JP2012182345A - Optical electronic component manufacturing method, manufacturing device and optical electronic component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture an LED package with high productivity by facilitating handling of substrates before and after encapsulation.SOLUTION: A pre-encapsulation substrate 1 is fitted into a carrier 14. Next, the carrier 14 is fixed to an upper die 18. Next, a lower die 17 and the upper die 18 are closed. This causes a plurality of LED chips 13 mounted on the pre-encapsulation substrate 1 to be dipped in fluid resin 26 filled in cavities. Next, the fluid resin 26 is hardened to form cured resin 28. This results in the plurality of LED chips 13 being resin sealed collectively. Next, the lower die 17 and the upper die 18 are opened and the carrier 14 having an encapsulated substrate 29 fitted therein is removed. Next, the encapsulated substrate 29 is projected from the carrier 14. Next, the encapsulated substrate 29 is cut. As a result, the encapsulated substrate 29 is separated into a plurality of LED packages respectively corresponding to each LED chip 13.

Description

  The present invention relates to an optoelectronic component manufacturing method, an apparatus, and an optoelectronic component, and in particular, an optoelectronic component manufacturing method, an manufacturing apparatus, and an optoelectronic device that manufacture an optoelectronic component from a pre-sealing substrate having a reflective member. It relates to parts.

  Conventionally, a package of an optoelectronic component such as an LED package is manufactured by mounting an optical element made of an LED chip or the like on a substrate (printed board, lead frame, etc.) and sealing the optical element with a resin. ing. For this purpose, a first method has been proposed in which after sealing an LED chip with a resin, a dome-shaped transparent cap is fixed thereon with an ultraviolet curable resin (for example, Patent Document 1). Also, using a substrate on which a reflective member (reflector) is formed in advance, a plurality of LED chips mounted on the substrate are collectively sealed with a resin to form a resin sealed body, and the resin sealed body A second method for manufacturing an LED package with a reflecting member by cutting (dividing) is performed (for example, Patent Document 2).

Japanese Patent Laid-Open No. 2002-232018 (5th page, FIG. 5) JP 2010-125647 A (pages 6-7, FIGS. 1-4)

  However, according to the first method described above, in addition to the need to manufacture a lens (dome-shaped transparent cap) by a separate process, it is necessary to fix the manufactured lens. Therefore, there is a problem that productivity is low. In addition, according to the second method described above, particularly when a thin substrate is used, there is a problem that it is difficult to handle the alignment and transport of the substrate and the resin sealing body on which the reflection member is formed in advance. It was.

  Hereinafter, the reference numerals in parentheses in the descriptions of “means for solving the problems” and “effects of the invention” are described for the purpose of facilitating the comparison between the terms in the description and the components shown in the drawings. is there. Further, these symbols and the like do not mean that “the meaning of the terms in the description is limited to the components shown in the drawings”.

  In order to solve the above-described problem, the method of manufacturing an optoelectronic component according to the present invention uses at least an upper mold (18) and a lower mold (17) facing the upper mold (18) and having a cavity (19). Then, a substrate body (2) having a plurality of regions (7), a reflecting member (8) formed in each of the plurality of regions (7) and having through holes or recesses (10), and a substrate body ( 2) or one or a plurality of optical elements (13) mounted on the bottom surface (11) of the recess (10), and a sealing resin (28) made of a cured resin (28) and sealing the optical element (13). And forming an optoelectronic component from the encapsulated substrate (29), the openings (15) corresponding to the reflecting members (8), respectively. A step of preparing a temporary fixing jig (14) having a substrate body (2) A step of preparing a pre-sealing substrate (1) provided with a projecting member (8) and an optical element (13); and a temporary fixing jig (14) so that the reflecting member (8) is fitted into the opening (15). And the opening (15) in plan view in a plurality of subcavities (25) provided in the cavity (19) and corresponding to the openings (15) respectively. And a step of fixing the temporary fixing jig (14) fitted with the pre-sealing substrate (1) to the upper mold (18) so as to overlap each other, and a state in which the cavity (19) is filled with the resin material A step of immersing the optical element (13) in a fluid resin (26) formed from a resin material by clamping the upper die (18) and the lower die (17), and the fluid resin A step of forming a cured resin (28) by curing (26) Opening the upper mold (18) and the lower mold (17), removing the temporary fixing jig (14) fitted with the sealed substrate (29) from the upper mold (18), sealing And removing the sealed substrate (29) from the temporary fixing jig (14) fitted with the stopped substrate (29). In the step of forming the cured resin (28), a plurality of subcavities (25) In the step of forming the lens portion (30) and forming the communicating portion (31) in the communicating passage (27) communicating between the plurality of sub-cavities (25) and taking out the sealed substrate (29). The first optoelectronic component having a plurality of lens portions (30) is manufactured by protruding the sealed substrate (29) and separating the communication portion (31) from the sealed substrate (29). Features.

  Further, the method for manufacturing an optoelectronic component according to the present invention is the above-described manufacturing method, wherein after the step of taking out the sealed substrate (29), the first optoelectronic component is separated to remove one of the plurality of regions (7). Forming a second optoelectronic component corresponding to each of the plurality of regions (7).

  The method for manufacturing an optoelectronic component according to the present invention includes the plurality of regions (7) by separating the first optoelectronic component after the step of taking out the sealed substrate (29) in the above-described manufacturing method. A step of forming a third optoelectronic component (38) corresponding to each region (7).

  In the method for manufacturing an optoelectronic component according to the present invention, in the above-described manufacturing method, in the step of immersing the optical element (13), the process passes through the communication path (27) provided over the entire circumference of the subcavity (25). The flowable resin (26) is caused to flow between the plurality of sub-cavities (25).

  In the method of manufacturing an optoelectronic component according to the present invention, in the above-described manufacturing method, in the step of immersing the optical element (13), the optical device is routed through a communication path (27) partially provided around the subcavity (25). Thus, the fluid resin (26) is caused to flow between the plurality of sub-cavities (25).

