JP6056934B2 - Light emitting device, resin package, resin molded body, and manufacturing method thereof - Google Patents

Description

  The present invention relates to a light emitting device used for a lighting fixture, a display, a backlight of a mobile phone, a moving image illumination auxiliary light source, and other general consumer light sources, a method for manufacturing the light emitting device, and the like.

  A light-emitting device using a light-emitting element emits light with a small color, high power efficiency, and vivid colors. In addition, since this light emitting element is a semiconductor element, there is no fear of a broken ball. Further, it has excellent initial driving characteristics and is strong against vibration and repeated on / off lighting. Because of such excellent characteristics, light-emitting devices using light-emitting elements such as light-emitting diodes (LEDs) and laser diodes (LDs) are used as various light sources.

  FIG. 14 is a perspective view showing a conventional method for manufacturing a light emitting device. FIG. 15 is a perspective view showing an intermediate body of a conventional light emitting device. FIG. 16 is a perspective view showing a conventional light emitting device.

  Conventionally, as a method of manufacturing a light emitting device, a lead frame is insert-molded with a non-translucent and light-reflective white resin, and a resin molded body having concave-shaped cups is formed at predetermined intervals through the lead frame. Is disclosed (for example, see Patent Document 1). Here, although the material of the white resin is not specified, a general thermoplastic resin is used from insert molding or drawing. As a general thermoplastic resin, for example, a thermoplastic resin such as a liquid crystal polymer, PPS (polyphenylene sulfide), and nylon is often used as a light-shielding resin molded body (see, for example, Patent Document 2).

  However, the thermoplastic resin has poor adhesion to the lead frame, and the resin part and the lead frame are likely to be peeled off. Moreover, since the thermosetting resin has low fluidity of the resin, it is inappropriate for molding a resin molded body having a complicated shape and has poor light resistance. In particular, the output of light emitting elements has been remarkably improved in recent years, and as the output of light emitting elements is increased, the light deterioration of packages made of thermoplastic resins has become remarkable.

  In order to solve these problems, a light-emitting device using a thermosetting resin as a material of a resin molded body is disclosed (for example, see Patent Document 3). FIG. 17 is a perspective view and a cross-sectional view showing a conventional light emitting device. FIG. 18 is a schematic cross-sectional view showing a conventional method for manufacturing a light emitting device. In this light emitting device, metal wiring is formed from a metal foil by a known method such as punching or etching, then the metal wiring is placed in a mold having a predetermined shape, and a thermosetting resin is injected from a resin injection port of the mold. However, transfer molding is disclosed.

  However, it is difficult for this manufacturing method to manufacture a large number of light emitting devices in a short time. Moreover, there is a problem that a large amount of the resin in the runner portion is discarded for one light emitting device.

  As a different light-emitting device and a manufacturing method thereof, a package substrate for mounting an optical semiconductor element having a light-reflective thermosetting resin composition layer on a wiring substrate and a manufacturing method thereof are disclosed (for example, see Patent Document 4). FIG. 19 is a schematic view showing a manufacturing process of a conventional light emitting device. This package substrate for mounting an optical semiconductor element has a plurality of concave portions, in which a flat printed wiring board is attached to a mold, a thermosetting resin composition for light reflection is injected, and heat-press molding is performed by a transfer molding machine. A matrix-shaped package substrate for mounting an optical semiconductor element is manufactured. It also describes that a lead frame is used instead of the printed wiring board.

  However, these wiring boards and lead frames have a flat plate shape, and the thermosetting resin composition is arranged on the flat plate shape, and since the adhesion area is small, the lead frame and the thermosetting resin are used when dicing. There exists a problem that it is easy to peel from a composition.

JP 2007-35794 A (particularly [0033]) Japanese Patent Laid-Open No. 11-0877780 JP 2006-140207 A (particularly [0028]) JP 2007-235085 A

  The present invention has been made in view of the above-described problems, and an object thereof is to provide a simple and inexpensive method for producing a large number of light emitting devices in a short time with high adhesion between a lead frame and a thermosetting resin composition. .

  Thus, as a result of intensive studies, the present invention has been completed.

  In this specification, the term “lead”, “resin part”, and “resin package” are used for the light emitting device after being singulated, and the terms “lead frame” and “resin molded body” are used before the singulation.

