WO2017188237A1 - Led light source device - Google Patents

Led light source device Download PDF

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Publication number
WO2017188237A1
WO2017188237A1 PCT/JP2017/016352 JP2017016352W WO2017188237A1 WO 2017188237 A1 WO2017188237 A1 WO 2017188237A1 JP 2017016352 W JP2017016352 W JP 2017016352W WO 2017188237 A1 WO2017188237 A1 WO 2017188237A1
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WIPO (PCT)
Prior art keywords
main surface
light source
source device
led light
insulating substrate
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PCT/JP2017/016352
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French (fr)
Japanese (ja)
Inventor
広明 佐野
清太郎 吉田
博之 澤野
健太郎 利根
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株式会社光波
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Publication of WO2017188237A1 publication Critical patent/WO2017188237A1/en

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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
    • H01L33/64—Heat extraction or cooling elements

Definitions

  • the present invention relates to an LED light source device.
  • the LED light source device includes a metal plate having a heat dissipation function, an insulating substrate disposed on the metal plate, having an opening exposing the metal plate, and having a wiring pattern formed on the upper surface, and a wiring pattern on the insulating substrate.
  • a plurality of LED elements connected and mounted in two layers, each layer covered with a phosphor-containing resin, a circular sealing frame provided on an insulating substrate so as to surround the plurality of LED elements, and sealing And a sealing material made of a transparent resin with a diffusing material filled inside the frame.
  • the LED light source device described in the conventional patent document 1 is mounted with the LED elements stacked, there is a possibility that the heat dissipation is inferior.
  • the opening for exposing the metal plate is formed on the insulating substrate, when the LED elements are arranged without being stacked, there is a disadvantage that the number of LED elements that can be mounted is reduced by the opening.
  • an object of the present invention is to provide an LED light source device that is excellent in heat dissipation and enables high-density mounting of LED elements.
  • a wiring pattern is formed on the first main surface of the insulating base material, and a metal layer is formed on the second main surface opposite to the first main surface.
  • a plurality of LED elements connected to the wiring pattern on the first main surface of the substrate and mounted at a predetermined mounting density, and a void ratio of the metal layer of the substrate equal to or lower than a predetermined value
  • An LED light source device comprising: a heat dissipating member joined via a metal joining layer.
  • heat dissipation is excellent, and high-density mounting of LED elements becomes possible.
  • FIG. 1 is a cross-sectional view schematically showing a schematic configuration of an LED light source device according to an embodiment of the present invention.
  • FIG. 2 is a plan view of the LED light source device shown in FIG.
  • FIG. 3 is a plan view of an LED light source device showing a modification of the frame member shown in FIG.
  • FIG. 4A is a diagram illustrating temperature unevenness of Comparative Example 1 having a void ratio of 90%.
  • FIG. 4B is a diagram illustrating a state of voids in Comparative Example 1 having a void ratio of 90%.
  • FIG. 5A is a diagram showing temperature unevenness in Comparative Example 2 with a void ratio of 51%.
  • FIG. 5B is a diagram showing a state of voids in Comparative Example 2 having a void ratio of 51%.
  • FIG. 6A is a diagram illustrating temperature unevenness of Example 1 having a void ratio of 7%.
  • FIG. 6B is a diagram illustrating a state of voids in Example 1 having a void ratio of 7%.
  • FIG. 7A is a diagram showing temperature unevenness in Example 2 with a void ratio of 2%.
  • FIG. 7B is a diagram illustrating a void state of Example 2 having a void ratio of 2%.
  • FIG. 1 is a cross-sectional view schematically showing a schematic configuration of an LED light source device according to an embodiment of the present invention.
  • FIG. 2 is a plan view of the LED light source device shown in FIG.
  • the LED light source device 1 includes a metal block 2, an insulating substrate 4 provided on the upper surface 2 a of the metal block 2 via a solder layer 3, and a plurality of high-density mountings on the insulating substrate 4.
  • a resin layer 7 and a sealing resin 8 that seals the surface of the phosphor-containing resin layer 7 are provided.
  • the metal block 2 is an example of a heat dissipation member.
  • the solder layer 3 is an example of a metal bonding layer.
  • the phosphor-containing resin layer 7 and the sealing resin 8 are examples of a sealing material.
  • the LED light source device 1 includes a power supply board 10 provided on the upper surface 2a of the metal block 2 via a spacer 9 and a pair of power supply harnesses 11A and 11B connected to the power supply board 10.
  • the metal block 2 is made of metal such as copper, copper alloy, aluminum, aluminum alloy, for example.
  • the metal block 2 has a surface area and volume equal to or larger than the surface area and volume of the insulating substrate 4.
  • the metal block 2 is preferably formed with a through hole or a screw hole for fixing the metal block 2.
  • it is preferable that the metal block 2 is surface-treated in order to prevent corrosion and form the solder layer 3.
  • a heatsink having a large number of fins may be attached to the lower surface 2b of the metal block 2.
  • the radiator is made of metal such as aluminum or aluminum alloy, for example. Further, the radiator may be provided with a heat pipe. The radiator may be provided with a forced cooling mechanism such as a fan or water cooling.
  • the solder layer 3 has a void ratio indicating a void ratio of preferably 10% or less or 7% or less, and more preferably 2% or less.
  • the solder layer 3 includes, for example, an Au—Sn alloy containing Au as a main component, an Sn—Cu alloy containing Sn as a main component, an Sn—Ag alloy, an Sn—Ag—Cu alloy, and an Sn—Ag— Bi based alloys, Sn—Zn based alloys and the like can be used.
  • the thickness of the solder layer 3 depends on the size of the insulating substrate 4, for example, if it is about ⁇ 20 mm, it is preferably 0.2 mm or less or 0.1 mm or less, for example.
  • the solder layer 3 having a low void ratio is formed by joining the metal block 2 and the insulating substrate 4 under reduced pressure (for example, 100 Pa to 20 kPa).
