JP2012084724A - Resin package, manufacturing method for the resin package, and light emitting device using the resin package - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin package which does not cause many burrs and is excellent in heat resistance, and to provide a light emitting device using the resin package.SOLUTION: A resin package manufacturing method of this invention comprises: a first step in which a metal plate having a through hole is sandwiched with a first metal mold and a second metal mold; and a second step in which a thermosetting resin is injected into the through hole and cured. In the first step, an elastic sheet is disposed between the metal plate and the second metal mold so as to close an opening of the through hole.

Description

  The present invention relates to a method of manufacturing a resin package that can be used for a light-emitting device that can be used for a display device, a lighting device, and the like, and a light-emitting device using the resin package, and in particular, a resin package using a thermosetting resin as a package material, and The present invention relates to a manufacturing method thereof and a light emitting device using the same.

  A light emitting device (LED: light emitting diode) using a semiconductor light emitting element has been put to practical use as a light source for a display device or a lighting device, has a longer life than a conventional light source, and can emit light with energy saving. Therefore, the expectation as a next-generation illumination light source is great.

  In recent years, there has been a demand for further higher output, and the improvement of the light emission efficiency of the semiconductor light emitting device is progressing. As the amount of heat generated from the semiconductor light emitting device during driving increases, the semiconductor light emitting device such as a resin package has been improved. The heat resistance of peripheral members is a problem. Therefore, the development of a package with excellent heat resistance is underway, and the structure that improves the heat dissipation by exposing the back surface of the electrode on which the semiconductor light emitting element is mounted from the back surface of the package, and the improvement of the resin used in the package itself In place of a conventionally used thermoplastic resin composition, a resin package mainly composed of a thermosetting resin composition has been developed (for example, Patent Document 1).

JP 2006-140207 A

  The thermosetting resin described in Patent Document 1 has a property that lowers viscosity by heating and is supplied into a mold and molded. At that time, it is necessary to precisely design the mold and a metal plate (member to be an electrode later) set in advance so that the resin does not flow out to unnecessary portions. In particular, in the case of an LED having a structure in which the electrode is exposed from the back surface of the resin package using a mold as shown in FIG. 8, the resin leaks to the back surface of the electrode and is molded to form burrs. If this happens, continuity will not be obtained when mounted on a circuit board. Therefore, a deburring process is required after molding. In addition, since the mold itself is very expensive, it is not practical to use it disposable, and it is generally used repeatedly. Even if the processing accuracy of the mold is increased, the shape of the mold increases as the number of uses increases. Deformation is inevitable. For this reason, generation of burrs is unavoidable, and a deburring process is essential.

  In order to solve the above problems, a light emitting device of the present invention includes a first step of sandwiching a metal plate having a through hole between a first upper mold and a second mold, and a thermosetting resin in the through hole. A second step of injecting and curing the resin package, and a method of manufacturing a resin package for a light-emitting device, comprising: a step between the metal plate and the second mold so as to close the opening of the through hole in the first step. The elastic sheet is sandwiched between the two.

  According to the present invention, at the time of molding a resin package made of a thermosetting resin, generation of burrs can be suppressed, a resin package having excellent heat resistance can be obtained with high productivity, and a light emitting device using the same By doing so, it is possible to obtain a light emitting device in which poor conduction is unlikely to occur.

1A, 1B, 1C, and 1D are views showing a method for manufacturing a resin package according to an embodiment of the present invention. FIG. 2 is a cross-sectional view showing a light emitting device using a resin package according to an embodiment of the present invention. Fig.3 (a) is a figure which shows the manufacturing method of the resin package which concerns on one Embodiment of this invention, FIG.3 (b) is the elements on larger scale. FIG. 4A is a cross-sectional view showing a light emitting device using a resin package according to one embodiment of the present invention, and FIG. 4B is a partially enlarged view thereof. FIG. 5A is a cross-sectional view showing a light emitting device using a resin package according to an embodiment of the present invention, and FIGS. 5B and 5C are partially enlarged views thereof. FIG. 6A is a perspective view showing a light emitting device using a resin package according to an embodiment of the present invention, and FIG. 6B is a bottom view thereof. 7A, 7B, 7C, and 7D are views showing a method for manufacturing a resin package according to an embodiment of the present invention. 8A, 8B, and 8C are views showing a conventional method for manufacturing a resin package.