  The present invention provides a method for manufacturing a light emitting device having a resin package having a light reflectivity at a wavelength of 350 nm to 800 nm of 70% or more after thermosetting and having a resin portion and a lead formed on substantially the same surface on the outer surface. The step of sandwiching the lead frame provided with the notch between the upper mold and the lower mold, and the mold sandwiched between the upper mold and the lower mold contain a light reflective substance. A method of manufacturing a light emitting device, comprising: forming a resin molded body on a lead frame by transfer molding a thermosetting resin to be cut; and cutting the resin molded body and the lead frame along a notch About. According to this configuration, since the thermosetting resin is filled in the notch, the adhesion area between the lead frame and the thermosetting resin is increased, and the adhesion between the lead frame and the thermosetting resin is improved. Can do. Further, since a thermosetting resin having a viscosity lower than that of the thermoplastic resin is used, the notched portion can be filled with the thermosetting resin without leaving a void. In addition, a large number of light emitting devices can be obtained at a time, and the production efficiency can be greatly improved. Further, the number of runners discarded can be reduced, and an inexpensive light emitting device can be provided.

  It is preferable that the lead frame is plated before being sandwiched between the upper mold and the lower mold. At this time, in the manufactured light emitting device, the cut surface is not plated, and the other portions are plated. It is not necessary to perform plating treatment for each light emitting device separated into pieces, and the manufacturing method can be simplified.

  In the lead frame, it is preferable that the cutout portion in the cut portion is about ½ or more of the entire surrounding circumference. Thereby, a lead frame can be reduced in weight and an inexpensive light-emitting device can be provided. Moreover, the part to be cut in the lead frame is reduced, and the peeling between the lead frame and the thermosetting resin can be further suppressed.

  The difference is that the notched portion is filled with a thermosetting resin, whereas a hole described later is not filled with a thermosetting resin. The notch and the hole penetrate the lead frame, whereas the groove described later does not penetrate the lead frame.

  The lead frame before being sandwiched between the upper mold and the lower mold is preferably provided with a hole. Thereby, a lead frame can be reduced in weight and an inexpensive light-emitting device can be provided. Since the hole portion can be plated, exposure of the lead frame can be suppressed.

  The lead frame before being sandwiched between the upper mold and the lower mold is preferably provided with a groove. Thereby, a lead frame can be reduced in weight and an inexpensive light-emitting device can be provided. Since the groove can be plated, exposure of the lead frame can be suppressed.

  It is preferable that the upper die and the lower die sandwich the lead frame in the portion where the light emitting element is placed or in the vicinity of the hole. As a result, flapping of the lead frame can be prevented and the occurrence of burrs can be reduced.

  The present invention is a light-emitting device having a resin package having a light reflectance at a wavelength of 350 nm to 800 nm of 70% or more after thermosetting and having a resin portion and a lead formed on substantially the same surface on the outer surface. The lead relates to a light emitting device in which at least one of the bottom surface and the top surface is plated, and the outer surface has a portion not plated. As a result, exposure of leads that are not plated can be prevented, and a large number of light emitting devices can be obtained at one time. Moreover, the light extraction efficiency from the light emitting device can be improved by plating only the portion that reflects the light from the light emitting element.

  The resin package preferably has the leads exposed from the four corners. Since the exposed portion of the lead can be reduced rather than providing the lead on the entire side surface of the resin package, the adhesion between the resin portion and the lead can be improved. Further, since an insulating resin portion is provided between the positive and negative leads, a short circuit can be prevented.

  It is preferable that the resin package is formed in an arc shape as viewed from the bottom surface side. A portion formed in an arc shape is subjected to a plating process, and a configuration in which a plating process is not performed on the cut surface may be employed. As a result, the bonding area with the solder or the like is expanded, and the bonding strength can be improved.

  The lead is preferably provided with a step. This step is preferably provided on the bottom surface of the resin package. The portion where the step is formed is plated, and the cut surface can be configured not to be plated. As a result, the bonding area with the solder or the like is expanded, and the bonding strength can be improved.

The present invention is a method for producing a resin package having a light reflectance at a wavelength of 350 nm to 800 nm after thermosetting of 70% or more, and a resin portion and a lead formed on substantially the same surface on the outer surface, A process of sandwiching a lead frame provided with a notch between an upper mold and a lower mold, and a thermosetting containing a light-reflective substance in the mold sandwiched between the upper mold and the lower mold The present invention relates to a method for manufacturing a resin package, which includes a step of forming a resin molded body on a lead frame by transfer molding a resin, and a step of cutting the resin molded body and the lead frame along a notch. According to this configuration, since the thermosetting resin is filled in the notch, the adhesion area between the lead frame and the thermosetting resin is increased, and the adhesion between the lead frame and the thermosetting resin is improved. Can do. Further, since a thermosetting resin having a viscosity lower than that of the thermoplastic resin is used, the notched portion can be filled with the thermosetting resin without leaving a void. In addition, a large number of resin packages can be obtained at one time, and the production efficiency can be greatly improved. Furthermore, runners discarded can be reduced, and an inexpensive resin package can be provided.

