WO2011092934A1 - 発光素子搭載用支持体及び発光装置 - Google Patents
発光素子搭載用支持体及び発光装置 Download PDFInfo
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- WO2011092934A1 WO2011092934A1 PCT/JP2010/071297 JP2010071297W WO2011092934A1 WO 2011092934 A1 WO2011092934 A1 WO 2011092934A1 JP 2010071297 W JP2010071297 W JP 2010071297W WO 2011092934 A1 WO2011092934 A1 WO 2011092934A1
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- light emitting
- emitting element
- mounting
- light
- insulating base
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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
- H01L33/483—Containers
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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
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L2224/42—Wire connectors; Manufacturing methods related thereto
- H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
- H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
- H01L2224/4805—Shape
- H01L2224/4809—Loop shape
- H01L2224/48091—Arched
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L2224/42—Wire connectors; Manufacturing methods related thereto
- H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
- H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
- H01L2224/481—Disposition
- H01L2224/48151—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive
- H01L2224/48221—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked
- H01L2224/48245—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being metallic
- H01L2224/48247—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being metallic connecting the wire to a bond pad of the item
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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
Definitions
- the present invention relates to a light-emitting element mounting support and a light-emitting device using the same, and more particularly to a light-emitting element mounting support excellent in the reliability of an insulating base on which a light-emitting element is mounted and a light-emitting device using the same. .
- a metal-resin package As a support for mounting a light emitting element used in such a light emitting device, for example, a metal-resin package is known (see, for example, Patent Document 1).
- the metal-resin package is formed by integrally forming a lead frame made of a conductive metal such as aluminum, copper, iron / copper alloy, or iron / nickel alloy, and a filler-containing resin in which a reflective filler is dispersed in the resin. Is.
- the filler-containing resin used in the metal-resin package has a large refractive index difference between the reflective filler and the resin, so that a high reflectance can be obtained and the raw material cost is low. Widely used.
- the metal-resin package heat denaturation is likely to occur in the resin part, and when a high-power light-emitting diode element (chip) is mounted, damage such as resin burning is likely to occur, and reliability as a light-emitting device There is a problem that it is inferior.
- the metal-resin package has a problem that it cannot be applied to a light emitting device in which an ultraviolet LED is mounted as a light emitting element because the resin portion is immediately damaged when irradiated with ultraviolet rays.
- a ceramic substrate such as an alumina substrate is increasingly used as a support for mounting a light emitting element.
- the alumina substrate has a firing temperature of 1500 to 1600 ° C.
- a conductive metal such as aluminum, copper, iron / copper alloy, or iron / nickel alloy
- the conductive metal may be oxidized or dissolved.
- a glass material is mentioned as such inorganic materials other than ceramics.
- the softening point (Ts) needs to be 655 ° C. or lower.
- a glass material having a softening point (Ts) of 655 ° C. or less for example, a material mainly composed of bismuth is known.
- those containing bismuth as a main component usually develop color and cannot be transparent. Therefore, when this is employed as a support for mounting a light emitting element, the reflectance with respect to light of a desired wavelength is lowered, and light from the light emitting element may not be extracted efficiently.
- the present invention has been made in order to solve the above-described problems, and has excellent heat dissipation, and even when a high-power light-emitting element is mounted, light emission that suppresses damage to the base due to heat and deterioration of hermeticity.
- An object is to provide a support for mounting elements.
- Another object of the present invention is to provide a light emitting device using the light emitting element mounting support.
- the present inventors have found that the above problems can be solved by the support for mounting a light emitting element and the light emitting device of the present invention, and have completed the present invention.
- the light emitting element mounting support of the present invention is formed by integrally molding an insulating base having a mounting portion on which a light emitting element is mounted and a lead frame for mounting the light emitting element mounted on the insulating base.
- the ceramic filler is preferably composed of one or a mixture of two or more selected from alumina powder, zirconia powder and titania powder.
- the lead frame is preferably a conductive metal or alloy selected from aluminum, copper, iron / copper alloy, or iron / nickel alloy.
- the glass ceramic composition preferably has a low melting point glass powder content of 60% by volume to 80% by volume and a ceramic filler content of 20% by volume to 40% by volume.
- the insulating base has a mounting portion on which a light emitting element recessed in a mortar shape is mounted, and a lead frame penetrates the insulating base and is exposed on a bottom surface of the mounting portion.
- the softening point (Ts) of the low melting glass powder is preferably 450 ° C. or higher and 630 ° C. or lower.