The best mode for carrying out the present invention will be described below with reference to the drawings. However, the form shown below illustrates the resin package for embodying the technical idea of the present invention, the manufacturing method thereof, and the light emitting device using the same, and is not limited to the following.
Further, the present specification by no means specifies the member shown in the claims as the member of the embodiment. In particular, the dimensions, materials, shapes, relative arrangements, and the like of the components described in the embodiments are not intended to limit the scope of the present invention only to the extent that there is no specific description. It is just an example. It should be noted that the size and positional relationship of the members shown in each drawing may be exaggerated for clarity of explanation. Furthermore, in the following description, the same name and symbol indicate the same or the same members, and detailed description thereof will be omitted as appropriate.

<Embodiment 1>
Hereinafter, the manufacturing method of the resin package concerning embodiment of this invention is demonstrated using figures. FIG. 1A to FIG. 1D are views showing a manufacturing method of the present embodiment, and FIG. 2 is a cross-sectional view showing a light emitting device 10 using a resin package obtained thereby. Further, for the sake of simplification of explanation, the explanation is made by using a single resin package for the light emitting device 10, but this is not restrictive, and it does not exclude the simultaneous production of a plurality of resin packages. Needless to say.

(First step)
First, a metal plate (lead frame) 11 having a through hole 11a is prepared. The metal plate 11 is provided in a package (resin molded body) of the light emitting device and functions as a pair of positive and negative electrodes for supplying power from the outside. The through hole 11a insulates the pair of positive and negative electrodes. This is a region where resin (bottom surface portion of the package) is provided.

  The metal plate 11 is set so as to be sandwiched between the first mold 1 and the second mold 2 of the resin molding machine, as shown in FIG. In the following description, the first mold 1 drawn on the upper side in the drawing is also called the upper mold, and the second mold 2 drawn on the lower side is also called the lower mold. Further, in the metal plate 11, a surface facing the first mold (upper mold) 1 is an upper surface, and a surface facing the second mold (lower mold) 2 is a lower surface.

  Since the lower surface of the metal plate 11 is exposed to the bottom surface of the resin package later, the lower mold 2 is provided so as to have substantially the same shape as the portion other than the through hole 11a that holds (pinches) the metal plate 11. For example, when the metal plate 11 has a flat plate shape as shown in FIG. 1, the upper surface of the lower mold 2 is also a flat surface without unevenness. An elastic sheet 12 is sandwiched between the lower surface of the metal plate 11 and the lower mold 2. At this time, it is preferable to stick the elastic sheet 12 to the lower surface of the metal plate 11 in advance.

(Second step)
Next, as shown in FIG. 1 (b), a resin injection port provided in the upper mold 1 in a through hole (cavity) 11 a of the metal plate 11 sandwiched between the upper mold 1 and the lower mold 2. A thermosetting resin is injected from 1a. In the present embodiment, since the elastic sheet 12 is provided on the lower surface of the metal plate 11, the thermosetting resin injected into the through hole 11a of the metal plate 11 is between the upper mold 1 and the elastic sheet. It is injected into the through-hole 11a formed in.

  A recess 1 b as shown in FIG. 1B may be provided on the lower surface of the upper mold 1, that is, the surface in contact with the metal plate 11. In that case, by providing so as to surround a part of the through hole 11a, when the light emitting device is used later, the side wall 13a can be formed around the light emitting element 14 as shown in FIG. Resin package having good adhesion to the metal plate 11 and high mechanical strength by integrally forming the side wall 13a simultaneously with the bottom surface portion 13b of the resin molded body formed by being injected into the through hole 11a of the metal plate 11 It can be. Such a side wall 13a may be formed by a method such as attaching a frame or drawing a frame after molding a resin package.