  It is preferable that the lead frame is plated before being sandwiched between the upper mold and the lower mold. At this time, the manufactured resin package is not subjected to the plating process on the cut surface, and the other part is subjected to the plating process. There is no need to perform plating for each individual resin package, and the manufacturing method can be simplified.

  The present invention is a resin package in which the light reflectance at a wavelength of 350 nm to 800 nm after thermosetting is 70% or more, and the resin portion and the lead are formed on substantially the same surface on the outer surface, and the lead is a bottom surface. Further, the present invention relates to a resin package in which at least one of the upper surface and the upper surface is plated, and the outer surface has a portion that is not plated. As a result, it is possible to prevent exposure of leads that are not plated, and to obtain a large number of resin packages at a time. Moreover, the light extraction efficiency from the light emitting device can be improved by plating only the portion that reflects the light from the light emitting element.

The present invention is a resin molding in which the light reflectivity at a wavelength of 350 nm to 800 nm after thermosetting is 70% or more, a plurality of recesses are formed, and a part of the lead frame is exposed on the inner bottom surface of the recesses A method of manufacturing a body, wherein a lead frame having a notch is used, and the lead frame is sandwiched between an upper mold and a lower mold having convex portions at positions where adjacent concave portions are molded in the resin molded body In the mold sandwiched between the upper mold and the lower mold, transfer-molding a thermosetting resin containing a light-reflective material, and filling the notch portion with the thermosetting resin, And forming a resin molded body on a lead frame. According to such a configuration, a large number of light emitting devices can be obtained at one time, and the production efficiency can be greatly improved.

  The present invention is a resin molding in which the light reflectivity at a wavelength of 350 nm to 800 nm after thermosetting is 70% or more, a plurality of recesses are formed, and a part of the lead frame is exposed on the inner bottom surface of the recesses The lead frame has a notch, and the notch is filled with a thermosetting resin to be a resin molded body, and has a side wall between adjacent recesses. It relates to a molded body. Thereby, the resin molding excellent in heat resistance and light resistance can be provided.

  According to the light emitting device and the manufacturing method thereof according to the present invention, it is possible to provide a light emitting device with high adhesion between the lead frame and the resin molded body. In addition, a large number of light emitting devices can be obtained in a short time, and the production efficiency can be greatly improved. Further, the number of runners discarded can be reduced, and an inexpensive light emitting device can be provided.

  DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method for manufacturing a light emitting device and a best embodiment of the light emitting device according to the present invention will be described in detail with reference to the drawings. However, the present invention is not limited to this embodiment.

<First Embodiment>
(Light emitting device)
The light emitting device according to the first embodiment will be described. FIG. 1 is a perspective view showing the light emitting device according to the first embodiment. FIG. 2 is a cross-sectional view showing the light emitting device according to the first embodiment. 2 is a cross-sectional view taken along the line II-II shown in FIG. FIG. 3 is a plan view showing the lead frame used in the first embodiment.

  The light emitting device 100 according to the first embodiment has a light reflectance of 70% or more at a wavelength of 350 nm to 800 nm after thermosetting, and the resin portion 25 and the lead 22 are formed on substantially the same surface on the outer surface 20b. A resin package 20 is provided. The lead 22 is plated on at least one of the bottom surface (the outer bottom surface 20a of the resin package 20) and the top surface (the inner bottom surface 27a of the recess 27). On the other hand, the side surface of the lead 22 (the outer surface 20b of the resin package 20) is not plated. On the outer side surface 20b of the resin package 20, the resin portion 25 occupies a large area, and the leads 22 are exposed from the corners.

The resin package 20 mainly includes a resin portion 25 containing a light reflective material 26 and leads 22. The resin package 20 has an outer bottom surface 20a on which the leads 22 are arranged, an outer side surface 20b from which a part of the leads 22 is exposed, and an outer upper surface 20c that forms a recess 27 that opens. The resin package 20 has a recess 27 having an inner bottom surface 27a and an inner surface 27b. The lead 22 is exposed on the inner bottom surface 27 a of the resin package 20, and the light emitting element 10 is placed on the lead 22. A sealing member 30 that covers the light emitting element 10 is disposed in the recess 27 of the resin package 20. The sealing member 30 contains a fluorescent material 40. The light emitting element 10 is electrically connected to the lead 20 via the wire 50. Leads 20 are not arranged on the outer upper surface 20 c of the resin package 20.