  • the insulating substrate 4 is formed on the insulating base material 40, the wiring pattern 41 formed on the first main surface 40 a on the upper surface of the base material 40, and the second main surface 40 b on the lower surface of the base material 40. And a metal layer 42.
  • the wiring pattern 41 is formed by etching a copper foil, for example.
  • a copper foil can be used for the metal layer 42.
  • One end of the wiring pattern 41 is connected to the electrode of the LED element 5, and the other end is connected to the connectors of the power supply harnesses 11 ⁇ / b> A and 11 ⁇ / b> B via the power supply substrate 10.
  • a ceramic substrate such as aluminum nitride having a high thermal conductivity is preferably used from the viewpoint of heat dissipation and heat resistance.
  • the LED element 5 may be a flip chip type having a pair of electrodes on the lower surface.
  • the LED elements 5 are mounted on the insulating substrate 4 at a predetermined mounting density.
  • the mounting density of the LED elements 5 is defined by the ratio of the total light emitting area to the mounting area.
  • the mounting density is preferably 50% or more.
  • the mounting area refers to the area inside the frame member 6.
  • the light emission area is an area of the LED element 5 in plan view.
  • the frame member 6 has, for example, a square shape and is formed of, for example, a silicone resin.
  • the frame member 6 is not limited to a square, and may be other shapes such as a rectangle or a circle.
  • the frame member 6 is preferably square or rectangular in order to increase the mounting density of the LED elements 5.
  • the phosphor-containing resin layer 7 is formed by mixing a resin 70 and a granular phosphor 71 at a predetermined ratio.
  • the resin 70 is formed of a material that is transparent to the emission wavelength of the LED element 5 and that can hold the phosphor 71.
  • a resin material for example, a transparent resin such as an epoxy resin, a silicone resin, or an acrylic resin can be used.
  • the color of the emitted light from the LED element 5 is blue and a phosphor that converts blue light into yellow light is used, part of the blue light emitted from the LED element 5 is converted into yellow light by the phosphor.
  • the blue light and the yellow light that have been converted and emitted from the LED element 5 and not converted into yellow light by the phosphor are combined, and white light is emitted from the LED light source device 1.
  • the sealing material 8 is formed from a material having transparency with respect to the emission wavelength of the LED element 5.
  • a resin material for example, a transparent resin such as an epoxy resin, a silicone resin, or an acrylic resin can be used.
  • the sealing material 8 may contain a diffusing material that diffuses the light emitted from the LED element 5.
  • the power supply substrate 10 has an octagonal shape, but is not limited to this shape.
  • the power supply substrate 10 has an opening 10a that is slightly larger than the outer shape of the frame member 6 so that the frame member 6 enters inside.
  • a wiring pattern (not shown) is formed on the upper surface of the power supply substrate 10.
  • One end of the wiring pattern of the power supply substrate 4 is electrically connected to the wiring pattern 41 of the insulating substrate 4 through the through hole 10b by solder, and the other end is electrically connected to the connector 111 of the power supply harnesses 11A and 11B. Is done.
  • the power supply harnesses 11 ⁇ / b> A and 11 ⁇ / b> B include an electric wire 110 and a connector 111.
  • the connector 111 is surface-mounted on the other end of the wiring pattern of the power supply substrate 10.
  • the power supply harnesses 11 ⁇ / b> A and 11 ⁇ / b> B are electrically connected to the LED element 5 through the wiring pattern of the power supply substrate 10, the through hole 10 b and the wiring pattern 41 of the insulating substrate 4.
  • FIG. 3 is a plan view of the LED light source device showing a modification of the frame member 6 shown in FIG.
  • the frame member 16 may be circular.
  • the power supply substrate 10 has an opening that is slightly larger than the outer shape of the frame member 16 so that the frame member 16 can enter inside.
  • 4A, 4B, 5A, 5B, 6A, and 6B are diagrams showing the relationship between the void ratio of the solder layer 3 and temperature unevenness.
  • 4A and 4B show Comparative Example 1 in which the void ratio is 90%, FIG. 4A shows temperature unevenness, and FIG. 4B shows the state of voids.
  • 5A and 5B show Comparative Example 2 in which the void ratio is 51%, FIG. 5A shows temperature unevenness, and FIG. 5B shows the state of voids.
  • 6A and 6B show Example 1 having a void ratio of 7%, FIG. 6A shows temperature unevenness, and FIG. 6B shows a void state.
  • 7A and 7B show Example 2 in which the void ratio is 2%, FIG.
  • FIG. 7A shows temperature unevenness
  • FIG. 7B shows the state of voids
  • 4A, 5A, 6A and 7A show the temperature scale on the left side
  • 4B, FIG. 5B, FIG. 6B, and FIG. 7B are photographs taken by enlarging the area inside the frame member 6.
  • Comparative Example 1, Comparative Example 2, Example 1 and Example 2 have a configuration corresponding to FIG. 2 except for the void ratio of the solder layer 3.
  • the size of the power supply substrate 10 was 40 mm ⁇ 40 mm.
  • Comparative Example 1 having a void ratio of 90%, since the voids 3a and 3b exist over a wide range as shown in FIG. 4B, a high temperature region of 70 ° C. or more is wide as shown in FIG. 4A. It can be seen that it exists over a range.
  • Comparative Example 2 with a void ratio of 51%, as shown in FIG. 5B, since the void 3c exists, the range is narrower than that of Comparative Example 1 as shown in FIG. It can be seen that the area exists.
  • Example 1 with a void ratio of 7% and Example 2 with a void ratio of 2% as shown in FIG. 6A and FIG. It can be seen that
  • the third embodiment has a configuration corresponding to FIG.
  • the size of the power supply substrate 10 was 60 mm ⁇ 60 mm.
  • the LED element 5 having the same size in plan view as that of Example 1 and 1 mm ⁇ 1 mm was used.