  After injecting and curing the thermosetting resin, the molded product is taken out from the molds 1 and 2 as shown in FIG. 1 (c), and further, the elastic sheet 12 is attached as shown in FIG. 1 (d). By removing, a resin package can be obtained. In addition, it can be set as a desired magnitude | size and shape by cutting the metal plate 11 and the resin molding as needed. For example, as shown in FIG. 1 (c), the metal plate extending from the side wall portion 13a may be cut with the extension portion having a desired length left, or as shown in FIG. 1 (d). Thus, it may be located at the same position as the outer surface of the side wall portion 13a, that is, so as not to have an extended portion (so as to be flush with the outer surface). In this embodiment, since an elastic sheet is used, it is difficult to form a gap between the lower mold and the metal plate, that is, it is difficult to form a gap into which a highly fluid thermosetting resin enters. Thereafter, no resin serving as a burr is formed on the lower surface of the metal plate, that is, the surface on the lower mold side. Therefore, a resin package and a light-emitting device can be obtained with high productivity without going through an excessive deburring process.

  As shown in FIG. 2, the light emitting element 13 is placed on the resin package molded in this manner, electrically connected to the metal plate 11 with the conductive wire 15, and sealed with the sealing member 16. The light emitting device 10 can be obtained.

  3 (a) and 3 (b) are diagrams showing a modification of the process of FIG. 1 (b). The pressing force between the upper mold 1 and the lower mold 2 sandwiching the metal plate 11 is shown in FIG. 3), the elastic sheet 12 is deformed as shown in FIG. 3B, and a part of the elastic sheet 12 enters the inside of the through hole 11a, and the central portion protrudes most. Protrusion 12a is provided. In this way, by making use of the elasticity of the elastic sheet 12, the adhesiveness between the molds 1 and 2 and the metal plate 11 can be increased, and burrs can be hardly generated.

  4A and 4B show a light emitting device 20 using a resin package obtained by forming the protruding portion 12a on the elastic sheet 12 as described above. The bottom surface portion 23b of the resin molded body is provided with a concave portion 23c in which the substantially central portion of the back surface is recessed most. The height (height from the bottom surface of the metal plate 11) and shape of the recess 23c are determined by the height and shape of the protruding portion 12a of the elastic sheet. Thus, even if the width of the through hole of the metal plate, that is, the width between the positive electrode and the negative electrode is narrow by providing the recess 23c on the back surface of the bottom surface portion 23b of the resin molded body, the circuit board It is possible to easily suppress a short circuit due to the spread of the solder when mounted on. Further, the lowermost portion of the bottom surface portion 23b of the resin molded body is positioned higher than the back surface of the metal plate 11, that is, floats from the circuit board at the time of mounting. The thermal load on the molding resin can be reduced.

  FIGS. 5A and 5B are a cross-sectional view and a partially enlarged view of a light emitting device 30 using a resin package in which an elastic sheet is deformed differently from FIGS. 3A and 3B. Here, a concave portion 33c is formed in which the back surface of the bottom surface portion 33b of the resin molded body is recessed most on the side close to the metal plate 11. By providing the recess 33c at such a position, the exposed amount of the side surface of the metal plate 11 can be increased, and a solder fillet is easily formed. Further, by forming the lowermost surface of the bottom surface portion 33b of the resin molded body so as to be at a height H from the back surface of the metal plate 11, it is possible to reduce a thermal load when the solder is melted. Such a shape is formed by pressing the elastic sheet so that a part of the elastic sheet protrudes into the through-hole as shown in FIG. It can be formed by pushing back downward. The pressing force applied to the vicinity of the center of the through hole is the largest, so when the elastic sheet is pressed from the lower direction, the central portion protrudes to the uppermost side, and when the protruding portion is pressed from the upper side, the pressing force applied to the central portion also increases. For this reason, the center portion is pushed most downward, and this shape is obtained. FIG. 5 (c) shows a state in which the protruding portion of the elastic sheet is pushed back with a pressure stronger than that in FIG. 5 (b), and the back surface of the bottom surface portion 33b and the back surface of the metal plate 11 are substantially flush with each other. Yes. Even in such a case, a large pressure is applied to the central portion of the bottom surface portion 33b. At this time, by controlling the pressing force, a minute concave portion 33 c is formed at the end of the bottom surface portion 33 b in contact with the metal plate 11. A solder fillet can also be formed in such a small recess.