  In the entire envelopment length of the outer side surface 20b of the resin package 20, the portion where the lead 22 is exposed is shorter than ½. In a method for manufacturing a light emitting device to be described later, a notch 21 a is provided in the lead frame 21 and the cut portion of the lead frame 21 is exposed from the resin package 20 because the notch 21 a is cut along the notch 21 a.

  In the resin package 20, the leads 22 are exposed from the four corners. The lead 22 is exposed on the outer side surface 20b and is not subjected to plating. Further, the lead 22 can have a structure exposed to the outer bottom surface 20a, and can be plated. Note that the outer surface 20b of the lead 22 can be plated after being separated into individual pieces.

  The light emitting device 100 has a light reflectance of 70% or more at a wavelength of 350 nm to 800 nm after thermosetting. This mainly indicates that the light reflectance in the visible light region is high. The light emitting element 10 preferably has an emission peak wavelength of 360 nm to 520 nm, but a light emitting element of 350 nm to 800 nm can also be used. In particular, the light emitting element 10 preferably has an emission peak wavelength in a short wavelength region of visible light of 420 nm to 480 nm. This resin package 20 has excellent light resistance to light on the short wavelength side of 480 nm or less and is not easily deteriorated. The resin package 20 is excellent in heat resistance because it hardly deteriorates even when the light emitting element 10 generates heat by supplying current.

  The resin package 20 is preferably made of a light-transmitting thermosetting resin that is highly filled with a light reflective material. For example, a thermosetting resin having a light transmittance of 80% or more at 350 nm to 800 nm is preferably used, and a thermosetting resin having a light transmittance of 90% or more is particularly preferable. This is because the deterioration of the resin package 20 can be suppressed by reducing the light absorbed by the thermosetting resin. The light reflecting material 26 preferably reflects 90% or more of light from the light emitting element 10, and particularly preferably reflects 95% or more. The light reflective material 26 preferably reflects 90% or more of the light from the fluorescent material 40, and particularly preferably reflects 95% or more. The light extraction efficiency from the light emitting device 100 can be improved by reducing the amount of light absorbed by the light reflective material 26.

  The shape of the light emitting device 100 is not particularly limited, but may be a polygonal shape such as a substantially rectangular parallelepiped, a substantially cube, or a substantially hexagonal column. The recess 27 preferably extends in the opening direction, but may be cylindrical. The shape of the recess 27 can be a substantially circular shape, a substantially elliptical shape, a substantially polygonal shape, or the like.

Hereinafter, each member will be described in detail.
(Light emitting element)
As the light emitting element, a substrate in which a semiconductor such as GaAlN, ZnS, SnSe, SiC, GaP, GaAlAs, AlN, InN, AlInGaP, InGaN, GaN, and AlInGaN is formed as a light emitting layer is preferably used. It is not limited. Those having an emission peak wavelength of 360 nm to 520 nm are preferred, but those having a wavelength of 350 nm to 800 nm can also be used. In particular, the light emitting element 10 preferably has an emission peak wavelength in a short wavelength region of visible light of 420 nm to 480 nm.

As the light emitting element, a face-up structure can be used, and a face-down structure can also be used. The size of the light emitting element is not particularly limited, and those having □ 350 μm, □ 500 μm, □ 1 mm, and the like can be used. A plurality of light emitting elements can be used, all of which may be of the same type, or of different types exhibiting red, green, and blue light emission colors that are the three primary colors of light.
(Resin package)
The resin package has a resin portion made of a thermosetting resin and leads, and is integrally molded. The resin package has a light reflectance at 350 nm to 800 nm of 70% or more, and a light reflectance of 420 nm to 520 nm is particularly preferably 80% or more. In addition, it is preferable that the light emitting region of the light emitting element and the light emitting region of the fluorescent material have high reflectance.

  The resin package has an outer bottom surface, an outer surface, and an outer upper surface. Leads are exposed from the outer surface of the resin package. The resin portion and the lead are formed on substantially the same surface. This substantially the same surface means that it was formed in the same cutting step.

  The outer shape of the resin package is not limited to a substantially rectangular parallelepiped, and may be a substantially cube, a substantially hexagonal column, or another polygonal shape. Further, when viewed from the outer upper surface side, shapes such as a substantially triangular shape, a substantially rectangular shape, a substantially pentagonal shape, and a substantially hexagonal shape can be employed.