- the 50% particle size (D50) of the low-melting glass powder is preferably 0.5 ⁇ m or more and 4 ⁇ m or less.
- the light-emitting device of the present invention includes the above-described support for mounting a light-emitting element of the present invention, and a light-emitting element mounted on a mounting portion of the support for mounting a light-emitting element.
- the present invention by using a predetermined glass ceramic composition as an insulating base on which a light-emitting element is mounted, light emission that has high heat resistance and suppresses damage to the base and airtightness due to heat.
- An element mounting support is obtained.
- the support for mounting a light emitting element of the present invention is excellent in heat dissipation because the lead frame is integrally formed with the insulating base.
- by adopting such a light emitting element mounting support even if a high output light emitting element is mounted, damage to the base due to heat and a decrease in hermeticity are suppressed, A light-emitting device that can quickly release heat generated from the light-emitting element to the outside can be obtained.
- the light emitting element mounting support of the present invention is a light emitting element in which an insulating base having a mounting portion on which the light emitting element is mounted and a lead frame for mounting the light emitting element mounted on the insulating base are integrally formed.
- an insulating base on which a light emitting element is mounted is a glass ceramic composition mainly composed of a low melting point glass powder having a softening point (Ts) of 630 ° C. or less and a ceramic filler as described above.
- Ts softening point
- a ceramic filler as described above.
- FIG. 1 is a cross-sectional view showing an example of a light-emitting element mounting support 1 according to the present invention.
- the light emitting element mounting support 1 includes an insulating base 2 on which the light emitting element is mounted, and a substantially flat lead frame 3 provided between the insulating base 2.
- the insulating base 2 is composed of a side surface portion 4 and a support portion 5, and the entire insulating base 2 is a sintered body of a glass ceramic composition containing a low melting point glass powder and a ceramic filler. Is formed.
- the insulating base 2 has a recess 6 surrounded by the side surface 4.
- the bottom surface of the concave portion 6 is formed by a surface that appears inside the concave portion 6 among the upper surface of the support portion 5 in the figure, and this bottom surface is a mounting portion 6a on which the light emitting element is mounted.
- the lead frame 3 is for mounting the light emitting element, and is provided integrally with the insulating base 2 so as to penetrate between the side surface portion 4 and the support portion 5.
- the lead frame 3 is made of a thin metal plate, and is installed in a state where the two lead frames 3a and 3b are exposed on the mounting portion 6a and face each other with an interval of about several mm. .
- the insulating base 2 on which the light emitting element is mounted is manufactured by mixing a low-melting glass powder and a ceramic filler into a glass ceramic composition and firing it.
- the low melting point glass powder that is the main component of the glass ceramic composition has a softening point (Ts) of 630 ° C. or lower.
- Ts softening point
- the softening point (Ts) of the low-melting glass powder is preferably 610 ° C. or lower.
- the softening point (Ts) of the low melting point glass powder is less than 450 ° C.
- the light emitting element is mounted by wire bonding to the light emitting element mounting support 1, or the light emitting element is mounted to form a light emitting device.
- the insulating base 2 may be deformed by heat. Therefore, the softening point (Ts) of the low-melting glass powder is preferably 450 ° C. or higher.
- the low melting point glass powder preferably has a glass transition point (Tg) of 350 ° C. or higher and 500 ° C. or lower.
- Tg glass transition point
- the glass transition point (Tg) is less than 350 ° C., the insulating base 2 may be deformed when the light emitting element is mounted.
- the glass transition point (Tg) exceeds 500 ° C., the conductive metal composing the lead frame 3 is oxidized and the thermal conductivity of the lead frame 3 is remarkably lowered when fired integrally with the lead frame 3. Or deformation due to heat during firing.
- SiO 2 is 40 mol% or more and 50 mol% or less
- B 2 O 3 is 38 mol% or more and 48 mol% or less
- ZrO 2 is 0 mol% or more in the following oxide conversion mol% display. 5 mol% or less
- ZnO of 0 mol% or more 10 mol% or less comprising at least one selected from K 2 O and Na 2 O, K 2 O, Na 2 O, or K 2 O and Na 2 O and more than 2 mol% 10 mol % Or less is preferable.
- SiO 2 is a component forming a glass skeleton.
- the content of SiO 2 is preferably 40.5 mol% or more, more preferably 42 mol% or more.
- the content of SiO 2 is preferably 48 mol% or less, more preferably 47 mol% or less.
