Light emitting device and method for manufacturing the same

Patent metadata

Field	Value
Publication number	US-10090446-B2
Application number	US-201214118176-A
Country	US
Kind code	B2
Filing date	May 15, 2012
Priority date	May 16, 2011
Publication date	Oct 2, 2018
Grant date	Oct 2, 2018

Abstract

To provide a light emitting device having high light extraction efficiency, and a method for manufacturing the light emitting device. A method for manufacturing a light emitting device ( 100 ) according to the present invention, includes: forming a sealing member ( 40 ) for sealing a light emitting element ( 10 ) on a base body ( 30 ) by dropping, the base body ( 30 ) including a conductive member ( 20 ) for connecting to the light emitting element ( 10 ), and a molding ( 25 ) integrally molded with the conductive member ( 20 ); the sealing member ( 10 ) being formed such that at least a part of a periphery of the sealing member ( 40 ) is located on an outward surface ( 38 ) of the conductive member ( 20 ) or the molding ( 25 ), the outward surface facing outward in a top view.

First claim

The invention claimed is:

1. A method for manufacturing a light emitting device, comprising:
providing an assembly comprising:
a base body comprising:
a conductive member, and
a molding that is molded with the conductive member, and

a light emitting element electrically connected to the conductive member; and

forming a sealing member that seals the light emitting element,
wherein said forming of the sealing member comprises dispensing a sealing member material on the base body,
wherein the sealing member is formed such that at least a part of a peripheral edge of the sealing member is located on an outward-facing surface of the conductive member or the molding, and
wherein the outward-facing surface is a convex curved surface, or a lower-side surface continuing from the convex curved surface.

2. The method according to claim 1 , wherein at least a part of an inward-facing surface of the base body comprises a convex curved surface at a top part thereof, said at least a part of the inward surface being located at an inner side of the peripheral edge of the sealing member.

3. The method according to claim 1 , wherein the base body has a protrusion or a groove, said at least a part of the peripheral edge of the sealing member being located on an outward-facing surface of the protrusion or the groove.

4. The method according to claim 3 , wherein the base body has a first protrusion or a first groove, and a second protrusion or a second groove located at an outer side of the first protrusion or the first groove, said at least a part of the peripheral edge of the sealing member being located on an outward-facing surface of any of the first and second protrusions and the first and second grooves.

5. The method according to claim 4 ,
wherein the sealing member comprises:
a first sealing portion for sealing the light emitting element; and
a second sealing portion for sealing the first sealing portion,

wherein the first sealing portion is formed such that at least a part of a peripheral edge of the first sealing portion is located on an outward-facing surface of the first protrusion or the first groove, and the second sealing portion is formed such that at least a part of a peripheral edge of the second sealing portion is located on an outward-facing surface of the second protrusion or the second groove.

6. The method according to claim 5 , wherein the sealing member contains a phosphor only in the first sealing portion, the phosphor being excitable by light emitted from the light emitting element.

7. The method according to claim 3 , wherein the protrusion or the groove is rounded at corners or at an entire part in a top view of the base body.

8. The method according to claim 3 , wherein the protrusion or the groove is formed in a frame shape surrounding the light emitting element.

9. The method according to claim 1 , wherein the base body has a recess inside which the light emitting element is mounted, the peripheral edge of the sealing member being located inside the recess.

10. The method according to claim 1 , further comprising, before dispensing the sealing member material on the base body, forming a coating having a critical surface tension of 50 mN/m or less, only on the outward-facing surface of the base body on which the peripheral edge of the sealing member is located, or on the outward-facing surface as well as a structural surface outside the outward-facing surface.

11. The method according to claim 1 , wherein a base material of the sealing member contains a phenyl silicone resin as a major component.

12. A light emitting device, comprising:
a base body comprising:
a conductive member, and
a molding that is molded with the conductive member;

a light emitting element electrically connected to the conductive member; and
a sealing member that seals the light emitting element,
wherein at least a part of a peripheral edge of the sealing member is located on an outward-facing surface of the conductive member or the molding,
wherein, at a contact point between the outward-facing surface and the peripheral edge of the sealing member, the sealing member makes an angle of approximately a contact angle or less to the outward-facing surface or to a tangent plane of the outward-facing surface, and
wherein the outward-facing surface is a convex curved surface, or a lower-side surface continuing from the convex curved surface.

13. The light emitting device according to claim 12 , wherein at least a part of the peripheral edge of the sealing member makes an angle of more than the contact angle to a horizontal plane.

14. The light emitting device according to claim 12 , wherein the base body has a protrusion or a groove, said at least a part of the peripheral edge of the sealing member being located on the outward-facing surface of the protrusion or the groove.

15. The light emitting device according to claim 14 ,
wherein the sealing member comprises:
a first sealing portion for sealing the light emitting element; and
a second sealing portion for sealing the first sealing portion,

wherein only the first sealing portion contains a phosphor that is excitable by light emitted from the light emitting element, and
wherein at least a part of a peripheral edge of the second sealing portion is located on the outward-facing surface of the protrusion or the groove.

16. The light emitting device according to claim 14 , wherein the base body has a recess inside which the light emitting element is mounted, the protrusion or the groove being located inside the recess.

17. The light emitting device according to claim 14 , wherein the base body has a recess inside which the light emitting element is mounted, and
the protrusion or the groove being located at an outer side of the recess.

18. The light emitting device according to claim 14 , wherein the protrusion or the groove is formed in a frame shape surrounding the light emitting element.

19. The light emitting device according to claim 17 , wherein the protrusion or the groove are formed in a strip shape on both sides of the recess.

20. The light emitting device according to claim 14 , wherein the protrusion or the groove is rounded at corners or at an entire part in a top view of the base body.

21. The light emitting device according to claim 12 , wherein the base body has a first protrusion or a first groove, and a second protrusion or a second groove at an outer side of the first protrusion or the first groove,
the sealing member comprises:
a first sealing portion for sealing the light emitting element; and
a second sealing portion for sealing the first sealing portion,

wherein only the first sealing portion contains a phosphor that is excitable by light emitted from the light emitting element,
wherein at least a part of a peripheral edge of the first sealing portion is located on an outward-facing surface of the first protrusion or the first groove, and
wherein at least a part of a peripheral edge of the second sealing portion is located on an outward-facing surface of the second protrusion or the second groove.

22. The light emitting device according to claim 12 , wherein the base body has an inward-facing surface at an outer side of the outward-facing surface on which the peripheral edge of the sealing member is located.

23. The light emitting device according to claim 12 , wherein a base material of the sealing member contains a phenyl silicone resin as a major component.

Assignees

• Kuramoto Masafumi
• Iwakura Daisuke
• Ozeki Kenji
• Tsuruha Tomoaki
• Okada Satoshi
• Hayashi Masaki
• Nichia Corp

Inventors

• Kuramoto Masafumi
• Iwakura Daisuke
• Ozeki Kenji
• Tsuruha Tomoaki
• Okada Satoshi
• Hayashi Masaki

Classifications

• H10W90/756

  between a chip and a stacked lead frame, conducting package substrate or heat sink · CPC title

• H10W90/753

  between laterally-adjacent chips · CPC title

• H10W90/00

  Package configurations · CPC title

• H10W74/00

  Encapsulations, e.g. protective coatings · CPC title

• H10W72/5525

  comprising copper [Cu] · CPC title