  The resin package has a recess having an inner bottom surface and an inner surface. A lead is disposed on the inner bottom surface of the recess. The concave portion can take various shapes such as a substantially circular shape, a substantially elliptical shape, a substantially rectangular shape, a substantially polygonal shape, and a combination thereof, as viewed from the outer upper surface side. The recess preferably has a shape that expands in the opening direction, but may have a cylindrical shape. The concave portion may be provided with a smooth slope, but it may be provided with fine irregularities on the surface to scatter light.

The leads are provided at a predetermined interval so as to form a pair of positive and negative. The lead on the inner surface of the recess and the lead on the outer bottom surface of the resin package are plated. Although this plating process can be performed before cutting out the resin molded body, it is preferable to use a lead frame that has been previously plated. On the other hand, the side surface of the lead is not plated.
(Resin part, resin molding)
It is preferable to use a triazine derivative epoxy resin which is a thermosetting resin as the material of the resin part and the resin molded body. The thermosetting resin can contain an acid anhydride, an antioxidant, a release material, a light reflecting member, an inorganic filler, a curing catalyst, a light stabilizer, and a lubricant. The light reflecting member is made of titanium dioxide and filled with 10 to 60 wt%.

The resin package is not limited to the above-described form, and is formed of at least one selected from the group consisting of epoxy resins, modified epoxy resins, silicone resins, modified silicone resins, acrylate resins, and urethane resins among thermosetting resins. It is preferable. Particularly preferred are epoxy resins, modified epoxy resins, silicone resins, and modified silicone resins. For example, an epoxy resin composed of triglycidyl isocyanurate, hydrogenated bisphenol A diglycidyl ether, etc., and an acid anhydride composed of hexahydrophthalic anhydride, 3-methylhexahydrophthalic anhydride, 4-methylhexahydrophthalic anhydride, etc. To 100 parts by weight of a colorless and transparent mixture obtained by dissolving and mixing with an epoxy resin in an equivalent amount, 0.5 parts by weight of DBU (1,8-Diazabicyclo (5,4,0) undecene-7) as a curing accelerator, It is possible to use a solid epoxy resin composition in which 1 part by weight of ethylene glycol, 10 parts by weight of titanium oxide pigment and 50 parts by weight of glass fiber are added as co-catalysts and B-staged by partial curing reaction by heating. it can.
(Lead, lead frame)
A flat metal plate can be used for the lead frame, but a metal plate provided with steps or irregularities can also be used.

  The lead frame is obtained by punching or etching a flat metal plate. The etched lead frame has irregularities in the cross-sectional shape, and can improve the adhesion to the resin molded body. In particular, when a thin lead frame is used, in order to improve the adhesion between the lead frame and the resin molded body in the punching process, a step or uneven shape is formed. Is small. However, in the etching process, it is possible to form a concavo-convex shape on the entire cross section (etched portion) of the lead frame, so that the bonding area between the lead frame and the resin molded body can be increased, and a resin package with higher adhesion can be obtained. Can be molded.

  On the other hand, in the processing method of punching a flat metal plate, the cost of replacement parts is increased due to wear of the die accompanying the punching, and the manufacturing cost of the lead frame is increased. On the other hand, in the etching process, a punching die is not used, and when the number of packages taken per frame is large, the lead frame manufacturing cost per package can be reduced.

  The etching process may be performed so as to penetrate the lead frame, or may be performed from only one side so as not to penetrate.

  The notch is formed so that the leads are a pair of positive and negative when the resin molded body is separated into a resin package. Further, the notch is formed so as to reduce the area for cutting the lead when the resin molded body is cut. For example, a notch portion is provided in the lateral direction so as to form a pair of positive and negative leads, and a notch portion is provided at a position corresponding to a cutout portion when the resin molded body is separated into pieces. However, a part of the lead frame is connected in order to prevent a part of the lead frame from dropping or to expose the lead on the outer surface of the resin package. In order to dice the resin molding using a dicing saw, it is preferable that the notch is linearly formed vertically and horizontally or diagonally.

