealingresin 30 are cut lengthwise and crosswise along cutting lines L to divide the LED elements 20 (cutting step). Then, for each diced LED package, thetransparent resin coat 40 is applied to the side surfaces of the sealingresin 30, which are exposed cut surfaces, by spraying or vapor deposition, for example (forming step of the protective layer). In this way, theLED package 1 shown inFIG. 1 is completed. -
FIG. 3 is a cross-sectional view of theLED package 1 taken along lines III-III inFIG. 1 . InFIG. 3 , KSF phosphor particles are exaggerated in order to illustrate the cut surface of the sealingresin 30, and thus the proportions of the illustrated elements are not necessarily correct. Since KSF phosphor is water-soluble and has lower resistance to moisture than YAG or other phosphors, a coating layer (dampproof coating) 62 is formed on eachphosphor particle 61 as shown in enlarged form inFIG. 3 . Hereinafter,phosphor particles 61 each having acoating layer 62 are also referred to as “wavelength conversion particles 60” for convenience sake. - When the sealing
resin 30 is cut in the cutting step during manufacture of theLED package 1, thecoating layer 62 of thewavelength conversion particles 60 are cut and their broken surfaces are exposed in the side surfaces of the sealingresin 30, as shown inFIG. 3 . KSF phosphor has lower resistance to moisture, and cutting thewavelength conversion particles 60 in this way causes the effect of the coating layers 62 to be lost. Thus, if left as it is, the phosphor included in the cut surface deteriorates due to moisture in the air, causing the color of emitted light to differ from the designed color. In particular, if phosphor particles are deposited in the sealingresin 30, these particles are crowded near the upper surface of the mountingsubstrate 10 and that portion is cut; thus, deterioration of KSF phosphor may occur more conspicuously. - However, in the
LED package 1, even if broken surfaces of thewavelength conversion particles 60 are exposed in the cutting step, thetransparent resin coat 40 applied to the cut surfaces of the sealingresin 30 covers the broken surfaces and thus prevent them from being exposed to the air. Since the upper surface of the sealingresin 30 is not a cut surface, broken surfaces of thewavelength conversion particles 60 are not exposed there. Accordingly, in theLED package 1, even if KSF phosphor, which easily deteriorates over time, is used, deterioration of the phosphor and discoloration of the emitted light are prevented. Since thetransparent resin coat 40 is made of a resin having a high light transmittance, brightness of theLED package 1 hardly decreases even with thetransparent resin coat 40. -
FIG. 4 is a perspective view of an LED package 2. Major components of the LED package 2 include a mountingsubstrate 10, anLED element 20, a sealingresin 30 and atransparent resin wall 50. The LED package 2 is identical in structure to theLED package 1 ofFIG. 1 , except that thetransparent resin coat 40 of theLED package 1 is replaced with thetransparent resin wall 50. - The
transparent resin wall 50 is an example of the protective layer made of the second resin (or second translucent resin), contains no phosphor particles, and covers the four side surfaces of the sealingresin 30, similarly to thetransparent resin coat 40. Thetransparent resin wall 50 is made of the same resin as thetransparent resin coat 40 of theLED package 1, for example, but laterally thicker than thetransparent resin coat 40, and corresponds to a resin frame enclosing the sealingresin 30. Preferably, thetransparent resin wall 50 also has a light transmittance of 80% or more, and a water absorption of 1% or less. -
FIGS. 5(C) to 5(E) are diagrams for explaining manufacturing steps of the LED package 2. In manufacturing the LED package 2,LED elements 20 are first mounted on the upper surface of the mountingsubstrate 10, and sealed with the sealingresin 30 containing the above-mentioned phosphors, together withwires 21. Since figures corresponding to these step are the same asFIGS. 2(A) and 2(B) for theLED package 1, they are omitted from illustration. - Subsequently, as shown in