- B 2 O 3 has an effect of lowering the softening point (Ts). If the content of B 2 O 3 is less than 38 mol%, there may not be enough to lower the softening point (Ts) or glass transition temperature (Tg). On the other hand, when the content of B 2 O 3 exceeds 48 mol%, it is difficult to obtain a stable glass and the chemical durability may be lowered.
- the content of B 2 O 3 is preferably 39 mol% or more, more preferably 41 mol% or more. Further, the content of B 2 O 3 is preferably 45 mol% or less, more preferably 43 mol% or less.
- ZrO 2 may be contained in a range of 5 mol% or less in order to increase the stability of the glass. When the content of ZrO 2 exceeds 5 mol%, the softening point (Ts) may be increased.
- the content of ZrO 2 is preferably 4 mol% or less.
- ZnO may be added to lower the softening point (Ts). If the ZnO content exceeds 10 mol%, the strength of the insulating base 2 may be reduced.
- the content of ZnO is preferably 9 mol% or less, and more preferably less than 4 mol%.
- the ZnO content is preferably 1 mol% or more.
- Na 2 O and K 2 O are added to promote vitrification and lower the softening point (Ts) and the glass transition point (Tg).
- the total content of Na 2 O and K 2 O is preferably 2 mol% or more and 10 mol% or less. When the total content of Na 2 O and K 2 O is less than 2 mol%, the softening point (Ts) and the glass transition point (Tg) increase, or the glass becomes unstable and phase separation is likely to occur. To do. On the other hand, when the total content of Na 2 O and K 2 O exceeds 10 mol%, the oxidation resistance is lowered, and the strength of the insulating base 2 is lowered.
- the total content of Na 2 O and K 2 O is more preferably 6 mol% or more and 8 mol% or less.
- the low-melting glass powder used for the glass ceramic composition is not necessarily limited to the above components, and can contain other components as long as various properties such as a softening point (Ts) and a glass transition point (Tg) are satisfied.
- Ts softening point
- Tg glass transition point
- the total content is preferably 10 mol% or less.
- Al 2 O 3 may be added in a range not exceeding 5 mol% in order to increase the stability, chemical durability, and strength of the glass.
- the content of Al 2 O 3 exceeds 5 mol%, the softening point (Ts) or the glass transition point (Tg) is likely to be too high.
- the content of Al 2 O 3 is preferably 3 mol% or less.
- CaO may be added in a range not exceeding 5 mol% in order to increase the stability of the glass and lower the softening point (Ts) and the glass transition point (Tg).
- the content of CaO is preferably 3 mol% or less, more preferably 1 mol% or less.
- MgO may be contained in a range of 5 mol% or less in order to stabilize the glass. If it exceeds 5 mol%, the softening point (Ts) may be increased.
- the content of MgO is preferably 3 mol% or less.
- BaO can also be added to stabilize the glass, but its content is preferably 1% or less.
- the low melting point glass powder used for the glass ceramic composition is prepared by mixing and mixing glass raw materials so as to have the glass composition as described above, and manufacturing the glass raw material by a melting method. It is obtained by pulverization by a pulverization method. In the case of the wet grinding method, it is preferable to use water as a solvent.
- the pulverization is performed using a pulverizer such as a roll mill, a ball mill, or a jet mill.
- the 50% particle size (D50) of the low melting glass powder used for the insulating base 2 is preferably 0.5 ⁇ m or more and 4 ⁇ m or less.
- the 50% particle size of the low-melting glass powder is less than 0.5 ⁇ m, the low-melting glass powder tends to agglomerate, making handling difficult, and the time required for pulverization may be too long.
- the 50% particle size of the low-melting glass powder exceeds 4 ⁇ m, the temperature at which the glass powder softens may increase or the low-melting glass powder may be insufficiently sintered. Adjustment of the particle size is performed by classification as necessary after pulverization, for example.
- the 50% particle size (D50) refers to a value measured using a laser diffraction / scattering particle size distribution analyzer.
- the maximum particle size of the low melting glass powder is preferably 20 ⁇ m or less. If the maximum particle size exceeds 20 ⁇ m, the sinterability of the low-melting glass powder is lowered, and undissolved components remain in the sintered body, which may reduce the reflectivity of the insulating base 2.
- the maximum particle size of the low melting glass powder is more preferably 10 ⁇ m or less.
- the ceramic filler those having a melting point of 1500 ° C. or higher and those conventionally used can be used without particular limitation, and for example, alumina powder, zirconia powder, titania powder, or a mixture thereof can be suitably used.