  • the mounting rate of the LED element 5 is 72% when the shape of the frame member 6 is square, whereas it is as small as 54% when the shape of the frame member 16 is circular. It can be seen that it is better to make the shape of the frame member square in order to increase the mounting rate.
  • this invention is not limited to the said embodiment, In the range which does not change the summary of invention, it can deform
  • the sealing material 8 may be omitted.
  • the present invention can be applied to an LED light source device that has excellent heat dissipation and requires high-density mounting of LED elements.
  • SYMBOLS 1 LED light source device, 2 ... Metal block, 2a ... Upper surface, 2b ... Lower surface, 3 ... Solder layer, 3a-3c ... Void, 4 ... Insulating substrate, 5 ... LED element, 6 ... Frame member, 7 ... Phosphor containing Resin layer, 8 ... sealing resin, 9 ... spacer, 10 ... power supply board, 10a ... opening, 10b ... through hole, 11A, 11B ... power supply harness, 16 ... frame member, 40 ... base material, 40a ... first Main surface, 40b ... second main surface, 41 ... wiring pattern, 42 ... metal layer, 70 ... resin, 71 ... phosphor, 110 ... electric wire, 111 ... connector

Abstract

In order to provide an LED light source device, which has excellent heat dissipating characteristics, and in which LED elements can be mounted at a high density, an LED light source device 1 is provided with: an insulating substrate 4, wherein a wiring pattern 41 is formed on a first main surface 40a of a base material 40 having insulating characteristics, and a metal layer 42 is formed on a second main surface 40b on the reverse side of the first main surface 40a; a plurality of LED elements 5, which are mounted, at a predetermined mounting density, on the first main surface 40a of the insulating substrate 4 by being connected to the wiring pattern 41; and a metal block 2 connected to the metal layer 42 of the insulating substrate 4 via a solder layer 3 having a void rate of a predetermined value or lower.

Description

ＬＥＤ光源装置LED light source device
　本発明は、ＬＥＤ光源装置に関する。 The present invention relates to an LED light source device.
　近年、発光ダイオード（ＬＥＤ）素子を高密度実装した高輝度高出力のＬＥＤ光源装置が提案されている（特許文献１参照）。 Recently, a high-luminance and high-power LED light source device in which light-emitting diode (LED) elements are mounted at high density has been proposed (see Patent Document 1).
　このＬＥＤ光源装置は、放熱機能を有する金属板と、金属板上に配置され、金属板を露出させる開口を有し、上面に配線パターンが形成された絶縁基板と、絶縁基板上に配線パターンに接続されて２層に実装され、層ごとに蛍光体含有樹脂で覆われた複数のＬＥＤ素子と、複数のＬＥＤ素子を囲むように絶縁基板上に設けられた円形の封止枠と、封止枠の内側に充填された拡散材入りの透明樹脂からなる封止材とを備える。 The LED light source device includes a metal plate having a heat dissipation function, an insulating substrate disposed on the metal plate, having an opening exposing the metal plate, and having a wiring pattern formed on the upper surface, and a wiring pattern on the insulating substrate. A plurality of LED elements connected and mounted in two layers, each layer covered with a phosphor-containing resin, a circular sealing frame provided on an insulating substrate so as to surround the plurality of LED elements, and sealing And a sealing material made of a transparent resin with a diffusing material filled inside the frame.
　また、従来、ＬＥＤ素子に発生する熱を放熱し易くするため、ＬＥＤ素子をボイドのないＡｕ－Ｓｎ合金はんだ層を介してアルミナ基板に接合したＬＥＤ光源装置が提案されている（例えば、特許文献２参照。）。 Conventionally, in order to easily dissipate heat generated in the LED element, an LED light source device in which the LED element is bonded to an alumina substrate via a void-free Au—Sn alloy solder layer has been proposed (for example, Patent Documents). 2).
特開２０１５－７０２４２号公報Japanese Patent Laying-Open No. 2015-70242 特開２００８－１０５４５号公報JP 2008-10545 A
　しかし、従来の特許文献１に記載されたＬＥＤ光源装置は、ＬＥＤ素子を重ねて実装しているため、放熱性に劣るおそれがある。また、絶縁基板に金属板を露出させるための開口を形成しているため、ＬＥＤ素子を重ねずに配置した場合には、開口によってＬＥＤ素子を実装できる数が減るという欠点がある。 However, since the LED light source device described in the conventional patent document 1 is mounted with the LED elements stacked, there is a possibility that the heat dissipation is inferior. In addition, since the opening for exposing the metal plate is formed on the insulating substrate, when the LED elements are arranged without being stacked, there is a disadvantage that the number of LED elements that can be mounted is reduced by the opening.
　したがって、本発明の目的は、放熱性に優れ、ＬＥＤ素子の高密度実装が可能なＬＥＤ光源装置を提供することにある。 Therefore, an object of the present invention is to provide an LED light source device that is excellent in heat dissipation and enables high-density mounting of LED elements.
　本発明は、上記目的を達成するため、絶縁性を有する基材の第１の主面に配線パターンが形成され、前記第１の主面と反対側の第２の主面に金属層が形成された基板と、前記基板の前記第１の主面に前記配線パターンに接続されて所定の実装密度で実装された複数のＬＥＤ素子と、前記基板の前記金属層にボイド率が所定の値以下の金属接合層を介して接合された放熱部材と、を備えたＬＥＤ光源装置を提供する。 In order to achieve the above object, according to the present invention, a wiring pattern is formed on the first main surface of the insulating base material, and a metal layer is formed on the second main surface opposite to the first main surface. A plurality of LED elements connected to the wiring pattern on the first main surface of the substrate and mounted at a predetermined mounting density, and a void ratio of the metal layer of the substrate equal to or lower than a predetermined value An LED light source device comprising: a heat dissipating member joined via a metal joining layer.
　本発明によれば、放熱性に優れ、ＬＥＤ素子の高密度実装が可能になる。 According to the present invention, heat dissipation is excellent, and high-density mounting of LED elements becomes possible.