FIG. 5(C) , the sealingresin 30 is entirely cut in the thickness direction while the mountingsubstrate 10 is left uncut, for example, thereby forminggrooves 31. Then, as shown inFIG. 5(D) , a transparent resin is filled into thegrooves 31 of the sealingresin 30, and cured to form thetransparent resin wall 50. Further, as shown inFIG. 5(E) , thetransparent resin wall 50 and mountingsubstrate 10 are entirely cut in the thickness direction along cutting lines L to divide theLED elements 20. In this way, the LED package 2 shown inFIG. 4 is completed. - Also in the LED package 2, even if KSF phosphor, which easily deteriorates over time, is used, deterioration of the phosphor and discoloration of the emitted light are prevented, similarly to the
LED package 1. Since thetransparent resin wall 50 is made of a resin having a high light transmittance, the LED package 2 can emit light even from its side surfaces, which ensures wide-ranging emission. - If manufacturing steps of the LED package include cutting the sealing
resin 30 or grinding a surface thereof, the protective layer formed on the cut or ground surface of the sealingresin 30 has the same effect of preventing deterioration of the phosphor and discoloration of the emitted light; the cutting is not limited to the step for dividing the elements into pieces. -
FIG. 6 is a cross-sectional view of anLED package 3.FIG. 6 shows a vertical cross section of theLED package 3, similarly toFIG. 3 . Major components of theLED package 3 include a mountingsubstrate 10, anLED element 20, a sealingresin 30 and atransparent resin coat 40′. TheLED package 3 differs from theLED package 1 ofFIG. 1 in that the upper surface of the sealingresin 30 is also provided with thetransparent resin coat 40′, but is otherwise identical thereto. - The
transparent resin coat 40′ is an example of the protective layer made of the second resin (or second translucent resin), contains no phosphor particles, and covers the four side surfaces and upper surface of the sealingresin 30. As in theLED package 3, the protective layer for preventing deterioration of the phosphor may be formed to cover not only the side surfaces but all of the exposed surfaces of the sealingresin 30. For example, if the upper surface of the sealingresin 30 is ground during manufacture of the LED package, this grinding causes broken surfaces of thewavelength conversion particles 60 to be exposed in the upper surface of the sealingresin 30; accordingly, thetransparent resin coat 40′ may also he formed on the upper surface of the sealingresin 30. - The
transparent resin wail 50 of the LED package 2, which is thicker than thetransparent resin coat 40, may also be formed to cover the four side surfaces and upper surface of the sealingresin 30. -
FIG. 7 is a cross-sectional view of anLED package 4.FIG. 7 also shows a vertical cross section of theLED package 4, similarly toFIG. 3 . TheLED package 4 differs from theLED packages FIGS. 1, 6 in that thetransparent resin coat LED package transparent resin coat 40″, but is otherwise identical thereto. Thetransparent resin coat 40″ of theLED package 4 is an example of the protective layer made of the second resin (or second translucent resin), and is provided only on the upper surface of the sealingresin 30. If manufacturing steps of the LED package do not include cutting the side surfaces of the sealingresin 30 but include grinding the upper surface thereof, thetransparent resin coat 40″ may be formed only on the upper surface of the sealingresin 30 where broken surfaces of thewavelength conversion particles 60 are exposed, as in theLED package 4. -
FIG. 8 is a cross-sectional view of anLED package 5.FIG. 8 also shows a vertical cross section of theLED package 5, similarly toFIG. 3 . TheLED package 5 differs from theLED package 4 ofFIG. 7 in that the mountingsubstrate 10 of theLED package 4 is replaced with alead frame 10′, but is otherwise identical thereto. - The
lead frame 10′ includes adie pad 11 on which theLED element 20 is mounted, andterminals die pad 11. Space between thedie pad 11 and theterminals resin 35, which electrically insulates thedie pad 11 from theterminals terminals terminals outer leads LED element 20 is mounted on a mountingsurface 11 a of thedie pad 11, and electrically connected to theterminals wires 21. - Manufacturing steps of the