- the 50% particle size (D50) of the ceramic filler is preferably, for example, from 0.5 ⁇ m to 4 ⁇ m.
- white ceramic fillers are present, but they may cause problems with the light-emitting element mounting support and should be avoided. Examples of this defect include a decrease in light reflectance, a decrease in strength, a decrease in sinterability, and an increase in the difference in thermal expansion coefficient from the lead frame due to a decrease in thermal expansion coefficient.
- the low melting glass powder is 60% by volume or more and 80% by volume or less and the ceramic filler is 20% by volume or more and 40% by volume or less.
- a ceramic composition is obtained.
- the ceramic filler is less than 20% by volume, there is a possibility that sufficient reflectance cannot be obtained in the sintered body of the glass ceramic composition.
- the ceramic filler exceeds 40% by volume, the sinterability of the glass ceramic composition is lowered, and the strength of the sintered body may be reduced.
- the lead frame 3 can be a conductive metal plate having a thickness of about 0.1 to 0.5 mm.
- the metal plate those conventionally used can be used without particular limitation, and for example, a conductive metal such as aluminum, copper, iron / copper alloy, or iron / nickel alloy can be suitably used.
- the lead frame 3 may be one in which a plating layer is provided by laminating nickel, gold, titanium, silver, or the like on the surface of the conductive metal plate to about several ⁇ m.
- the light emitting element mounting support 1 of the present invention has been described by way of an example, but the configuration thereof can be appropriately changed as long as it is not contrary to the gist of the present invention.
- FIG. 2 is a cross-sectional view showing a state where the light emitting element 7 is mounted on the light emitting element mounting support 1 of the present invention.
- the light emitting element 7 is fixed to the surface of the end portion of the lead frame 3a exposed on the mounting portion 6a using a conductive adhesive, and the upper side surface in the drawing is the light emitting surface 7a.
- An electrode (anode) is provided on a part of the light emitting surface 7a.
- the other electrode (cathode) is provided on a contact surface 7b (lower side in the figure) that contacts the lead frame 3a.
- the electrode (anode) on the light emitting surface 7 a side is connected to the opposing lead frame 3 b by a bonding wire 8.
- the electrode (anode) on the light emitting surface 7a side is connected to the lead frame 3b, and the electrode (anode) on the contact surface 7b side is connected to the lead frame 3a.
- the heat generated from the light emitting element 7 when energized is transmitted to the lead frame 3a on which the light emitting element 7 is mounted, and is quickly released to the outside of the light emitting device 10, and is also transmitted to the bonding wire 8 to form the lead frame. Also emitted from the light emitting device 10 from 3b.
- the light-emitting device 10 of the present invention is one in which a light-emitting element 7 such as a light-emitting diode is mounted on the mounting portion 6a of the light-emitting element mounting support 1 as described in FIG.
- a sealing material 9 is injected into the recess 6 of the light emitting element mounting support 1 so as to cover the light emitting element 7 and the bonding wire 8, thereby forming a light emitting device 10.
- a silicone resin or an epoxy resin can be used, and a silicone resin is particularly preferable because it is excellent in light resistance and heat resistance.
- a phosphor or the like By adding a phosphor or the like to the resin component, the color of light obtained as the light emitting device 10 can be adjusted as appropriate.
- the light emitting device of the present invention is not limited to the one in which the sealing material 9 is injected into the recess 6.
- a lid-like member is provided at the opening of the recess 6.
- the inside of the recess 6 may be hollow, or as shown in FIG. 2, the light emitting element 7 may be simply mounted on the light emitting element mounting support 1.
- the light emitting device of the present invention by using the light emitting element mounting support 1 with high heat resistance, even when the amount of heat generated from the light emitting element 7 is large, the insulating base 2 portion on which the light emitting element 7 is mounted.
- the light emitting device 10 can maintain stable performance without causing any damage such as burning or cracking due to heat.
- the lead frame 3 is provided integrally with the insulating base 2 without being oxidized, the heat generated from the light emitting element 7 is quickly released to the outside of the light emitting device 10 through the lead frame 3. Therefore, even if the light-emitting element 7 with high output is mounted, it is possible to emit light with high luminance while suppressing a decrease in light emission efficiency due to an excessive temperature rise.
- Such a light emitting device 10 of the present invention can be suitably used as, for example, a backlight such as a liquid crystal display, an operation button light emitting portion of a small information terminal, illumination for automobiles or decoration, and other light sources.