図１は、本発明の実施の形態に係るＬＥＤ光源装置の概略の構成を模式的に示す断面図である。FIG. 1 is a cross-sectional view schematically showing a schematic configuration of an LED light source device according to an embodiment of the present invention. 図２は、図１に示すＬＥＤ光源装置の平面図である。FIG. 2 is a plan view of the LED light source device shown in FIG. 図３は、図２に示す枠部材の変形例を示すＬＥＤ光源装置の平面図である。FIG. 3 is a plan view of an LED light source device showing a modification of the frame member shown in FIG. 図４Ａは、ボイド率が９０％の比較例１の温度ムラを示す図である。FIG. 4A is a diagram illustrating temperature unevenness of Comparative Example 1 having a void ratio of 90%. 図４Ｂは、ボイド率が９０％の比較例１のボイドの状態を示す図である。FIG. 4B is a diagram illustrating a state of voids in Comparative Example 1 having a void ratio of 90%. 図５Ａは、ボイド率が５１％の比較例２の温度ムラを示す図である。FIG. 5A is a diagram showing temperature unevenness in Comparative Example 2 with a void ratio of 51%. 図５Ｂは、ボイド率が５１％の比較例２のボイドの状態を示す図である。FIG. 5B is a diagram showing a state of voids in Comparative Example 2 having a void ratio of 51%. 図６Ａは、ボイド率が７％の実施例１の温度ムラを示す図である。FIG. 6A is a diagram illustrating temperature unevenness of Example 1 having a void ratio of 7%. 図６Ｂは、ボイド率が７％の実施例１のボイドの状態を示す図である。FIG. 6B is a diagram illustrating a state of voids in Example 1 having a void ratio of 7%. 図７Ａは、ボイド率が２％の実施例２の温度ムラを示す図である。FIG. 7A is a diagram showing temperature unevenness in Example 2 with a void ratio of 2%. 図７Ｂは、ボイド率が２％の実施例２のボイドの状態を示す図である。FIG. 7B is a diagram illustrating a void state of Example 2 having a void ratio of 2%.
　以下、本発明の実施の形態及び実施例について図面を参照して説明する。なお、各図中、実質的に同一の機能を有する構成要素については、同一の符号を付してその重複した説明を省略する。 Hereinafter, embodiments and examples of the present invention will be described with reference to the drawings. In addition, in each figure, about the component which has the substantially same function, the same code | symbol is attached | subjected and the duplicate description is abbreviate | omitted.
　図１は、本発明の実施の形態に係るＬＥＤ光源装置の概略の構成を模式的に示す断面図である。図２は、図１に示すＬＥＤ光源装置の平面図である。 FIG. 1 is a cross-sectional view schematically showing a schematic configuration of an LED light source device according to an embodiment of the present invention. FIG. 2 is a plan view of the LED light source device shown in FIG.
　このＬＥＤ光源装置１は、図１に示すように、金属ブロック２と、金属ブロック２の上面２ａにはんだ層３を介して設けられた絶縁基板４と、絶縁基板４に高密度実装された複数のＬＥＤ素子５と、複数のＬＥＤ素子５全体を囲むように絶縁基板４上に形成された枠部材６と、枠部材６の内側に複数のＬＥＤ素子５を覆うように形成された蛍光体含有樹脂層７と、蛍光体含有樹脂層７の表面を封止する封止樹脂８とを備える。ここで、金属ブロック２は、放熱部材の一例である。はんだ層３は、金属接合層の一例である。蛍光体含有樹脂層７及び封止樹脂８は、封止材の一例である。 As shown in FIG. 1, the LED light source device 1 includes a metal block 2, an insulating substrate 4 provided on the upper surface 2 a of the metal block 2 via a solder layer 3, and a plurality of high-density mountings on the insulating substrate 4. LED element 5, frame member 6 formed on insulating substrate 4 so as to surround the plurality of LED elements 5, and phosphor containing the plurality of LED elements 5 formed inside frame member 6 A resin layer 7 and a sealing resin 8 that seals the surface of the phosphor-containing resin layer 7 are provided. Here, the metal block 2 is an example of a heat dissipation member. The solder layer 3 is an example of a metal bonding layer. The phosphor-containing resin layer 7 and the sealing resin 8 are examples of a sealing material.
　また、ＬＥＤ光源装置１は、金属ブロック２の上面２ａにスペーサ９を介して設けられた給電基板１０と、給電基板１０に接続された一対の給電用ハーネス１１Ａ、１１Ｂとを備える。 Further, the LED light source device 1 includes a power supply board 10 provided on the upper surface 2a of the metal block 2 via a spacer 9 and a pair of power supply harnesses 11A and 11B connected to the power supply board 10.
　金属ブロック２は、例えば、銅、銅合金、アルミニウム、アルミニウム合金等の金属から形成されている。金属ブロック２は、絶縁基板４の表面積及び体積と同等かそれよりも大きい表面積及び体積を有する。金属ブロック２は、金属ブロック２を固定するための貫通孔又はネジ穴が形成されているのが好ましい。また、金属ブロック２は、腐食防止、及びはんだ層３の形成のため、表面処理されているのが好ましい。 The metal block 2 is made of metal such as copper, copper alloy, aluminum, aluminum alloy, for example. The metal block 2 has a surface area and volume equal to or larger than the surface area and volume of the insulating substrate 4. The metal block 2 is preferably formed with a through hole or a screw hole for fixing the metal block 2. Moreover, it is preferable that the metal block 2 is surface-treated in order to prevent corrosion and form the solder layer 3.