  Also, the method for manufacturing an optoelectronic component according to the present invention is the above-described manufacturing method, in which the cavity (19) is placed between the upper mold (18) and the lower mold (17) before the step of filling the cavity (19). The step of supplying the release film (40) and the release film (40) on the mold surfaces (22, 39) corresponding to the whole of at least a plurality of regions (7) of the mold surface (39) constituting the cavity (19). ).

  Further, in the method for manufacturing an optoelectronic component according to the present invention, in the above manufacturing method, the individual pressing members (50) elastically supported by the upper mold (18) are provided corresponding to the reflecting members (8), respectively. The step of fixing the temporary fixing jig (14) to the upper mold (18) is characterized in that the reflecting member (8) is pressed by the individual pressing member (50).

  The optoelectronic component manufacturing method according to the present invention is the above-described manufacturing method, wherein elastic support is provided outside a portion corresponding to the entire plurality of regions (7) of the mold surface (39) constituting the cavity (19). In the step of immersing the optical element (13) in the flowable resin (26), the flowable resin (26) presses the moveable member (53) in the step of immersing the optical element (13) in the flowable resin (26). A resin reservoir (54) is formed.

  The apparatus for manufacturing an optoelectronic component according to the present invention includes at least an upper mold (18) and a lower mold (17) facing the upper mold (18) and having a cavity (19). A substrate body (2) having (7), a reflecting member (8) formed in each of a plurality of regions (7) and having a through hole or a recess (10), and a substrate body (2) or a recess (10 in the through hole). ) And one or a plurality of optical elements (13) mounted on the bottom surface (11) and a sealing resin (28) made of a cured resin (28) and sealing the optical element (13). An optoelectronic component manufacturing apparatus for use in manufacturing an optoelectronic component from a sealed substrate (29) after forming a substrate (29), wherein a reflecting member (8) and an optical element ( 13) and a receiving means for receiving the pre-sealing substrate (1) provided with the pre-sealing base The temporary fixing jig (14) having an opening (15) provided so as to correspond to the reflecting member (8) included in (1), and the reflecting member (8) fitted in the opening (15) In the cavity (19) including the fixing means for fixing the temporary fixing jig (14) to the upper mold (18) and the cavity (19) including the reflection member (8) in the substrate (1) before sealing in plan view. Supply means for supplying, mold opening / closing means for opening or closing the upper mold (18) and lower mold (17), and projecting means for projecting the sealed substrate (29) from the temporary fixing jig (14) ( 33), and the cavity (19) includes a subcavity (25) composed of a recess provided corresponding to each of the reflecting members (8), and a communication path (27) communicating the subcavities (25) with each other. The projecting means (33) is sealed from the temporary fixing jig (14). And separating the communication unit (31) consisting of cured resin (28) in the communication passage (27) from the sealing already substrate (29) by projecting a substrate (29).

  The optoelectronic component manufacturing apparatus according to the present invention is characterized in that, in the above-described manufacturing apparatus, the communication path (27) is formed over the entire circumference of the sub-cavity (25).

  The optoelectronic component manufacturing apparatus according to the present invention is characterized in that, in the above-described manufacturing apparatus, the communication path (27) is partially formed around the sub-cavity (25).

  An optoelectronic component manufacturing apparatus according to the present invention is the above-described manufacturing apparatus, wherein a film supply means for supplying a release film (40) between an upper mold (18) and a lower mold (17), a cavity ( And a film contact means for bringing the release film (40) into close contact with the mold surfaces (22, 39) corresponding to the whole of at least a plurality of regions (7) among the mold surfaces (39) constituting 19). To do.

  Further, the optoelectronic component manufacturing apparatus according to the present invention includes the individual pressing member (50) provided to be elastically supported in the upper mold (18) in correspondence with the reflecting member (8). The reflective member (8) is pressed by the individual pressing member (50) in a state where the temporary fixing jig (14) is fixed to the upper mold (18).

  In addition, the optoelectronic component manufacturing apparatus according to the present invention is the above-described manufacturing apparatus, wherein the optoelectronic component is elastically supported outside the portion corresponding to the entire plurality of regions (7) of the mold surface (39) constituting the cavity (19). The fluid resin (26) presses the movable member (53) while the upper mold (18) and the lower mold (17) are clamped in the movable member (53). A resin reservoir (54) into which (26) flows is formed.

  The optoelectronic component according to the present invention includes a substrate body (2) having a plurality of regions (7), a reflecting member (8) formed in each of the plurality of regions (7) and having a through hole or a recess (10). The optical element (13) is composed of one or a plurality of optical elements (13) mounted on the bottom surface (11) of the substrate body (2) or the recess (10) in the through hole and the cured resin (28). After the sealed substrate (29) having the sealing resin (28) to be formed is formed, it is an optoelectronic component manufactured from the sealed substrate (29) so as to correspond to each of the reflecting members (8). In the state where the reflecting member (8) is fitted in the opening (15) provided in the temporary fixing jig (14), the temporary fixing jig (14) is a fluid resin on the side where the optical element (13) is exposed. At least fill the through hole or recess (10) by being immersed in (26) Between the lens part (30) made of the cured resin (28) and the lens part (30) made of the cured resin (28) formed by curing the flowable resin (26) thus introduced. The communication portion (31) that communicates with each other is pressed and the sealed substrate (29) is protruded from the temporary fixing jig (14) to be separated from the communication portion (31) around the lens portion (30). The side wall portion (35) or the side wall portion (35) formed separately from the communication portion (31) is provided.

  The optoelectronic component according to the present invention is characterized in that, in the above-described optoelectronic component, the communication portion (31) is formed over the entire circumference of the lens portion (30).

  The optoelectronic component according to the present invention is characterized in that, in the above-described optoelectronic component, the communication portion (31) is partially formed around the lens portion (30).

  The optoelectronic component according to the present invention is characterized in that, in the above-described optoelectronic component, each corresponds to a plurality of regions (7) including a part of the plurality of regions (7).

  The optoelectronic component (38) according to the present invention corresponds to each of the regions (7) included in the plurality of regions (7) in the above-described optoelectronic component.