The lead frame is formed using a good electrical conductor such as iron, phosphor bronze, or copper alloy, for example. Further, in order to increase the reflectance of light from the light emitting element, metal plating such as silver, aluminum, copper, and gold can be performed. It is preferable to apply metal plating before sandwiching between the upper die and the lower die, such as after providing a notch or after etching, but before the lead frame is integrally formed with the thermosetting resin. Metal plating can also be applied.
(Sealing member)
The material of the sealing member is a thermosetting resin. Among thermosetting resins, it is preferably formed of at least one selected from the group consisting of epoxy resins, modified epoxy resins, silicone resins, modified silicone resins, acrylate resins, and urethane resins, particularly epoxy resins and modified epoxy resins. Silicone resins and modified silicone resins are preferred. The sealing member is preferably a hard member in order to protect the light emitting element. Moreover, it is preferable to use resin excellent in heat resistance, a weather resistance, and light resistance for a sealing member. The sealing member can be mixed with at least one selected from the group consisting of a filler, a diffusing agent, a pigment, a fluorescent material, and a reflective material in order to have a predetermined function. A diffusing agent may be contained in the sealing member. As a specific diffusing agent, barium titanate, titanium oxide, aluminum oxide, silicon oxide, or the like can be suitably used. Moreover, an organic or inorganic coloring dye or coloring pigment can be contained for the purpose of cutting an undesired wavelength. Furthermore, the sealing member can also contain a fluorescent material that absorbs light from the light emitting element and converts the wavelength.
(Fluorescent substance)
The fluorescent substance may be any substance that absorbs light from the light emitting element and converts the wavelength into light of a different wavelength. For example, nitride phosphors / oxynitride phosphors / sialon phosphors mainly activated by lanthanoid elements such as Eu and Ce, lanthanoid elements such as Eu, and transition metal elements such as Mn. Alkaline earth halogen apatite phosphor, alkaline earth metal borate phosphor, alkaline earth metal aluminate phosphor, alkaline earth silicate, alkaline earth sulfide, alkaline earth thiogallate Organic earth mainly activated by lanthanoid elements such as alkaline earth silicon nitride, germanate or rare earth aluminate, rare earth silicate or Eu mainly activated by lanthanoid elements such as Ce and It is preferably at least one selected from organic complexes and the like. As specific examples, the following phosphors can be used, but are not limited thereto.

Nitride-based phosphors mainly activated with lanthanoid elements such as Eu and Ce are M ₂ Si ₅ N ₈ : Eu, MAlSiN ₃ : Eu (M is selected from Sr, Ca, Ba, Mg, Zn) At least one or more). In addition to M ₂ Si ₅ N ₈ : Eu, MSi ₇ N ₁₀ : Eu, M _1.8 Si ₅ O _0.2 N ₈ : Eu, M _0.9 Si ₇ O _0.1 N ₁₀ : Eu (M Is at least one selected from Sr, Ca, Ba, Mg, and Zn.

An oxynitride phosphor mainly activated by a lanthanoid element such as Eu or Ce is MSi ₂ O ₂ N ₂ : Eu (M is at least one selected from Sr, Ca, Ba, Mg, Zn) Etc.).

Eu, sialon phosphors activated mainly with lanthanoid elements such as Ce _{is, M p / 2 Si 12-} p-q Al p + q O q N 16-p: Ce, M-Al-Si-O-N (M is at least one selected from Sr, Ca, Ba, Mg, and Zn. Q is 0 to 2.5, and p is 1.5 to 3).

Alkaline earth halogen apatite phosphors mainly activated by lanthanoid compounds such as Eu and transition metal elements such as Mn include M ₅ (PO ₄ ) ₃ X: R (M is Sr, Ca, Ba). X is at least one selected from F, Cl, Br and I. R is any one of Eu, Mn, Eu and Mn. Etc.).

The alkaline earth metal borate phosphor has M ₂ B ₅ O ₉ X: R (M is at least one selected from Sr, Ca, Ba, Mg, Zn. X is F, Cl , Br, or I. R is Eu, Mn, or any one of Eu and Mn.).

Alkaline earth metal aluminate phosphors include SrAl ₂ O ₄ : R, Sr ₄ Al ₁₄ O ₂₅ : R, CaAl ₂ O ₄ : R, BaMg ₂ Al ₁₆ O ₂₇ : R, BaMg ₂ Al ₁₆ O ₁₂ : R, BaMgAl ₁₀ O ₁₇ : R (R is Eu, Mn, or any one of Eu and Mn).

Examples of the alkaline earth sulfide phosphor include La ₂ O ₂ S: Eu, Y ₂ O ₂ S: Eu, and Gd ₂ O ₂ S: Eu.