　なお、放熱効果を高めるため、金属ブロック２の下面２ｂに、多数のフィンを有する放熱器を取り付けてもよい。放熱器は、例えば、アルミニウム又はアルミニウム合金等の金属から形成されている。また、放熱器は、ヒートパイプを備えたものでもよい。また、放熱器は、ファンや水冷等の強制冷却機構を備えたものでもよい。 In order to enhance the heat dissipation effect, a heatsink having a large number of fins may be attached to the lower surface 2b of the metal block 2. The radiator is made of metal such as aluminum or aluminum alloy, for example. Further, the radiator may be provided with a heat pipe. The radiator may be provided with a forced cooling mechanism such as a fan or water cooling.
　はんだ層３は、放熱性の観点より、ボイドの割合を示すボイド率が１０％以下又は７％以下が好ましく、２％以下がより好ましい。はんだ層３は、例えば、Ａｕを主成分とするＡｕ－Ｓｎ系合金や、Ｓｎを主成分とするＳｎ－Ｃｕ系合金、Ｓｎ－Ａｇ系合金、Ｓｎ－Ａｇ－Ｃｕ系合金、Ｓｎ－Ａｇ－Ｂｉ系合金、Ｓｎ－Ｚｎ系合金等を用いることができる。はんだ層３の厚さは、絶縁基板４のサイズにもよるが、例えば□２０ｍｍ程度であれば、例えば０．２ｍｍ以下又は０．１ｍｍ以下が好ましい。ボイド率の低いはんだ層３は、金属ブロック２と絶縁基板４とを減圧（例えば、１００Ｐａ～２０ｋＰａ）下で接合することにより形成される。 From the viewpoint of heat dissipation, the solder layer 3 has a void ratio indicating a void ratio of preferably 10% or less or 7% or less, and more preferably 2% or less. The solder layer 3 includes, for example, an Au—Sn alloy containing Au as a main component, an Sn—Cu alloy containing Sn as a main component, an Sn—Ag alloy, an Sn—Ag—Cu alloy, and an Sn—Ag— Bi based alloys, Sn—Zn based alloys and the like can be used. Although the thickness of the solder layer 3 depends on the size of the insulating substrate 4, for example, if it is about □ 20 mm, it is preferably 0.2 mm or less or 0.1 mm or less, for example. The solder layer 3 having a low void ratio is formed by joining the metal block 2 and the insulating substrate 4 under reduced pressure (for example, 100 Pa to 20 kPa).
　絶縁基板４は、絶縁性を有する基材４０と、基材４０の上面の第１の主面４０ａに形成された配線パターン４１と、基材４０の下面の第２の主面４０ｂに形成された金属層４２とを備える。配線パターン４１は、例えば銅箔をエッチングして形成される。金属層４２は、例えば銅箔を用いることができる。配線パターン４１は、一端がＬＥＤ素子５の電極に接続され、他端が給電基板１０を介して給電用ハーネス１１Ａ、１１Ｂのコネクタに接続される。基材４０は、放熱性及び耐熱性の観点より、例えば、熱伝導率が大きい窒化アルミニウム等のセラミック基板を用いるのが好ましい。 The insulating substrate 4 is formed on the insulating base material 40, the wiring pattern 41 formed on the first main surface 40 a on the upper surface of the base material 40, and the second main surface 40 b on the lower surface of the base material 40. And a metal layer 42. The wiring pattern 41 is formed by etching a copper foil, for example. For example, a copper foil can be used for the metal layer 42. One end of the wiring pattern 41 is connected to the electrode of the LED element 5, and the other end is connected to the connectors of the power supply harnesses 11 </ b> A and 11 </ b> B via the power supply substrate 10. For the base material 40, for example, a ceramic substrate such as aluminum nitride having a high thermal conductivity is preferably used from the viewpoint of heat dissipation and heat resistance.
　ＬＥＤ素子５は、一対の電極を下面に有するフリップチップタイプのものを用いることができる。ＬＥＤ素子５は、例えば、青色光を出射する青色ＬＥＤ素子を用いることができる。ＬＥＤ素子５は、所定の実装密度で絶縁基板４上に実装されている。ＬＥＤ素子５の実装密度は、実装面積に対する発光面積の合計の比率で定義される。実装密度は、５０％以上が好ましい。実装面積は、枠部材６の内側の面積をいう。発光面積は、ＬＥＤ素子５の平面視の面積である。 The LED element 5 may be a flip chip type having a pair of electrodes on the lower surface. As the LED element 5, for example, a blue LED element that emits blue light can be used. The LED elements 5 are mounted on the insulating substrate 4 at a predetermined mounting density. The mounting density of the LED elements 5 is defined by the ratio of the total light emitting area to the mounting area. The mounting density is preferably 50% or more. The mounting area refers to the area inside the frame member 6. The light emission area is an area of the LED element 5 in plan view.
　枠部材６は、例えば正方形を有し、例えばシリコーン樹脂から形成される。なお、枠部材６は、正方形に限られず、長方形でも円形等の他の形状でもよい。枠部材６は、正方形や長方形の方がＬＥＤ素子５の実装密度を高める上で好ましい。 The frame member 6 has, for example, a square shape and is formed of, for example, a silicone resin. The frame member 6 is not limited to a square, and may be other shapes such as a rectangle or a circle. The frame member 6 is preferably square or rectangular in order to increase the mounting density of the LED elements 5.
　蛍光体含有樹脂層７は、樹脂７０と粒状の蛍光体７１とを所定の比率で混合して形成されたものである。樹脂７０は、ＬＥＤ素子５の発光波長に対して透過性を有し、かつ、蛍光体７１を保持できる材料から形成される。このような樹脂材料として、例えば、エポキシ樹脂、シリコーン樹脂、アクリル樹脂等の透明樹脂を用いることができる。 The phosphor-containing resin layer 7 is formed by mixing a resin 70 and a granular phosphor 71 at a predetermined ratio. The resin 70 is formed of a material that is transparent to the emission wavelength of the LED element 5 and that can hold the phosphor 71. As such a resin material, for example, a transparent resin such as an epoxy resin, a silicone resin, or an acrylic resin can be used.