  According to the present invention, by using the temporary fixing jig (14), the pre-sealing substrate (1) and the sealed substrate are sealed in each step from the conveyance of the pre-sealing substrate (1) to after the resin sealing. Handling such as conveyance and alignment with the substrate (29) can be easily performed. Thus, the pre-sealing substrate (1) and the sealed substrate (29) can be easily handled to produce an optoelectronic component with high productivity.

1 (1) is a plan view showing a pre-sealing substrate used in the present invention, and FIG. 1 (2) is a cross section showing the pre-sealing substrate shown in FIG. 1 (1) along the line AA. FIG. 2 (1) to 2 (3) show a step of aligning the pre-sealing substrate and the carrier in Example 1 of the present invention, and disposing the carrier in which the pre-sealing substrate is inserted above the lower mold. It is sectional drawing which shows a process and the state just before the process of immersing an LED chip in fluid resin, respectively. 3 (1) to 3 (3) are cross-sectional views respectively showing the process from the step of immersing the LED chip in the fluid resin to the step of taking out the sealed substrate. 4 (1) to 4 (3) are cross-sectional views respectively showing the process from the process of protruding the sealed substrate to the process of separating the sealed substrate. FIGS. 5 (1) to (3) show a state where the reflecting member and the LED chip are provided on the lead frame, a sealed substrate, and a state where the sealed substrate is separated into LED packages, respectively. FIG. 5 (4) is a front sectional view of the LED package shown in FIG. 5 (3). FIG. 6 is a cross-sectional view illustrating the case of resin sealing using a release film in Example 2 of the present invention. FIG. 7 is a cross-sectional view illustrating the case of resin sealing using a release film and a resin reservoir in Example 3 of the present invention.

  First, as shown in FIG. 2A, the pre-sealing substrate 1 is fitted into the carrier 14 by fitting the reflecting member 8 of the pre-sealing substrate 1 into the opening 15 of the carrier 14. Next, as shown in FIGS. 2 (2) and (3), the lower mold 17 and the upper mold 18 are clamped in a state where the carrier 14 in which the substrate 1 before sealing is fitted is fixed to the upper mold 18. . As a result, as shown in FIG. 3 (1), the plurality of LED chips 13 mounted on the pre-sealing substrate 1 are immersed in the fluid resin 26 filled in the cavity 19 (see FIG. 2 (2)). (Immerse). Next, the fluid resin 26 is cured to form a cured resin 28. As a result, as shown in FIG. 3B, the plurality of LED chips 13 mounted on the pre-sealing substrate 1 are collectively resin-sealed. Next, as shown in FIGS. 3 (2) to 4 (2), the lower mold 17 and the upper mold 18 are opened, and the carrier 14 in which the sealed substrate 29 is fitted is taken out. The sealed substrate 29 is protruded. Next, as shown in FIGS. 4 (2) to (3), the protruding sealed substrate 29 is cut. As a result, the sealed substrate 29 is separated into a plurality of LED packages 38 corresponding to the respective LED chips 13.

  Example 1 relating to a method of manufacturing an optoelectronic component, a manufacturing apparatus, and an optoelectronic component according to the present invention will be described with reference to FIGS. In addition, in order to make it easy to understand, all the drawings shown below are schematically omitted or exaggerated as appropriate. In the following description, a lead frame will be described as an example of the substrate body.

  A substrate 1 before sealing shown in FIG. 1 has a lead frame 2. The lead frame 2 is provided with an outer frame 3, connecting portions 4 and 5 extending along the X direction and the Y direction, respectively, and a plurality of regions 7 partitioned in a lattice shape by virtual lines 6. The substrate 1 before sealing includes a plurality of reflecting members 8. A plurality of reflecting members 8 are provided in each region 7. The reflecting member 8 is formed on the lead frame 2 in advance by a method such as injection molding, transfer molding, compression molding, or the like, and is made of a thermosetting resin containing a filler for reflecting and radiating light. The reflecting member 8 has an upper surface 9, a recess 10, a bottom surface 11, and a slope 12. Note that a through hole may be provided in the reflecting member 8 instead of the recess 10 and the surface of the lead frame 2 exposed at the through hole may be a surface corresponding to the bottom surface 11 (see FIG. 1B).

  The substrate 1 before sealing has a plurality of LED chips 13. The plurality of LED chips 13 are respectively attached to the bottom surface 11 in each region 7. The bottom surface 11 and the inclined surface 12 of each reflecting member 8 have a function of reflecting the light generated by each LED chip 13. An electrode (not shown) of the LED chip 13 and a lead (not shown) of the lead frame 2 are electrically connected. This connection is performed by a known method such as wire bonding or flip chip bonding.

  A method of manufacturing the optoelectronic component according to this embodiment will be described with reference to FIGS. First, as shown in FIG. 2A, the pre-sealing substrate 1 shown in FIG. 1 and a carrier (temporary fixing jig) 14 into which the pre-sealing substrate 1 is fitted are prepared.

  The carrier 14 has an opening 15 into which the reflecting member 8 of the substrate 1 before sealing is fitted, and a thin plate-like pressing portion 16 provided on the periphery of the opening 15. The pressing portion 16 presses the outer edge of the upper surface 9 (lower surface in the drawing) of the reflecting member 8 in a state where the reflecting member 8 is fitted in the opening 15 (see FIG. 2B).

  Next, the pre-sealing substrate 1 and the carrier 14 are received by a receiving means (not shown) of the optoelectronic component manufacturing apparatus. Thereafter, as shown in FIG. 2A, the carrier 14 and the pre-sealing substrate 1 are aligned so that the opening 15 of the carrier 14 and the reflecting member 8 of the pre-sealing substrate 1 overlap in plan view. To do.

  Next, as shown in FIGS. 2 (1) and (2), the reflecting member 8 of the substrate 1 before sealing is fitted into the opening 15 of the carrier 14. As a result, the pre-sealing substrate 1 is fitted into the carrier 14.

  Next, the reflecting member 8 of the substrate 1 before sealing is fitted into the opening 15 (see FIG. 2 (1)) between the opposing lower mold 17 and upper mold 18 shown in FIG. 2 (2). The loaded carrier 14 is carried in. Thereafter, as shown in FIG. 2B, the carrier 14 is fixed at a predetermined position of the upper mold 18 in a state where the reflection member 8 of the substrate 1 before sealing is fitted into the opening 15. As means for fixing, well-known means such as clamping with a jig and suction are used.