- the light emitting element mounting support 1 of the present invention is manufactured as follows. In the following description, the members used for the manufacture will be described with the same reference numerals as those of the finished product.
- FIGS. 4 to 9 are cross-sectional views showing an example of the manufacturing process of the light emitting element mounting support 1 of the present invention.
- the light emitting element mounting support 1 is manufactured by manufacturing the unfired side surface member 4A and the unfired support member 5A in the molds 40 and 50, and then attaching them to the lead frame 3.
- the unburned light emitting element mounting support 1 is sandwiched and stacked to be fired while being housed in the molds 40 and 50 and then cooled.
- a powder 40 made of a glass ceramic composition is filled into a mold 40 for producing the side surface portion 4.
- the powder filled in the mold 40 is press-molded so as to be pressed and hardened by a press plate P using a press molding machine.
- a frame 41 for separating and removing the side member 4 obtained after firing the non-fired side member 4 ⁇ / b> A from the mold 40 is fitted to the bottom surface of the mold 40.
- an adhesive is applied to the upper surface of the unfired side member 4A, and the lead frames 3a and 3b are placed thereon and fixed to the surface of the unfired side member 4A.
- a mold 50 for producing the support portion 5 is filled with powder made of a glass ceramic composition.
- the powder filled in the mold 50 is press-molded by the press plate P using a press molding machine.
- a frame 51 for separating and removing the support member 5 obtained after firing the unfired support member 5 ⁇ / b> A from the mold 50 is fitted to the bottom surface of the mold 50.
- the lead frame mounting surface of the unfired side member 4A is brought into contact with the surface of the unfired support member 5A.
- the unfired light emitting element mounting support 1A is formed by superimposing the unfired side member 4A and the unfired support member 5A. Thereafter, the unsintered light emitting element mounting support 1A is fired while being accommodated in the mold, and then the mold is removed from the sintered body to obtain the light emitting element mounting support.
- the baking is performed at a temperature of 550 ° C. to 630 ° C. for 30 minutes to 60 minutes. In particular, it is preferably performed at a temperature of 580 ° C. or higher and 600 ° C. or lower. If the firing temperature exceeds 630 ° C., the conductive metal constituting the lead frame 3 may be oxidized, and the thermal conductivity of the lead frame 3 may be reduced or the conductivity may be reduced. Moreover, when the lead frame 3 has aluminum as a main component, there is a possibility that the aluminum melts and the lead frame 3 is deformed. On the other hand, if the firing temperature is lower than 550 ° C., the sintering does not proceed sufficiently and the dense insulating base 2 may not be obtained.
- the sintered body is cooled for a certain period, and then a pressure of 3 kPa is applied to the frame body 41 in the direction toward the side surface portion 4 as shown in FIG. Thereby, the side surface portion 4 is pressed in the downward direction in the figure on the contact surface with the projection portion 410 of the frame body 41, and is separated from the mold 40. Further, a pressure of 3 kPa is also applied to the frame body 51 in the direction toward the support portion 5. Thereby, the support part 5 is pressed in the upward direction in the figure on the contact surface with the projection part 510 of the frame 51, and is separated from the mold 50.
- the sintered body is molded into the mold 40.
- 50 is not necessarily required, but, for example, the molds 40, 50 are separated from the unfired side surface member 4A and the unfired support member 5A at a stage before firing, and thereafter The unfired light emitting element mounting support 1A may be fired. Further, the order of forming each part can be appropriately changed as long as the light emitting element mounting support 1 can be manufactured.
- Example 1 First, a low melting glass powder was produced. That is, in mol% in terms of oxide, the SiO 2 45mol%, B 2 O 3 to 41.5Mol%, a ZrO 2 4mol%, 1.5mol% of ZnO, 2 mol% of Na 2 O, K 2 The raw materials were blended and mixed so that O would be 6 mol%. The raw material mixture was put in a platinum crucible and melted at 1300 to 1400 ° C. for 60 minutes, and then the molten glass was poured out and cooled. This glass was pulverized with an alumina ball mill for 20 to 60 hours to produce a low-melting glass powder. In addition, ethyl alcohol was used as a solvent for pulverization.
- the glass transition point (Tg) of the obtained low-melting glass powder was measured up to 1000 ° C. under a temperature rising rate of 10 ° C./min using a thermal analyzer TG-DTA2000 manufactured by Mac Science Co. Tg) was 443 ° C. The softening point (Ts) was 602 ° C.