　ＬＥＤ素子５の出射光の色を青色とし、蛍光体として青色の光を黄色の光に変換するものを用いた場合、ＬＥＤ素子５から出射された青色光の一部は蛍光体によって黄色光に変換され、ＬＥＤ素子５から出射され、蛍光体によって黄色光に変換されなかった青色光と黄色光とが合成されてＬＥＤ光源装置１から白色光が出射される。 When the color of the emitted light from the LED element 5 is blue and a phosphor that converts blue light into yellow light is used, part of the blue light emitted from the LED element 5 is converted into yellow light by the phosphor. The blue light and the yellow light that have been converted and emitted from the LED element 5 and not converted into yellow light by the phosphor are combined, and white light is emitted from the LED light source device 1.
　封止材８は、ＬＥＤ素子５の発光波長に対して透過性を有する材料から形成される。このような樹脂材料として、例えば、エポキシ樹脂、シリコーン樹脂、アクリル樹脂等の透明樹脂を用いることができる。なお、封止材８は、ＬＥＤ素子５から出射された光を拡散する拡散材を含有してもよい。 The sealing material 8 is formed from a material having transparency with respect to the emission wavelength of the LED element 5. As such a resin material, for example, a transparent resin such as an epoxy resin, a silicone resin, or an acrylic resin can be used. The sealing material 8 may contain a diffusing material that diffuses the light emitted from the LED element 5.
　給電基板１０は、図２に示すように、８角形を有するが、この形状に限定されない。給電基板１０は、枠部材６が内側に入るように、枠部材６の外形よりもやや大きい開口１０ａを有する。給電基板１０の上面に配線パターン（図示せず）が形成されている。給電基板４の配線パターンの一端は、スルーホール１０ｂを介して絶縁基板４の配線パターン４１にはんだにより電気的に接続され、他端は、給電用ハーネス１１Ａ、１１Ｂのコネクタ１１１に電気的に接続される。 As shown in FIG. 2, the power supply substrate 10 has an octagonal shape, but is not limited to this shape. The power supply substrate 10 has an opening 10a that is slightly larger than the outer shape of the frame member 6 so that the frame member 6 enters inside. A wiring pattern (not shown) is formed on the upper surface of the power supply substrate 10. One end of the wiring pattern of the power supply substrate 4 is electrically connected to the wiring pattern 41 of the insulating substrate 4 through the through hole 10b by solder, and the other end is electrically connected to the connector 111 of the power supply harnesses 11A and 11B. Is done.
　給電用ハーネス１１Ａ、１１Ｂは、電線１１０と、コネクタ１１１とを備える。コネクタ１１１は、給電基板１０の配線パターンの他端に表面実装されている。給電用ハーネス１１Ａ、１１Ｂは、給電基板１０の配線パターン、スルーホール１０ｂ及び絶縁基板４の配線パターン４１を介してＬＥＤ素子５に電気的に接続される。 The power supply harnesses 11 </ b> A and 11 </ b> B include an electric wire 110 and a connector 111. The connector 111 is surface-mounted on the other end of the wiring pattern of the power supply substrate 10. The power supply harnesses 11 </ b> A and 11 </ b> B are electrically connected to the LED element 5 through the wiring pattern of the power supply substrate 10, the through hole 10 b and the wiring pattern 41 of the insulating substrate 4.
（実施の形態の効果）
　本実施の形態によれば、以下の作用、効果を奏する。
（ａ）ＬＥＤ素子５の基材として熱伝導率の高い窒化アルミニウム製の絶縁基板４を用い、この絶縁基板４に金属ブロック２を減圧下ではんだ接合しているので、ＬＥＤ素子５から金属ブロック２に至る熱抵抗が小さくなり、放熱性に優れたＬＥＤ光源装置１を提供することができる。
（ｂ）放熱性に優れた構造を有していることに加えて枠部材７を四角にしているため、枠部材７の内側にＬＥＤ素子５を高密度実装することができる。
（ｃ）絶縁基板４よりも表面積及び体積が大きい金属ブロック２を絶縁基板４に接合しているので、枠部材６の内側の実装面積（発熱面積）が小さくても十分に熱拡散ができ、放熱性に優れたＬＥＤ光源装置１を提供することができる。 (Effect of embodiment)
According to the present embodiment, the following operations and effects are achieved.
(A) Since the insulating substrate 4 made of aluminum nitride having high thermal conductivity is used as the base material of the LED element 5 and the metal block 2 is solder-bonded to the insulating substrate 4 under reduced pressure, the metal block from the LED element 5 is Therefore, the LED light source device 1 having a low heat resistance and excellent heat dissipation can be provided.
(B) Since the frame member 7 has a square shape in addition to having a structure excellent in heat dissipation, the LED elements 5 can be mounted at high density inside the frame member 7.
(C) Since the metal block 2 having a larger surface area and volume than the insulating substrate 4 is bonded to the insulating substrate 4, sufficient heat diffusion can be achieved even if the mounting area (heat generation area) inside the frame member 6 is small, The LED light source device 1 excellent in heat dissipation can be provided.
（枠部材の変形例）
　図３は、図２に示す枠部材６の変形例を示すＬＥＤ光源装置の平面図である。図３に示すように、枠部材１６は円形でもよい。これにより、図２に示す枠部材６と比べてＬＥＤ素子５の実装密度が小さくなるが、光束のゆがみが少なくなるという利点がある。給電基板１０は、内側に枠部材１６が入るように枠部材１６の外形よりもやや大きい開口を有する。 (Modification of frame member)
FIG. 3 is a plan view of the LED light source device showing a modification of the frame member 6 shown in FIG. As shown in FIG. 3, the frame member 16 may be circular. Thereby, compared with the frame member 6 shown in FIG. 2, the mounting density of the LED elements 5 is reduced, but there is an advantage that the distortion of the light beam is reduced. The power supply substrate 10 has an opening that is slightly larger than the outer shape of the frame member 16 so that the frame member 16 can enter inside.