  The lower mold 17 has a cavity block 20 in which a cavity 19 is formed. The cavity 19 is the entire space filled with the fluid resin (see the fluid resin 26 shown in FIG. 2 (3)). The lower mold 17 includes a peripheral member 21 provided around the cavity block 20. A cavity 19 is formed by the mold surface (upper surface) 22 of the cavity block 20 and the inner surface 23 of the peripheral member 21. The peripheral member 21 is supported by an elastic member 24 composed of a coil spring, a disc spring, or the like. The peripheral member 21 also functions as an intermediate mold that constitutes the cavity 19.

  The cavity 19 has a plurality of subcavities 25 each formed of a recess. The plurality of subcavities 25 respectively correspond to the LED chips 13 mounted on the bottom surface 11 in each region 7 of the substrate 1 before sealing. When the carrier 14 is fixed to the upper mold 18, the LED chip 13 mounted on the pre-sealing substrate 1 and the subcavity 25 provided in the lower mold 17 are aligned.

  Next, a resin material (not shown) is supplied to the cavity 19 including the subcavity 25 shown in FIG. From the viewpoint of form, as the resin material, a solid material such as powder, granule, granule, lump, and sheet, or a liquid resin having fluidity at room temperature can be used. From the viewpoint of characteristics and resin types, a thermosetting resin having translucency, such as an epoxy resin or a silicone resin, can be used as the resin material.

  Next, the resin material is heated by a heater (not shown) provided in the lower mold 17. When a solid material is used as the resin material, as shown in FIGS. 2 (2) and 2 (3), the resin material is melted in the cavity 19 to generate the fluid resin 26. When a liquid resin is used as the resin material, the liquid resin is injected into the cavity 19. In this case, the injected liquid resin itself is the fluid resin 26. As a result, the cavity 19 is filled with the fluid resin 26.

  Next, as shown in FIG. 2 (3), the lower mold 17 and the upper mold 18 are clamped by relatively lowering the lower mold 17 and the upper mold 18. FIG. 2 (3) shows an example in which the upper mold 18 is lowered. In the process of clamping the lower mold 17 and the upper mold 18, the carrier 14 and the peripheral member 21 are brought into contact with each other.

  Next, as shown in FIG. 2 (3) and FIG. 3 (1), the lower mold 17 and the upper mold 18 are completely clamped by continuously lowering the upper mold 18. At this stage, the lower surface of each reflecting member 8 and the lower surface of the carrier 14, the mold surface (upper surface) 22 of the cavity block 20, and the inner surface 23 of the peripheral member 21 shown in FIG. A cavity 19 is formed (see FIG. 2 (2)). By completely clamping the lower mold 17 and the upper mold 18, the fluidity in the cavity 19 (including the sub-cavity 25 (see FIG. 2 (2)) filled with the fluid resin 26. Each LED chip 13 is immersed (immersed) in the resin 26.

  Here, the configuration of a molding die composed of the lower die 17 and the upper die 18 will be described. In at least one of the lower mold 17 and the upper mold 18, a space in which the sub cavities 25 communicate with each other in a state where the lower mold 17 and the upper mold 18 are completely clamped, that is, a communication path 27 (FIG. 3 (1)) is provided. Reference) is intentionally provided. In the present embodiment, a communication passage 27 communicating with the adjacent subcavity 25 is provided in a part of the periphery of each subcavity 25. The height of the communication passage 27 is preferably as small (low) as possible within a range in which the fluid resin 26 can flow between the sub-cavities 25.

  Now, as shown in FIG. 3 (1), in the step of immersing each LED chip 13 in the fluid resin 26, the fluid resin 26 is caused to flow through the communication path 27. Therefore, each subcavity 25 can be filled with the fluid resin 26 uniformly.

  Next, in the state shown in FIG. 3A, the fluid resin 26 is continuously heated. As a result, as shown in FIG. 3A and FIG. 3B, the fluid resin 26 is cured to form a cured resin 28. The cured resin 28 corresponds to a sealing resin for resin-sealing the LED chip 13. Thereby, a sealed substrate (resin sealing body) 29 having the lead frame 2, the reflecting member 8, the LED chip 13, and the cured resin 28 is formed. The sealed substrate 29 is formed in a state where the reflecting member 8 is fitted in the carrier 14 and is fixed to the upper mold 18 in that state. Thereafter, the upper mold 18 is raised to completely open the lower mold (not shown) and the upper mold 18.

  As shown in FIG. 3 (2), the sealed substrate 29 has a convex lens portion 30 and a thin plate-like communication portion 31 each made of a cured resin 28. The lens unit 30 is composed of a cured resin 28 formed in each of the sub cavities 25 (see FIG. 2B). The communication part 31 is comprised by the cured resin 28 formed in the communication path 27 (refer FIG. 3 (1)).

  Next, from the state shown in FIG. 3 (2), the state where the sealed substrate 29 fitted in the carrier 14 is fixed to the upper mold 18 is released. The sealed substrate 29 fitted in the carrier 14 is taken out from the upper mold 18 using an appropriate taking-out means (not shown). As a result, as shown in FIG. 3 (3), a sealed substrate 29 fitted into the carrier 14 is obtained.

  Next, as shown in FIG. 4A, the sealed substrate 29 fitted into the carrier 14 is placed on the fixing jig 32. Thereafter, the sealed substrate 29 is ejected from the carrier 14 by projecting the sealed substrate 29 (specifically, the communicating portion 31 of the sealed substrate 29) using the projecting means 33.

  The protruding means 33 has cylindrical portions 34 respectively corresponding to the lens portions 30 of the sealed substrate 29. The cylindrical portion 34 includes the lens portion 30 in plan view, and has a slightly larger planar dimension than the lens portion 30.