- the 50% particle size (D50) of the low-melting glass powder thus obtained was 2.8 ⁇ m when measured using a laser diffraction / scattering type particle size distribution analyzer.
- This low-melting glass powder was mixed and mixed so that 65% by mass of alumina powder (50% particle size (D50) was 2.8 ⁇ m, Showa Denko, trade name: AL-47H) was 35% by mass. Thus, a glass ceramic composition was produced.
- the glass ceramic composition was filled in the side surface mold 40 and the support mold 50, and the powder was press molded using a press molding machine (see FIGS. 4 and 6).
- an adhesive is applied to the surface of the unfired side surface member 4A of the side surface mold 40, and as shown in FIG. 3b was placed and fixed.
- the side part mold 40 and the support part mold 50 were overlapped and fired as shown in FIG. Firing was performed at 590 ° C. for 40 minutes.
- the sintered bodies in the side surface mold 40 and the support mold 50 are removed from the molds 40 and 50 by the frame body 41 and the frame body 51 (see FIG. 9), and light emission is performed.
- An element mounting support 1 was obtained.
- the lead frame 3 of the obtained light emitting element mounting support 1 was not oxidized and could be applied as the light emitting device 10.
- the present invention by using a predetermined glass ceramic composition as an insulating base on which a light-emitting element is mounted, light emission that has high heat resistance and suppresses damage to the base and airtightness due to heat.
- An element mounting support is obtained.
- a light emitting device capable of quickly releasing heat generated from the element to the outside can be obtained.
- SYMBOLS 1 Light emitting element mounting support body, 2 ... Insulating base, 3 ... Lead frame, 4 ... Side surface part, 4A ... Unsintered side member, 5 ... Support part, 5A ... Unsintered support member, 6 ... Recessed part, 6a DESCRIPTION OF SYMBOLS ... Mounting part, 7 ... Light emitting element, 8 ... Bonding wire, 9 ... Sealing material, 10 ... Light emitting device, 40, 50 ... Mold, 41, 51 ... Frame
Abstract
Description
メタル-樹脂パッケージは、アルミニウム、銅、鉄/銅合金、又は鉄/ニッケル合金等の導電性金属からなるリードフレームと、樹脂中に反射性フィラーを分散させたフィラー含有樹脂とを一体として形成したものである。このリードフレーム上に発光素子を搭載することにより、発光素子から生じた熱が速やかに放散される。メタル-樹脂パッケージに用いられるフィラー含有樹脂は、反射性フィラーと樹脂との屈折率差が大きいため、高い反射率を得ることができ、また原料コストも安価なため、発光素子搭載用の支持体として、広く用いられている。