（実施例１、２）
　図４Ａ、図４Ｂ、図５Ａ、図５Ｂ、図６Ａ及び図６Ｂは、はんだ層３のボイド率と温度ムラとの関係を示す図である。図４Ａ及び図４Ｂは、ボイド率が９０％の比較例１を示し、図４Ａは温度ムラ、図４Ｂはボイドの状態を示す図である。図５Ａ及び図５Ｂは、ボイド率が５１％の比較例２を示し、図５Ａは温度ムラ、図５Ｂはボイドの状態を示す図である。図６Ａ及び図６Ｂは、ボイド率が７％の実施例１を示し、図６Ａは温度ムラ、図６Ｂはボイドの状態を示す図である。図７Ａ及び図７Ｂは、ボイド率が２％の実施例２を示し、図７Ａは温度ムラ、図７Ｂはボイドの状態を示す図である。図４Ａ、図５Ａ、図６Ａ、図７Ａは、左側に温度のスケールを示す。図４Ｂ、図５Ｂ、図６Ｂ、図７Ｂは、いずれも枠部材６の内側の領域を拡大して撮影した写真である。 (Examples 1 and 2)
4A, 4B, 5A, 5B, 6A, and 6B are diagrams showing the relationship between the void ratio of the solder layer 3 and temperature unevenness. 4A and 4B show Comparative Example 1 in which the void ratio is 90%, FIG. 4A shows temperature unevenness, and FIG. 4B shows the state of voids. 5A and 5B show Comparative Example 2 in which the void ratio is 51%, FIG. 5A shows temperature unevenness, and FIG. 5B shows the state of voids. 6A and 6B show Example 1 having a void ratio of 7%, FIG. 6A shows temperature unevenness, and FIG. 6B shows a void state. 7A and 7B show Example 2 in which the void ratio is 2%, FIG. 7A shows temperature unevenness, and FIG. 7B shows the state of voids. 4A, 5A, 6A and 7A show the temperature scale on the left side. 4B, FIG. 5B, FIG. 6B, and FIG. 7B are photographs taken by enlarging the area inside the frame member 6. FIG.
　比較例１、比較例２、実施例１及び実施例２は、はんだ層３のボイド率を除いて図２に対応する構成を有する。給電基板１０のサイズは、４０ｍｍ×４０ｍｍとした。ＬＥＤ素子５は、平面視のサイズで１ｍｍ×１ｍｍのものを用いたＬＥＤ素子５の実装数は、１１個×１１個＝１２１個とした。枠部材６の内側の面積（実装面積）は、１３ｍｍ×１３ｍｍ＝１６９ｍｍ２とした。発光面積の合計は、１２１ｍｍ２とした。したがって、ＬＥＤ素子５の実装密度は、発光面積／実装面積＝１２１／１６９＝０．７２＝７２％となる。 Comparative Example 1, Comparative Example 2, Example 1 and Example 2 have a configuration corresponding to FIG. 2 except for the void ratio of the solder layer 3. The size of the power supply substrate 10 was 40 mm × 40 mm. The number of LED elements 5 using 1 mm × 1 mm in the size in plan view was 11 × 11 = 121. The inner area (mounting area) of the frame member 6 was 13 mm × 13 mm = 169 mm 2 . The total light emitting area was 121 mm 2 . Therefore, the mounting density of the LED elements 5 is light emission area / mounting area = 121/169 = 0.72 = 72%.
　ボイド率が９０％の比較例１は、図４Ｂに示すように、ボイド３ａ、３ｂが広い範囲に渡って存在しているため、図４Ａに示すように、７０℃以上の高温の領域が広い範囲に渡って存在していることが分かる。ボイド率が５１％の比較例２は、図５Ｂに示すように、ボイド３ｃが存在しているため、図５Ａに示すように、比較例１よりも範囲は狭いが、７０℃以上の高温の領域が存在していることが分かる。ボイド率が７％の実施例１及びボイド率が２％の実施例２は、それぞれ図６Ａ、図７Ａに示すように、７０℃以上の高温の領域は存在しておらず、優れた放熱効果を発揮していることが分かる。 In Comparative Example 1 having a void ratio of 90%, since the voids 3a and 3b exist over a wide range as shown in FIG. 4B, a high temperature region of 70 ° C. or more is wide as shown in FIG. 4A. It can be seen that it exists over a range. In Comparative Example 2 with a void ratio of 51%, as shown in FIG. 5B, since the void 3c exists, the range is narrower than that of Comparative Example 1 as shown in FIG. It can be seen that the area exists. In Example 1 with a void ratio of 7% and Example 2 with a void ratio of 2%, as shown in FIG. 6A and FIG. It can be seen that
（実施例３）
　実施例３は、図３に対応する構成としたものである。給電基板１０のサイズは、６０ｍｍ×６０ｍｍとした。ＬＥＤ素子５は、実施例１と同じの平面視のサイズで１ｍｍ×１ｍｍのものを用いた。ＬＥＤ素子５の実装数は、実施例１よりも増やして１３個×１３個＝１６９個とした。枠部材１６の内側の直径を２０ｍｍとしたことから、各部材１６の内側の面積（実装面積）は、直径２０ｍｍ×２０ｍｍ×π／４＝３１４ｍｍ２とした。発光面積の合計は、１６９ｍｍ２とした。したがって、ＬＥＤ素子５の実装密度は、発光面積／実装面積＝１６９／３１４＝０．５４＝５４％となる。ＬＥＤ素子５の実装率は、枠部材６の形状が四角の場合、７２％であるのに対し、枠部材１６の形状が円形の場合、５４％と小さくなった。実装率を高くするには、枠部材の形状を四角にした方がよいことが分かる。 (Example 3)
The third embodiment has a configuration corresponding to FIG. The size of the power supply substrate 10 was 60 mm × 60 mm. The LED element 5 having the same size in plan view as that of Example 1 and 1 mm × 1 mm was used. The number of LED elements 5 mounted was increased from that in Example 1 to 13 × 13 = 169. Since the inner diameter of the frame member 16 was 20 mm, the inner area (mounting area) of each member 16 was 20 mm × 20 mm × π / 4 = 314 mm 2 . The total light emitting area was 169 mm 2 . Therefore, the mounting density of the LED elements 5 is light emitting area / mounting area = 169/314 = 0.54 = 54%. The mounting rate of the LED element 5 is 72% when the shape of the frame member 6 is square, whereas it is as small as 54% when the shape of the frame member 16 is circular. It can be seen that it is better to make the shape of the frame member square in order to increase the mounting rate.