  In the state shown in FIG. 4 (1), the cylindrical portion 34 protrudes the sealed substrate 29, so that the lens portion 30 and the communication portion 31 in the sealed substrate 29 as shown in FIG. The communication part 31 in the vicinity of the lens part 30 is separated. Thereby, the side wall part 35 is formed in the part isolate | separated from the communication part 31 in the lens part 30, or the part which the communication part 31 isolate | separated in the vicinity of the lens part 30.

  Next, as shown in FIGS. 4 (2) and (3), after the sealed substrate 29 having the side wall portion 35 is fixed on a stage (not shown), a predetermined cutting is performed using the rotary blade 36. The sealed substrate 29 is cut along the line 37 (full cut). As a result, the sealed substrate 29 shown in FIG. 4B is separated into LED packages 38. The LED package 38 as a final product includes a substrate portion (not shown) corresponding to a part obtained by dividing the substrate 2 (see FIG. 4A), the reflecting member 8, the LED chip 13, and the lens portion 30. And a side wall portion 35.

FIG. 5A shows a planar positional relationship among the pre-sealing substrate 1, the carrier 14 and the cavity block 20 shown in FIG. In FIG. 5A, the alternate long and short dash line indicates a line constituting the cavity 19 (see FIG. 2B), and the broken line indicates the inner edge of the holding portion 16 of the carrier 14 (see FIG. 2A). FIG. 5B shows a partial planar shape of the sealed substrate 29.
5 (3) and 5 (4) show the LED package 38 after being singulated as a plan view and a front sectional view, respectively. In the present embodiment, in the cavity block 20 of the lower mold 17, a communication passage 27 that connects the sub-cavities 25 adjacent to each other in the X direction and the Y direction is formed. These communication passages 27 have line-shaped planar shapes that respectively follow the X direction and the Y direction.

  In the present application document, the communication passage 27 includes a passage extending further outward from the outermost region 7 of the entire plurality of regions 7 (passage in which no adjacent subcavity 25 exists). For example, the communication passage 27 includes a passage extending further leftward from the region 7 shown on the leftmost side in FIG.

  As described above, according to the present embodiment, by using the carrier 14, the pre-sealing substrate 1 and the sealed substrate 29 are used in each process from the conveyance of the pre-sealing substrate 1 to after the resin sealing. Handling and positioning can be easily performed. Accordingly, the LED package 38 can be manufactured with high productivity by easily handling the pre-sealing substrate 1 and the sealed substrate 29.

  In addition, according to the present embodiment, the communication path 27 for communicating the sub cavities 25 with each other in a state where the lower mold 17 and the upper mold 18 are completely clamped is provided in at least one of the lower mold 17 and the upper mold 18. Intentionally provided. Thereby, in the process of immersing each LED chip 13 in the fluid resin 26, the fluid resin 26 is caused to flow through the communication path 27. Accordingly, each subcavity 25 can be filled with the fluid resin 26 uniformly. As a result, the size and shape of the lens portion 30 and the communication portion 31 formed in each region 7 (see FIG. 3C) can be made closer to each other.

  Further, according to the present embodiment, the height of the communication path 27 is made as small as possible within the range in which the fluid resin 26 can flow between the sub-cavities 25. Thereby, the communication part 31 is formed thinly. Therefore, the sealed substrate 29 can be smoothly protruded from the carrier 14. As a result, the LED package 38 having excellent appearance quality in the inner wall portion 35 can be manufactured.

  In the step of cutting the sealed substrate 29, a laser beam, a wire saw, a band saw, a water jet or the like may be used in addition to the rotary blade 36. In addition to the full cut shown in FIG. 4 (3), an external force is applied to the sealed substrate 29 after forming a groove in the thickness direction at the cutting line 37 of the sealed substrate 29 (after half-cutting). In addition, the sealed substrate 29 can be separated into LED packages 38.

  Hereinafter, a case where the configuration of the region 7 in the X direction × Y direction is 16 × 16 will be described as an example of cutting. In the present embodiment, the LED package 38 including one region 7 has been described. As described in the present embodiment, when a single region 7 is used as a unit, 256 (= 16 × 16) LED packages 38 each having a single region 7 can be manufactured.

  When a plurality of regions 7 composed of a part (a part) of the plurality of regions 7 are divided into units, an LED package constituted by a plurality of regions 7 composed of a part thereof can be manufactured. it can. As an example, when the configuration of the plurality of regions 7 consisting of a part thereof is 4 × 4 (= 16), an LED package comprising the 16 regions 7 and having a matrix-like and planar light source is obtained. Can be manufactured individually. As another example, in the case where the configuration of the plurality of regions 7 made of a part thereof is 1 × 8 (= 8), 32 LED packages each having the light source in a row formed of the eight regions 7 are provided. Can be manufactured.

  As still another example, the sealed substrate 29 may be cut along cutting lines at the outer edges of the plurality of regions 7 having a 16 × 16 configuration, and unnecessary portions located outside the cutting lines may be discarded. it can. In this case, one LED package having 256 (= 16 × 16) regions 7 and having a matrix-like and planar light source can be manufactured. In this case, in the communication passage 27 extending further outward from the outermost region 7 of the entire plurality of regions 7, the rectangular tube-like projecting means 33 having a planar shape including the entire plurality of regions 7 is used. The sealed substrate 29 may be protruded. Thereby, the communication path 27 is separated from the sealed substrate 29, and one LED package having 256 regions 7 and having a matrix-like and planar light source can be manufactured.

  Further, in the present embodiment, in the cavity block 20 of the lower mold 17, the communication passage 27 that communicates between the sub-cavities 25 adjacent to each other has a line-shaped planar shape that follows the X direction and the Y direction, respectively. did. Not only this but the communicating path 27 which connects the subcavities 25 which adjoin diagonally may be formed. Those communication passages 27 have a planar shape of “X” shape. The planar shape of the communication path 27 is a line segment that follows the X direction and the Y direction, or “X”, and the lens portions 30 and the communication portion are partially communicated with each other. 31 can be easily separated.

  Further, the adjacent sub cavities 25 may be communicated with each other in all portions around each sub cavity 25. In this case, the lens units 30 communicate with each other through the communication path 27 in all the portions around the lens units 30. Also in this case, the lens portion 30 and the communication portion 31 can be easily separated by forming the communication passage 27 to be small (low), that is, by forming the communication portion 31 thin.