LED package 5 do not include cutting the side surfaces of the sealingresin 30, but may include grinding the upper surface thereof. Thus, the upper surface of the sealingresin 30 where broken surfaces of thewavelength conversion particles 60 are exposed is provided with atransparent resin coat 40″. If not only the upper surface but also the side surfaces of the sealingresin 30 are ground, the transparent resin coat may also be formed similarly on these ground surfaces. - The
transparent resin coats transparent resin wall 50 need not be completely transparent, but may be a translucent and semitransparent resin. In particular, thetransparent resin wall 50 of the LED package 2 may be replaced with a white resin wall, if it is desired to emit light upward. In particular, thetransparent resin coats 40′, 40″, which cover the upper surface of the sealingresin 30, may contain a scattering agent. The scattering agent diffuses light in the transparent resin coat, allowing all the upper surface of the sealingresin 30 to emit light uniformly. - Even if a phosphor other than KSF phosphor is used, the
transparent resin coat transparent resin wall 50 may be formed similarly to theLED packages 1 to 5. If each particle of the phosphor has a coating layer for preventing deterioration and manufacturing steps of the LED package include cutting or grinding the sealingresin 30, the effect of preventing deterioration of the phosphor and discoloration of the emitted light may be produced. - The
LED element 20 need not be mounted by wire bonding, but may be flip-chip mounted. Unlike theLED packages 1 to 5, even if a phosphor board for wavelength conversion is placed on the upper surface of theLED element 20, for example, a transparent resin coat or wall may be formed similarly on that board. If the phosphor board has a cut or ground surface, the effect of preventing deterioration of the phosphor and discoloration of the emitted light may be produced.
Claims (8)
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JP2017-017853 | 2017-02-02 | ||
JP2017017853 | 2017-02-02 | ||
PCT/JP2018/003689 WO2018143437A1 (en) | 2017-02-02 | 2018-02-02 | Led package and method for manufacturing same |
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US17/573,527 Active US11626546B2 (en) | 2017-02-02 | 2022-01-11 | LED package and method for manufacturing same |
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JP6940775B2 (en) * | 2018-10-30 | 2021-09-29 | 日亜化学工業株式会社 | Manufacturing method of light emitting device |
CN109890188B (en) * | 2019-02-15 | 2021-03-23 | 华为技术有限公司 | Packaging assembly and electronic equipment |
JP7403072B2 (en) * | 2020-01-29 | 2023-12-22 | パナソニックIpマネジメント株式会社 | Light emitting device and lighting device |
JP7288200B2 (en) * | 2020-07-30 | 2023-06-07 | 日亜化学工業株式会社 | Light emitting device and package |
TWI789740B (en) * | 2021-04-13 | 2023-01-11 | 光感動股份有限公司 | Light-emitting diode packaging structure and manufacturing method of light-emitting diode packaging structure |
CN113514300A (en) * | 2021-07-09 | 2021-10-19 | 长鑫存储技术有限公司 | Semiconductor structure processing jig and manufacturing method thereof |
WO2023162462A1 (en) * | 2022-02-22 | 2023-08-31 | ソニーグループ株式会社 | Light emitting device and image display device |
TWI813406B (en) * | 2022-08-02 | 2023-08-21 | 啟碁科技股份有限公司 | Package structure and method for fabricating the same |
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JP3332880B2 (en) * | 1998-12-29 | 2002-10-07 | 株式会社シチズン電子 | Method for manufacturing surface mount light emitting diode |
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2018
- 2018-02-02 US US16/482,986 patent/US20190348579A1/en not_active Abandoned
- 2018-02-02 DE DE112018000656.5T patent/DE112018000656T5/en active Pending
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2022
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JPWO2018143437A1 (en) | 2019-11-07 |
DE112018000656T5 (en) | 2019-10-24 |
WO2018143437A1 (en) | 2018-08-09 |
US11626546B2 (en) | 2023-04-11 |
JP7164586B2 (en) | 2022-11-01 |
US20220140207A1 (en) | 2022-05-05 |
JP2021061416A (en) | 2021-04-15 |
CN110235259A (en) | 2019-09-13 |
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