　なお、本発明は、上記実施の形態に限定されず、発明の要旨を変更しない範囲内で種々に変形可能である。 In addition, this invention is not limited to the said embodiment, In the range which does not change the summary of invention, it can deform | transform variously.
　また、本発明の要旨を変更しない範囲内で、上記実施の形態の構成要素の一部を省くことが可能である。例えば、封止材８を省いてもよい。 Further, it is possible to omit some of the constituent elements of the above-described embodiment within a range not changing the gist of the present invention. For example, the sealing material 8 may be omitted.
　本発明は、放熱性に優れ、ＬＥＤ素子の高密度実装が必要なＬＥＤ光源装置に適用することができる。 The present invention can be applied to an LED light source device that has excellent heat dissipation and requires high-density mounting of LED elements.
１…ＬＥＤ光源装置、２…金属ブロック、２ａ…上面、２ｂ…下面、３…はんだ層、３ａ～３ｃ…ボイド、４…絶縁基板、５…ＬＥＤ素子、６…枠部材、７…蛍光体含有樹脂層、８…封止樹脂、９…スペーサ、１０…給電基板、１０ａ…開口、１０ｂ…スルーホール、１１Ａ、１１Ｂ…給電用ハーネス、１６…枠部材、４０…基材、４０ａ…第１の主面、４０ｂ…第２の主面、４１…配線パターン、４２…金属層、７０…樹脂、７１…蛍光体、１１０…電線、１１１…コネクタ
  DESCRIPTION OF SYMBOLS 1 ... LED light source device, 2 ... Metal block, 2a ... Upper surface, 2b ... Lower surface, 3 ... Solder layer, 3a-3c ... Void, 4 ... Insulating substrate, 5 ... LED element, 6 ... Frame member, 7 ... Phosphor containing Resin layer, 8 ... sealing resin, 9 ... spacer, 10 ... power supply board, 10a ... opening, 10b ... through hole, 11A, 11B ... power supply harness, 16 ... frame member, 40 ... base material, 40a ... first Main surface, 40b ... second main surface, 41 ... wiring pattern, 42 ... metal layer, 70 ... resin, 71 ... phosphor, 110 ... electric wire, 111 ... connector

Claims (5)

  1. 　絶縁性を有する基材の第１の主面に配線パターンが形成され、前記第１の主面と反対側の第２の主面に金属層が形成された基板と、
    　前記基板の前記第１の主面に前記配線パターンに接続されて所定の実装密度で実装された複数のＬＥＤ素子と、
    　前記基板の前記金属層にボイド率が所定の値以下の金属接合層を介して接合された放熱部材と、
    　を備えたＬＥＤ光源装置。     A substrate having a wiring pattern formed on a first main surface of an insulating base material and a metal layer formed on a second main surface opposite to the first main surface;
    A plurality of LED elements connected to the wiring pattern on the first main surface of the substrate and mounted at a predetermined mounting density;
    A heat dissipation member bonded to the metal layer of the substrate via a metal bonding layer having a void ratio of a predetermined value or less;
    LED light source device comprising:
  2. 　前記金属接合層の前記ボイド率は、７％以下である、
    　請求項１に記載のＬＥＤ光源装置。     The void ratio of the metal bonding layer is 7% or less.
    The LED light source device according to claim 1.
  3. 　前記ＬＥＤ素子の実装密度は、実装面積に対する発光面積の合計が５０％以上である、
    　請求項１又は２に記載のＬＥＤ光源装置。     The mounting density of the LED elements is 50% or more of the total light emitting area with respect to the mounting area.
    The LED light source device according to claim 1.
  4. 　前記基板は、窒化アルミニウムからなる、請求項１から３のいずれか１項に記載のＬＥＤ光源装置。 4. The LED light source device according to claim 1, wherein the substrate is made of aluminum nitride.
  5. 　絶縁性を有する基材の第１の主面に配線パターンが形成され、前記第１の主面と反対側の第２の主面に金属層が形成された窒化アルミニウムからなる絶縁基板と、
    　前記絶縁基板の前記第１の主面に前記配線パターンに接続されて５０％以上の実装密度でフリップチップ実装された複数のＬＥＤ素子と、
    　前記絶縁基板上に前記複数のＬＥＤ素子を囲むように設けられた枠部材と、
    　前記枠部材の内側に封止された透光性を有する封止部材と、
    　前記絶縁基板の表面積及び体積よりも大きい表面積及び体積を有し、前記絶縁基板の前記金属層にボイド率が７％以下のはんだ層を介して接合された放熱部材と、
    　を備えたＬＥＤ光源装置。     An insulating substrate made of aluminum nitride in which a wiring pattern is formed on a first main surface of an insulating base material and a metal layer is formed on a second main surface opposite to the first main surface;
    A plurality of LED elements connected to the wiring pattern on the first main surface of the insulating substrate and flip-chip mounted at a mounting density of 50% or more;
    A frame member provided on the insulating substrate so as to surround the plurality of LED elements;
    A translucent sealing member sealed inside the frame member;
    A heat radiating member having a surface area and volume larger than the surface area and volume of the insulating substrate, and bonded to the metal layer of the insulating substrate via a solder layer having a void ratio of 7% or less;
    LED light source device comprising:
PCT/JP2017/016352 2016-04-28 2017-04-25 Led light source device WO2017188237A1 (en)

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