  In this embodiment, an example in which one LED chip 13 is mounted in one region 7 has been described. The present invention is not limited to this, and the present invention can also be applied to the case where a plurality of LED chips 13 are mounted in one region 7. In the first case, a plurality of LED chips 13 can be mounted on the bottom surface 11 in one recess 10 of one reflecting member 8. As a second case, one LED chip 13 can be mounted on each bottom surface 11 in each of the plurality of recesses 10 included in one reflection member 8. In these two cases, for example, if one LED chip 13 that generates red (R), green (G), and blue (B) light is used as the LED chip 13, one of these three types of light is generated. One LED package 38 that produces synthesized white light can be manufactured.

  A second embodiment of the present invention will be described below with reference to FIG. In the present embodiment, as shown in FIG. 6, the cavity 19 is filled with the fluid resin 26 while the release film 40 is in close contact with the mold surface 39 constituting the entire cavity 19. The mold surface 39 is constituted by the mold surface (upper surface) 22 of the cavity block 20 and the inner surface 23 of the peripheral member 21 shown in FIG.

  On the outer side of the peripheral member 21 on the lower mold 17 side, a film supply means (not shown) including a film feed roll and a film take-up roll is provided. Further, on the outer side of the peripheral member 21 on the lower mold 17 side, a film pressing member 41 that can be moved up and down is provided on the upper side, and a film support member 42 is provided on the lower side so as to face each other. The film support member 42 is supported by an elastic member 43 made of a coil spring or the like. A frame-shaped member 44 is provided outside the film support member 42.

  Seal members 45 and 46 are preferably provided between the upper surface of the frame-shaped member 44 and the lower surface of the film pressing member 41 and between the upper surface of the film pressing member 41 and the lower surface of the upper mold 18. . With these seal members 45 and 46, the cavity 19 can be blocked from the outside of the lower mold 17 and the upper mold 18 in a state where the lower mold 17 and the upper mold 18 are clamped.

  According to the present embodiment, first, as shown in FIG. 6 (1), the release film 40 is clamped by using the film pressing member 41 and the film supporting member 42 by lowering the film pressing member 41 ( Clamp). At this stage, the release film 40 is clamped with a force that allows the release film 40 to slip (slide and move) between the film pressing member 41 and the film support member 42. Thereafter, the release film 40 is adsorbed on the mold surface 39 constituting the cavity 19 by using a film adsorbing means including a suction path (not shown) provided in the lower mold 17. Thereby, the sandwiched release film 40 is appropriately slipped. Therefore, the release film 40 can be brought into close contact with the mold surface 39 without generating a gap or a wrinkle in the release film 40 over the entire surface of the mold surface 39.

  Next, in the same manner as in Example 1, a resin material (not shown) is supplied to the cavity 19 including the subcavity 25. In this embodiment, the resin material is supplied to the cavity 19 in a state where the release film 40 is adsorbed on the mold surface 39 constituting the cavity 19.

  Next, as shown in FIG. 6 (2), the resin material is heated and melted to produce the fluid resin 26. In parallel with this, the following operation is performed. First, the film pressing member 41 is lowered to completely hold the release film 40. Secondly, the upper die 18 is lowered and the upper die 18 and the film pressing member 41 are brought into contact with each other through the seal member 46. Thus, the lower die 17 and the upper die 18 are clamped in the middle.

  At this point, the following state is realized. First, the cavity 19 (see FIG. 6 (1)) is blocked from the outside. Second, the cavity 19 is filled with the flowable resin 26. Third, wrinkles occur in the release film 40 in the vicinity of the outer edge portion 47 of the cavity 19, in other words, in a portion corresponding to the outside of the plurality of regions 7 shown in FIG.

  Next, the upper die 18 is further lowered from the state shown in FIG. 6B, and the lower die 17 and the upper die 18 are completely clamped. Thus, the LED chip 13 is immersed (immersed) in the fluid resin 26 in the cavity 19 filled with the fluid resin 26. Thereafter, the sealed substrate 29 is formed by curing the fluid resin 26 in the same manner as in the first embodiment (see FIGS. 3A and 3B).

  According to the present embodiment, first, as shown in FIG. 6B, there is a release film 40 in close contact with the mold surface 39 on the lower mold 17 side. Thereby, since the mold surface 39 and the cured resin 28 are not in direct contact, the sealed substrate 29 fitted in the carrier 14 can be easily pulled away from the release film 40. Accordingly, even when the lead frame shown in FIG. 1 (2) is thin, the sealed substrate 29 can be easily taken out from the lower mold 17 without generating a large stress in the sealed substrate 29 ( (See FIGS. 3 (1) and (2)).

  Second, in a state where the lower mold 17 and the upper mold 18 are completely clamped, wrinkles of the release film 40 are generated outside the plurality of regions 7 shown in FIG. Thus, wrinkles generated in the release film 40 can be prevented from adversely affecting the surface shape of the LED package 38.

  According to the present embodiment, the quality of the LED package (including appearance quality, the same applies hereinafter) can be improved based on the above two reasons. Moreover, the yield (non-defective product rate) at the time of manufacturing an LED package can be improved.

  In the state where the lower mold 17 and the upper mold 18 are clamped in the middle, it is preferable to decompress the cavity 19 using a suction path (not shown) provided in the upper mold 18. As a result, first, dust, gas components and the like existing in the cavity 19 are discharged to the outside of the cavity 19. Second, a gas component contained in the fluid resin 26 and having a possibility of causing bubbles in the LED package is discharged to the outside of the cavity 19. Therefore, the quality of the LED package can be improved, and the yield (non-defective product rate) when manufacturing the LED package can be improved.

  Embodiment 3 of the present invention will be described below with reference to FIG. In the present embodiment, as shown in FIG. 7 (1), the following components are added to the configuration of the second embodiment. The first component is an individual pressing member 50 supported by an elastic member 49 made of a coil spring or the like in a recess 48 provided in the upper mold 18. Each individual pressing member 50 individually presses each reflecting member 8 included in the pre-sealing substrate 1 in a state where the pre-sealing substrate 1 is fixed to the upper mold 18. The second component is formed of a coil spring or the like in a recess 51 provided in the vicinity of the outer edge of the cavity block 20, in other words, in a portion corresponding to the outside of the plurality of regions 7 shown in FIG. The movable member 53 is supported by the elastic member 52.