(Elastic sheet)
The elastic sheet 12 is for making it difficult for the resin to enter the gap formed between the molds 1 and 2 and the metal plate 12, and has elasticity that can be deformed relatively easily by the pressing force of the upper and lower molds. It is what you have. Thereby, it deform | transforms according to the surface shape of a metal mold | die with a fine unevenness | corrugation or distortion, and a metal plate, and the clearance gap can be reduced. Specifically, heat resistant resins such as polyimide and polyester can be used. The heat resistant temperature is preferably 120 ° C. to 250 ° C. from the molding temperature and the temperature of the light emitting element mounting process. Moreover, you may have the adhesion layer which can be affixed on a metal plate. The adhesive layer has excellent adhesion to the metal plate (lead frame) from the viewpoint of preventing the generation of resin burrs during molding, and it has excellent releasability due to poor solder mounting if adhesive paste remains after peeling. Acrylic and silicone materials can be used as the adhesive material.

  A sheet having a thickness of 15 to 100 microns can be used as the elastic sheet. From the viewpoint of cost and productivity, it is preferable to use a sheet of 20 to 60 microns, more preferably 25 to 50 microns. By sticking the sheet base material and adhesive layer to the through hole cross section of the metal plate, the molded resin does not enter the through hole, so that it becomes a fine fillet at the time of solder mounting, improving the solder mountability, etc. The electrical connection reliability is improved.

(Thermosetting resin)
As the thermosetting resin used for the resin package, specifically, an epoxy resin composition, a silicone resin composition, a modified epoxy resin composition such as a silicone-modified epoxy resin, a modified silicone resin composition such as an epoxy-modified silicone resin, Examples thereof include a polyimide resin composition and a modified polyimide resin composition. In particular, fine particles such as TiO ₂ , SiO ₂ , Al ₂ O ₃ , MgO, MgCO ₃ , CaCO ₃ , Mg (OH) ₂ , and Ca (OH) ₂ are mixed in these resins as fillers. Thus, it is preferable to adjust the light transmittance so that about 60% or more of light from the light emitting element is shielded, more preferably about 90%. Here, either the light may be reflected or absorbed by the substrate, but when the light-emitting device is used for illumination or the like, it is more preferable to shield the light by reflecting it. Therefore, it is preferable that the reflectance with respect to the light from the light emitting element is 60% or more, more preferably 90% or more. For example, when TiO ₂ is used, it is preferably added in an amount of 10 to 30 wt%, more preferably 15 to 25 wt%. These various fillers can be used alone or in combination of two or more. For example, a filler for adjusting the reflectance and a filler for adjusting the expansion coefficient are used in combination. Can be used.

  In the case of use in a display or the like, in order to improve the contrast, it is preferable that the light absorption rate from the light emitting element is 60% or more, more preferably 90% or more. In such cases, as the filler, carbon such as acetylene black, activated carbon, graphite, transition metal oxides such as iron oxide, manganese dioxide, cobalt oxide, molybdenum oxide, or colored organic pigments are used depending on the purpose. can do.

The linear expansion coefficient of the thermosetting resin is preferably adjusted to 5 to 35 × 10 ⁻⁶ / K, more preferably 7 to 20 × 10 ⁻⁶ / K. Thereby, it is possible to easily suppress the warpage that occurs during cooling after the base is molded, and it is possible to manufacture with high yield. In addition, in this specification, the linear expansion coefficient of a base | substrate refers to the linear expansion coefficient below the glass transition temperature of the thermosetting resin composition adjusted with various fillers.

  From another point of view, it is preferable to control the linear expansion coefficient of the thermosetting resin so that the difference from the linear expansion coefficient of the metal plate is small. Preferably, it is 0.5 to 2.0 times, more preferably 0.6 to 1.4 times the metal plate. Thereby, in the light emitting device after separation, the first and second conductive members and the base are prevented from peeling off, and an optical semiconductor device having excellent reliability can be obtained.

(Metal plate)
The metal plate is a plate-like member having a region where the light emitting element can be placed, and has a through hole that functions as a pair of positive and negative electrodes after resin molding. As shown in FIG. 2, it is also possible to use a flat surface on both the upper and lower sides or a part provided with a recess or notch. Furthermore, you may provide the thin part 41a as shown in FIG.6 (c) in the side surface of a through-hole. 6A and 6B are diagrams showing a light emitting device 40 using a black resin suitable for a display. FIG. 6A is a perspective view, FIG. 6B is a bottom view, and FIG. It is sectional drawing in a X-ray. In order to obtain a high-definition image, it is preferable to arrange the light emitting devices at a high density in the display. Therefore, as shown in FIG. 6B, the metal plate 41 is formed from the end (outer surface) of the resin molded body. It is preferable to provide them so as to be separated from each other. Therefore, the concave portion 43 c of the bottom surface portion 43 b formed by the convex portion of the elastic sheet is formed around the entire back surface of the metal plate 11. By doing in this way, it is possible to mount with good adhesion and high density without forming a solder fillet on the outer wall of the light emitting device.