一方、このようなセラミックス以外の無機材料として、ガラス素材が挙げられる。上記発光素子搭載用支持体としてガラス素材を用いる場合、軟化点(Ts)が655℃を超えるものを用いると、導電性金属(リードフレーム)の酸化や溶解が生じるおそれがある。従って、発光素子搭載用支持体としてガラス素材を用いる場合には、軟化点(Ts)が655℃以下のものであることが必要である。
655℃以下の軟化点(Ts)を有するガラス素材としては、例えばビスマスを主成分とするものが知られている。しかしながら、ビスマスを主成分とするものは、通常発色してしまい、透明なものが得られない。したがって、これを発光素子搭載用支持体として採用すると、所望の波長の光に対する反射率が低下し、発光素子からの光を効率的に取り出せない場合がある。
また、本発明は、上記発光素子搭載用支持体を用いた発光装置の提供を目的とする。
前記リードフレームは、アルミニウム、銅、鉄/銅合金、又は鉄/ニッケル合金から選択される導電性金属又は合金であることが好ましい。
前記ガラスセラミックス組成物は、低融点ガラス粉末の含有比率が60体積%以上80体積%以下であり、セラミックスフィラーの含有比率が20体積%以上40体積%以下であることが好ましい。
前記低融点ガラス粉末の軟化点(Ts)は、450℃以上630℃以下であることが好ましい。
また、本発明の発光装置は、上記した本発明の発光素子搭載用支持体と、前記発光素子搭載用支持体の搭載部に搭載される発光素子と、を有することを特徴とする。
また、本発明によれば、このような発光素子搭載用支持体の採用により、高出力の発光素子を搭載しても、熱による基台の損傷や、気密性の低下が抑制され、また、発光素子から生じる熱を、外部に速やかに放出できる発光装置が得られる。
本発明の発光素子搭載用支持体は、発光素子が搭載される搭載部を有する絶縁性基台と、この絶縁性基台に搭載される発光素子を実装するリードフレームとを一体成形した発光素子搭載用支持体であって、該絶縁性基台が、低融点ガラス粉末とセラミックスフィラーとを含むガラスセラミックス組成物の焼結体からなり、該低融点ガラス粉末の軟化点(Ts)が630℃以下であることを特徴とする。
また、発光素子が搭載される絶縁性基台として、上述したガラスセラミックス組成物を採用することにより、比較的低温度で焼成できるため、導電性金属からなるリードフレームの酸化や溶解を生じさせることなく、この絶縁性基台とリードフレームとを一体として焼成して製造できる。したがって、耐熱性と共に、優れた放熱性を有する発光素子搭載用支持体が得られる。
発光素子搭載用支持体1は、発光素子が搭載される絶縁性基台2と、この絶縁性基台2の間に設けられた略平板状のリードフレーム3を有している。絶縁性基台2は、側面部4と、支持部5とで構成されており、この絶縁性基台2全体が、低融点ガラス粉末とセラミックスフィラーとを含むガラスセラミックス組成物の焼結体で形成されている。
絶縁性基台2は、側面部4で囲まれた凹部6を有している。凹部6の底面は、支持部5の図中の上側表面のうち、凹部6の内側に現れた面によって形成され、この底面が、発光素子が搭載される搭載部6aとなっている。
低融点ガラス粉末の軟化点(Ts)が630℃を超えると、リードフレーム3と一体として焼成したときに、リードフレーム3を構成する導電性金属の酸化が進行してリードフレーム3の熱伝導性が著しく低下したり、焼成時の熱による変形が生じたりする。
低融点ガラス粉末の軟化点(Ts)は、好ましくは610℃以下である。
一方、低融点ガラス粉末の軟化点(Ts)が450℃未満であると、発光素子搭載用支持体1にワイヤボンディングして発光素子を実装したり、発光素子を搭載して発光装置としたものを照明器具等にハンダ付けする際に、熱によって絶縁性基台2が変形するおそれがある。
したがって、低融点ガラス粉末の軟化点(Ts)は、450℃以上であることが好ましい。
一方、SiO2の含有量が50mol%を超える場合、軟化点(Ts)やガラス転移点(Tg)が過度に高くなるおそれある。SiO2の含有量は、好ましくは40.5mol%以上、より好ましくは42mol%以上である。また、SiO2の含有量は、好ましくは48mol%以下、より好ましくは47mol%以下である。
Na2OおよびK2Oの含有量の合計は、2mol%以上10mol%以下であることが好ましい。Na2OおよびK2Oの含有量の合計が2mol%未満であると、軟化点(Ts)やガラス転移点(Tg)が高くなったり、ガラスが不安定となって分相しやすくなったりする。一方、Na2OおよびK2Oの含有量の合計が10mol%を超えると、耐酸化性が低下したり、絶縁性基台2の強度が低下したりする。Na2OおよびK2Oの含有量の合計は、より好ましくは6mol%以上、8mol%以下である。
Al2O3の含有量が5mol%を超える場合、軟化点(Ts)やガラス転移点(Tg)が過度に高くなるおそれがある。Al2O3の含有量は、好ましくは3mol%以下である。
BaOも、ガラスを安定化するために添加できるが、その含有量は、1%以下が好ましい。
低融点ガラス粉末の最大粒径は、より好ましくは10μm以下である。