  As shown in FIG. 7B, each individual pressing member 50 presses each reflecting member 8 individually. As a result, even when each reflecting member 8 has a variation in thickness, the upper surface 9 (the lower surface of each reflecting member 8 in the figure) of each reflecting member 8 is evenly held by the pressing portion 16 of the carrier 14. Can be pressed against.

  As shown in FIG. 7 (2), the movable member 53 is lowered by being pressed by the fluid resin 26. Accordingly, when surplus occurs in the fluid resin 26, the movable member 53 pressed by the fluid resin 26 is lowered. Therefore, the resin reservoir 54 that accommodates the surplus of the fluid resin 26 is formed.

  According to the present embodiment, even when each reflecting member 8 has a variation in thickness, the upper surface 9 of each reflecting member 8 can be pressed evenly against the pressing portion 16 of the carrier 14. Further, even when the amount of the supplied resin material varies, the surplus of the fluid resin 26 can be accommodated in the formed resin reservoir 54. By these things, the dimension and shape of the lens part 30 and the communication part 31 which are formed in each area | region 7 shown by FIG. 3 (3) can be closely approached.

  In each of the embodiments so far, the case where the lead frame 2 is used as the substrate body has been described. As the substrate body, it is possible to use a printed circuit board based on a laminated material such as glass epoxy, a ceramic material, or a metal material. Moreover, the flexible printed circuit board which uses a resin film as a base material can also be used. Furthermore, the planar shape of the substrate body is not limited to a quadrilateral, and may be a substantially circular shape (the same shape as a semiconductor wafer).

  Moreover, in each Example so far, the LED chip 13 was illustrated and demonstrated as the optical element with which the board | substrate 1 before sealing was mounted | worn, and the LED package 38 was each illustrated as an optoelectronic component manufactured. The present invention is not limited to this, and the present invention may be applied using a combination of a light emitting element and a light receiving element as an optical element mounted on the substrate 1 before sealing. In this case, a light receiving / emitting element can be manufactured as an optoelectronic component. Further, the present invention may be applied using a laser diode chip as an optical element mounted on the substrate 1 before sealing. In this case, a laser diode package can be manufactured as an optoelectronic component.

  Moreover, in each Example so far, as shown to FIG. 1 (1), the several area | region 7 partitioned off by the virtual line 6 at the grid | lattice form was provided in the lead frame 2. As shown in FIG. However, the present invention is not limited to this, and a plurality of regions can be provided in the lead frame in a manner other than the lattice shape. For example, a plurality of regions may be provided in a honeycomb shape (honeycomb shape) in plan view in the lead frame. In the case where the lead frame is provided with a plurality of regions other than the lattice shape, a laser beam, a wire saw, a band saw, a water jet, or the like can be used in the step of cutting the sealed substrate.

  In addition, the present invention is not limited to the above-described embodiments, and may be arbitrarily combined, changed, or selected as necessary without departing from the spirit of the present invention. It can be done.

1 Board before sealing 2 Lead frame (board body)
3 Outer frame 4, 5 Connecting portion 6 Virtual line 7 Area 8 Reflecting member 9 Upper surface 10 Recessed portion 11 Bottom surface 12 Slope 13 LED chip (optical element)
14 Carrier (temporary fixing jig)
DESCRIPTION OF SYMBOLS 15 Opening 16 Holding part 17 Lower mold | type 18 Upper mold | type 19 Cavity 20 Cavity block 21 Peripheral member 22 Mold surface 23 Inner side surface 24, 43, 49, 52 Elastic member 25 Subcavity 26 Flowable resin 27 Communication path 28 Curing resin (sealing) resin)
DESCRIPTION OF SYMBOLS 29 Sealed board | substrate 30 Lens part 31 Communication part 32 Fixing jig 33 Ejecting means 34 Cylindrical part 35 Side wall part 36 Rotary blade 37 Cutting line 38 LED package 39 Mold surface 40 Release film 41 Film pressing member 42 Film support member 44 Frame Shaped members 45, 46 Seal member 47 Outer edge portion 48 Recessed portion 50 Individual pressing member 51 Recessed portion 53 Movable member 54 Resin pool

Claims (19)