Examples of rare earth aluminate phosphors mainly activated with lanthanoid elements such as Ce include Y ₃ Al ₅ O ₁₂ : Ce, (Y _0.8 Gd _0.2 ) ₃ Al ₅ O ₁₂ : Ce, Y ₃ There are YAG phosphors represented by the composition formula of (Al _0.8 Ga _0.2 ) ₅ O ₁₂ : Ce, (Y, Gd) ₃ (Al, Ga) ₅ O ₁₂ : Ce. Further, there are Tb ₃ Al ₅ O ₁₂ : Ce, Lu ₃ Al ₅ O ₁₂ : Ce, etc. in which a part or all of Y is substituted with Tb, Lu or the like.

Other phosphors include ZnS: Eu, Zn ₂ GeO ₄ : Mn, MGa ₂ S ₄ : Eu (M is at least one selected from Sr, Ca, Ba, Mg and Zn). is there.

  These phosphors can be used alone or in combination of two or more to achieve colors such as blue, green, yellow, and red, as well as their intermediate colors such as blue-green, yellow-green, and orange. it can.

(Other)
In the light emitting device, a Zener diode can be further provided as a protective element. The Zener diode can be placed on the lead on the inner bottom surface of the recess apart from the light emitting element. Further, the Zener diode may be mounted on the lead on the inner bottom surface of the recess, and the light emitting element may be mounted thereon. In addition to the 280 μm size, a □ 300 μm size can also be used.
(Method for Manufacturing Light-Emitting Device According to First Embodiment)
A method for manufacturing the light emitting device according to the first embodiment will be described. FIG. 4 is a schematic cross-sectional view illustrating the method for manufacturing the light emitting device according to the first embodiment. FIG. 5 is a plan view showing the resin molded body according to the first embodiment.

  The manufacturing method of the light emitting device according to the first embodiment includes a step of sandwiching the lead frame 21 provided with the notch 21a between the upper mold 61 and the lower mold 62, and the upper mold 61 and the lower mold 62. A step of forming a resin molded body 24 on the lead frame 21 by transfer-molding a thermosetting resin 23 containing the light-reflective material 26 in a mold 60 sandwiched between And cutting the resin molded body 24 and the lead frame 21 along the line.

  First, a mold 60 composed of an upper mold 61 and a lower mold 62 used for the transfer mold will be described.

  The upper die 61 includes a flat plate main body portion that constitutes an upper portion of the upper die, an outer wall portion formed in a frame shape from an end portion of the main body portion, a plurality of protruding portions protruding from the main body portion, and an outer wall portion And an injection port penetrating a part in the horizontal direction.

  The outer wall portion protrudes perpendicularly from the end portion of the main body portion, and the first outer wall portion, the second outer surface, the third outer surface, and the fourth outer surface of the resin molded body are respectively molded. Two outer wall portions, a third outer wall portion, and a fourth outer wall portion are provided. That is, the outer wall portion is a portion for molding the outline of the resin molded body, and is formed in a rectangular shape in plan view. What is necessary is just to form the shape of an outer wall part suitably according to the shape of a desired resin molding.

  The protruding portion is a portion that comes into contact with the lead frame 21 during transfer molding. By preventing the thermosetting resin 23 from flowing into the contact portion, a part of the lead frame 21 is removed from the resin molded body 24. An exposed portion that is exposed can be formed. The protruding portion protrudes downward from the main body portion and is formed so as to be surrounded by the outer wall. The protruding portion is formed flat at a portion that contacts the lead frame 21. In order to efficiently form recesses per area of the upper surface of the resin molded body 24, protrusions are formed in one direction and at equal intervals, and in each protrusion, protrusions are formed at 90 ° direction and at equal intervals from the one direction. Preferably it is formed.

  The injection port is for injecting the thermosetting resin 23, and is formed in the horizontal direction so as to penetrate the substantially central lower end of the outer wall portion. The injection port has a semicircular cross section, and is formed so that the width becomes narrower from the inlet portion toward the outlet portion of the inlet.

  Although not particularly shown, a pin insertion hole penetrating the main body is formed in the upper part of the upper mold 61. The pin insertion hole is a hole for inserting a pin when the resin molded body 24 is removed from the upper mold 61.

  The lower mold 62 is a plate material having a predetermined thickness and has a flat surface. The lower mold 62 molds the space portion by being brought into contact with the upper mold 61.

  Next, each manufacturing process will be described.

  The lead frame 21 is subjected to a metal plating process after providing the notch 21a.

  First, the lead frame 21 provided with the notch 21 a is sandwiched between the upper mold 61 and the lower mold 62. A space is provided in the mold 60 by being sandwiched between the upper mold 61 and the lower mold 62.