セラミックスフィラーが20体積%未満であると、ガラスセラミックス組成物の焼結体において、十分な反射率を得られないおそれがある。一方、セラミックスフィラーが40体積%を超えると、ガラスセラミックス組成物の焼結性が低くなり、焼結体の強度が低下するおそれがある。
このため、通電時に発光素子7から生じた熱は、発光素子7が搭載されたリードフレーム3aを伝わって、発光装置10の外部に速やかに放出されるとともに、ボンディングワイヤ8を伝わって、リードフレーム3bからも、発光装置10の外部に放出される。
この樹脂成分に、蛍光体等を添加することにより、発光装置10として得られる光の色を、適宜調整することができる。
また、リードフレーム3が、酸化されることなく絶縁性基台2と一体として設けられているため、リードフレーム3を通して、発光素子7から生じた熱が速やかに発光装置10外部に放出される。したがって、高出力の発光素子7を搭載したものであっても、過度な温度上昇による発光効率の低下を抑制して、高輝度に発光させることができる。
このような本発明の発光装置10は、例えば液晶ディスプレイ等のバックライト、小型情報端末の操作ボタン発光部、自動車用あるいは装飾用の照明、その他の光源として好適に使用できる。
なお、以下の説明では、その製造に用いる部材について、完成品の部材と同一の符号を付して説明する。
発光素子搭載用支持体1は、例えば図4~図9に示すように、金型40、50内で、未焼成側面部材4A及び未焼成支持部材5Aを製造した後、これらをリードフレーム3を挟んで重ね合わせて未焼成発光素子搭載用支持体1とし、これらを金型40、50内に収容した状態のまま焼成した後、冷却して得られる。
焼成温度が630℃を超えると、リードフレーム3を構成する導電性金属が酸化して、リードフレーム3の熱伝導性が低下したり導電性が低下したりするおそれがある。また、リードフレーム3がアルミニウムを主成分とする場合には、アルミニウムが溶解して、リードフレーム3が変形するおそれがある。一方、焼成温度が550℃未満であると、焼結が十分進行せず、緻密な絶縁性基台2を得られないおそれがある。
また、枠体51に対しても、支持部5に向かう方向に、3kPaの圧力を加える。これにより、支持部5は、枠体51の突起部510との接触面において、図中の上向きの方向に押圧され、金型50から分離される。
まず、低融点ガラス粉末を製造した。すなわち、下記酸化物換算のmol%表示で、SiO2を45mol%、B2O3を41.5mol%、ZrO2を4mol%、ZnOを1.5mol%、Na2Oを2mol%、K2Oを6mol%となるように原料を配合、混合し、この原料混合物を白金ルツボに入れて1300~1400℃で60分間溶融させた後、この溶融状態のガラスを流し出し冷却した。このガラスをアルミナ製ボールミルにより20~60時間粉砕して低融点ガラス粉末を製造した。なお、粉砕時の溶媒にはエチルアルコールを用いた。
このようにして得られた低融点ガラス粉末の50%粒径(D50)をレーザー回折/散乱式粒度分布測定装置を用いて測定したところ、2.8μmであった。
得られた発光素子搭載用支持体1のリードフレーム3は、酸化されておらず、発光装置10として適用できるものであった。
なお、2010年2月1日に出願された日本特許出願2010-020240号の明細書、特許請求の範囲、図面及び要約書の全内容をここに引用し、本発明の開示として取り入れるものである。
Claims (8)
- 発光素子が搭載される搭載部を有する絶縁性基台と、前記絶縁性基台に搭載される発光素子を実装するリードフレームとを一体成形した発光素子搭載用支持体であって、
前記絶縁性基台が、低融点ガラス粉末とセラミックスフィラーとを含むガラスセラミックス組成物の焼結体からなり、前記低融点ガラス粉末の軟化点(Ts)が630℃以下であることを特徴とする発光素子搭載用支持体。 - 前記セラミックスフィラーは、アルミナ粉末、ジルコニア粉末及びチタニア粉末から選択される1種又は2種以上の混合物からなることを特徴とする請求項1に記載の発光素子搭載用支持体。
- 前記リードフレームが、アルミニウム、銅、鉄/銅合金、又は鉄/ニッケル合金から選択される導電性金属又は合金であることを特徴とする請求項1又は2に記載の発光素子搭載用支持体。
- 前記ガラスセラミックス組成物において、低融点ガラス粉末の含有比率が60体積%以上80体積%以下であり、セラミックスフィラーの含有比率が20体積%以上40体積%以下であることを特徴とする請求項1乃至3のいずれか1項に記載の発光素子搭載用支持体。
- 前記絶縁性基台がすり鉢状に凹陥する発光素子の搭載される搭載部を有し、リードフレームが前記絶縁性基台を貫通して前記搭載部の底面に露出していることを特徴とする請求項1乃至4のいずれか1項に記載の発光素子搭載用支持体。
- 前記低融点ガラス粉末の軟化点(Ts)が450℃以上630℃以下であることを特徴とする請求項1乃至4のいずれか1項に記載の発光素子搭載用支持体。
- 前記低融点ガラス粉末の50%粒径(D50)が0.5μm以上4μm以下であることを特徴とする請求項1乃至4のいずれか1項に記載の発光素子搭載用支持体。
- 請求項1乃至7のいずれか1項に記載の発光素子搭載用支持体と、
前記発光素子搭載用支持体の搭載部に搭載される発光素子と、
を有することを特徴とする発光装置。
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