Using at least an upper mold and a lower mold facing the upper mold and having a cavity, a substrate body having a plurality of regions, a reflecting member formed in each of the plurality of regions and having a through hole or a recess, and the through After forming a sealed substrate having one or a plurality of optical elements respectively mounted on the substrate main body or the bottom surface of the recess in the hole and a sealing resin made of a cured resin and sealing the optical element, the sealing An optoelectronic component manufacturing method for manufacturing an optoelectronic component from a stopped substrate,
Preparing a temporary fixing jig having an opening corresponding to each of the reflecting members;
Preparing a pre-sealing substrate provided with the reflecting member and the optical element on the substrate body;
A step of fitting the pre-sealing substrate into the temporary fixing jig so as to fit the reflective member into the opening;
The temporary fixing jig in which the pre-sealing substrate is fitted so that the openings overlap each other in a plan view included in a plurality of subcavities provided in the cavity and corresponding to the openings, respectively. Fixing to the upper mold;
A step of filling the cavity with a resin material;
Immersing the optical element in a fluid resin formed from the resin material by clamping the upper mold and the lower mold; and
Forming the cured resin by curing the flowable resin;
Opening the upper mold and the lower mold; and
Removing the temporary fixing jig fitted with the sealed substrate from the upper mold;
A step of taking out the sealed substrate from the temporary fixing jig in which the sealed substrate is fitted,
In the step of forming the curable resin, each of the plurality of sub-cavities forms a lens portion, and a communication portion is formed in a communication path that communicates between the plurality of sub-cavities.
In the step of taking out the sealed substrate, the first optoelectronic component having a plurality of the lens portions is manufactured by protruding the sealed substrate and separating the communication portion from the sealed substrate. A method for manufacturing an optoelectronic component. In the manufacturing method of the optoelectronic component described in Claim 1,
After the step of taking out the sealed substrate, the method includes a step of separating the first optoelectronic component to form a second optoelectronic component corresponding to each of the plurality of regions including a part of the plurality of regions. A method for manufacturing an optoelectronic component. In the manufacturing method of the optoelectronic component described in Claim 1,
After the step of taking out the sealed substrate, the method includes a step of forming a third optoelectronic component corresponding to each of the regions included in the plurality of regions by separating the first optoelectronic component. A method for manufacturing an optoelectronic component. In the manufacturing method of the optoelectronic component in any one of Claims 1-3,
In the step of immersing the optical element, the flowable resin is caused to flow between the plurality of sub-cavities via the communication path provided over the entire circumference of the sub-cavity. . In the manufacturing method of the optoelectronic component in any one of Claims 1-3,
In the step of immersing the optical element, the flowable resin is caused to flow between the plurality of sub-cavities via the communication path partially provided around the sub-cavity. Production method. In the manufacturing method of the optoelectronic component in any one of Claims 1-3,
Before the step of filling the cavity, a step of supplying a release film between the upper die and the lower die, and at least the entire region of the mold surface constituting the cavity And a step of bringing the release film into close contact with a corresponding mold surface. In the manufacturing method of the optoelectronic component in any one of Claims 1-3,
Individual pressing members elastically supported in the upper mold are provided corresponding to the reflecting members, respectively.
In the step of fixing the temporary fixing jig to the upper mold, the reflecting member is pressed by the individual pressing member, respectively. In the manufacturing method of the optoelectronic component in any one of Claims 1-3,
A movable member elastically supported outside the portion corresponding to at least the entire plurality of regions of the mold surface constituting the cavity is provided,
In the step of immersing the optical element in the flowable resin, the flowable resin presses the movable member to form a resin reservoir into which the flowable resin flows. An upper mold and a lower mold facing the upper mold and having a cavity; a substrate body having a plurality of regions; a reflecting member formed in each of the plurality of regions and having a through hole or a recess; The sealing is performed after forming a sealed substrate having one or a plurality of optical elements respectively mounted on the substrate body or the bottom surface of the recess in the through hole, and a sealing resin made of a cured resin and sealing the optical element. An optoelectronic component manufacturing apparatus used when manufacturing an optoelectronic component from a stopped substrate,
Receiving means for receiving a pre-sealing substrate in which the reflecting member and the optical element are provided on the substrate body;
A temporary fixing jig having openings provided so as to correspond to the reflecting members of the substrate before sealing,
Fixing means for fixing the temporary fixing jig to the upper mold in a state where the reflecting member is fitted in the opening;
Supply means for supplying a resin material to the cavity including the reflection member in the pre-sealing substrate in plan view;
Mold opening and closing means for opening or clamping the upper mold and the lower mold;
Protruding means for projecting the sealed substrate from the temporary fixing jig,
The cavity has a subcavity formed of a recess provided corresponding to each of the reflecting members, and a communication path communicating the subcavities with each other,
An apparatus for manufacturing an optoelectronic component, wherein the protruding means separates the communicating portion made of the cured resin in the communication path from the sealed substrate by protruding the sealed substrate from the temporary fixing jig. The optoelectronic component manufacturing apparatus according to claim 9,
The apparatus for manufacturing an optoelectronic component, wherein the communication path is formed over the entire circumference of the sub-cavity. The optoelectronic component manufacturing apparatus according to claim 9,
An apparatus for manufacturing an optoelectronic component, wherein the communication path is partially formed around the subcavity. In the optoelectronic component manufacturing apparatus according to any one of claims 9 to 11,
Film supply means for supplying a release film between the upper mold and the lower mold;
An apparatus for manufacturing an optoelectronic component, comprising: a film contact means for bringing the release film into close contact with a mold surface corresponding to at least the whole of the mold surfaces constituting the cavity. In the optoelectronic component manufacturing apparatus according to any one of claims 9 to 11,
In the upper mold, each pressing member provided elastically corresponding to each of the reflecting members,
An apparatus for manufacturing an optoelectronic component, wherein the reflecting member is pressed by the individual pressing member in a state where the temporary fixing jig is fixed to the upper mold. In the optoelectronic component manufacturing apparatus according to any one of claims 9 to 11,
A movable member elastically supported outside the portion corresponding to the whole of the plurality of regions of the mold surface constituting the cavity;
In the state where the upper mold and the lower mold are clamped, a resin reservoir into which the fluid resin flows is formed by the fluid resin pressing the movable member. apparatus. A substrate body having a plurality of regions; a reflecting member formed in each of the plurality of regions and having a through hole or a recess; and one or a plurality of optical elements respectively mounted on the substrate body or the bottom surface of the recess in the through hole. An optoelectronic component manufactured from the sealed substrate after forming a sealed substrate made of a cured resin and having a sealing resin for sealing the optical element,
The temporary fixing jig is immersed in a fluid resin on the side where the optical element is exposed in a state where the reflective member is fitted in an opening provided in the temporary fixing jig so as to correspond to each of the reflective members. A lens part made of a cured resin formed by curing the flowable resin introduced so as to fill at least the through hole or the recess,
Formed separately from the communicating part around the lens part by pressing the communicating part made of the cured resin and communicating between the lens parts by protruding the sealed substrate from the temporary fixing jig. An optoelectronic component comprising: a side wall portion or a side wall portion formed by separating the communication portion. The optoelectronic component according to claim 15, wherein
2. The optoelectronic component according to claim 1, wherein the communication portion is formed over the entire circumference of the lens portion. The optoelectronic component according to claim 15, wherein
2. The optoelectronic component according to claim 1, wherein the communication part is partially formed around the lens part. The optoelectronic component according to claim 15, wherein
An optoelectronic component corresponding to each of the plurality of regions formed of a part of the plurality of regions. The optoelectronic component according to claim 15, wherein
An optoelectronic component corresponding to each of the regions included in the plurality of regions.

Images