  Specific materials for the metal plate include copper, aluminum, gold, silver, tungsten, iron, nickel, cobalt, and other metals or iron-nickel alloys, phosphor bronze, iron-containing copper, molybdenum, and these are simple or alloys. Can be used as Furthermore, a material capable of reflecting light from the light emitting element is preferably provided on the outermost surface, and specifically, gold, silver, copper, Pt, Pd, Al, W, Mo, Ru, Rh, and the like are preferable. In particular, the reflectance in the visible range is preferably 70% or more, and Ag, Ru, Rh, Pt, Pd, etc. are preferably used. Further, the surface gloss of the metal plate is preferably higher, preferably 0.5 or more, more preferably 1.0 or more. The glossiness shown here is a number obtained by 45 ° irradiation and vertical light reception using a Nippon Denshoku micro surface color difference meter VSR 300A.

<Embodiment 2>
7A, 7B, 7C, and 7D are views for explaining a method of manufacturing a resin package in which an elastic sheet 72 is provided also on the first mold (upper mold) 1 side. Here, as shown in FIG. 7A, the elastic sheet 72 is attached to the first mold (upper mold 1). Thus, by providing an elastic sheet on both the upper and lower sides of the metal plate 11 and holding it with a mold, the pressing force applied to the metal plate can be absorbed by the elastic sheet. Therefore, deformation of the metal plate 11 can be reduced, and variation in the width of the through hole 11a can be reduced. Furthermore, since it is possible to prevent the resin from entering the surface on the side where the light emitting element is mounted, that is, the upper surface of the metal plate 11, it is possible to suppress mounting defects and conductive wire connection defects. Furthermore, since the mold and the metal plate can be kept out of direct contact with each other, the upper surface of the metal plate is hardly damaged, and the surface subjected to high gloss processing by plating or the like can be kept as it is. it can. As the elastic sheet provided on the upper mold side, the same type as the elastic sheet provided on the lower mold side can be used.

  The method for producing a resin package according to the present invention can be used as a resin package used in various light emitting devices and the like because it can suppress the generation of burrs during molding and can obtain a resin package having excellent heat resistance with a high yield. .

1 ... 1st mold (upper mold)
DESCRIPTION OF SYMBOLS 1a ... Resin injection | pouring port 1b ... Recessed part 2 ... 2nd metal mold | die (lower metal mold | die)
10, 20, 30, 40 ... Light emitting device 11, 41 ... Metal plate (lead frame)
11a ... Through hole 41a ... Thin portions 12, 72 ... Elastic sheet 12a ... Protruding portions 13, 43 of the elastic sheet ... Resin molding (package)
13a, 43a ... side wall parts 13b, 23b, 33b, 43b ... bottom face parts 23c, 33c, 43c ... back surface recess 14 ... light emitting element 15 ... conductive wire 16 ... sealing member 103 ... reflector 104 ... Ni / Ag plating 105 ... metal Wiring 200 ... Optical semiconductor element mounting region (concave portion)
300 ... resin injection port 301 ... mold

Claims (5)

A first step of sandwiching a metal plate having a through hole between a first mold and a second mold;
A second step of injecting and curing a thermosetting resin into the through hole;
A method of manufacturing a resin package for a light-emitting device,
In the first step, an elastic sheet is sandwiched between the metal plate and the second mold so as to close the opening of the through hole.   The method of manufacturing a resin package according to claim 1, wherein the elastic sheet is provided so as to protrude into the opening.   The method for manufacturing a resin package according to claim 1, wherein the first step includes sandwiching an elastic sheet between the first mold and the metal plate. A resin package including a metal plate in a thermosetting resin molded body,
The metal plate has a through hole, and the resin molded body provided in the through hole has a recess on the bottom surface.   A light emitting device in which a light emitting element is mounted on the resin package according to claim 4.

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