  At this time, it arrange | positions so that the notch part 21a in the position in which the recessed part 27 is formed may be pinched | interposed by the protrusion part which the upper metal mold | die 61 has, and the lower metal mold | die 62. FIG. Thereby, the fluttering of the lead frame 21 in the notch 21a is suppressed, and the generation of burrs can be reduced.

Next, a thermosetting resin 23 containing the light-reflective material 26 is transferred and molded in a mold sandwiched between the upper mold 61 and the lower mold 62, and a resin molded body is formed on the lead frame 21. The thermosetting resin 23 containing the light-reflecting material 26 is injected from the injection port into the space provided in the mold 60 that forms the layer 24, and transfer molding is performed by applying a predetermined temperature and pressure. . Since the upper die 61 and the lower die 62 sandwich the lead frame 21 in the vicinity of the notch 21a, the lead frame 21 does not flutter when the thermosetting resin 23 is transferred and molded. Generation of burrs can be suppressed at the inner bottom surface 27a.

  A pin is inserted into the pin insertion portion, and the resin molded body 24 is removed from the upper mold 61. It is preferable that a predetermined temperature is applied in the mold 60 to perform temporary curing, and then the mold 60 is removed from the mold 60, and then the main curing is performed by applying a temperature higher than the temporary curing.

  Next, the light emitting element 10 is placed on the lead frame 21 on the inner bottom surface 27 a of the recess 27 formed in the resin molded body 24, and is electrically connected to the lead frame 21 by the wire 50. The step of mounting the light emitting element 10 can be performed after the resin molded body 24 is removed from the mold 60, and the light emitting element 10 is mounted on the resin package 20 cut and separated into individual pieces. May be. Further, the light emitting element may be mounted face down without using a wire. After mounting the light emitting element 10 on the lead frame 21, the sealing member 30 containing the fluorescent material 40 is filled in the recess 27 and cured.

Next, the resin molded body 24 and the lead frame 21 are cut along the notch 21a.
The resin molded body 24 in which the plurality of recesses 27 are formed is cut in the longitudinal direction and the lateral direction so that the side walls between the adjacent recesses 27 are separated at a substantially central position. As a cutting method, dicing is performed from the resin molded body 24 side using a dicing saw. As a result, the resin molded body 24 and the lead frame 21 are substantially flush with the cut surface, and the lead frame 21 is exposed from the resin molded body 24. By providing the cutout portion 21 a in this way, the lead frame 21 to be cut is reduced, and peeling between the lead frame 21 and the resin molded body 24 can be suppressed. Further, not only the upper surface of the lead frame 21 but also the side surface corresponding to the notch 21a is in close contact with the resin molded body 24, so that the adhesion strength between the lead frame 21 and the resin molded body 24 is improved.
<Second Embodiment>
A light emitting device according to the second embodiment will be described. FIG. 6 is a perspective view showing a light emitting device according to the second embodiment. FIG. 7 is a plan view showing a lead frame used in the second embodiment. FIG. 8 is a plan view showing a resin molded body according to the second embodiment. A description of the configuration almost the same as that of the light emitting device according to the first embodiment may be omitted.

In the light emitting device according to the second embodiment, the light emitting element 10 is placed in a recess provided in the resin package 120. The outer upper surface 120c of the resin package 120 has a corner formed in an arc shape. Further, the side surface of the lead 122 is formed in an arc shape when viewed from the upper surface, and the lead 122 is provided with a step so as to slightly protrude from the resin portion 125 when viewed from the upper surface. The upper surface and outer bottom surface 120a of the protruding lead 122 and the arc-shaped surface portion are plated. On the other hand, the outer surface 120b other than the arc shape of the lead 122 is not plated. In this way, the bonding strength with a conductive member such as solder is increased by widening the plated portion.
(Method for Manufacturing Light-Emitting Device According to Second Embodiment)
In the method for manufacturing the light emitting device according to the second embodiment, the lead frame 121 is provided with a notch 121a and a hole 121b. The shape of the hole 121b is preferably a circular shape, but may be a polygonal shape such as a square shape or a hexagonal shape, an elliptical shape, or the like. The position of the hole 121b in the lead frame 121 is preferably on the extension line of the notch 121a and in the vicinity of a point where they intersect each other. The size of the hole 121b is not particularly limited, but a wide opening is preferable when the hole 121b is used as an electrode and increases the bonding strength with the conductive member. In addition, the adhesion area with the conductive member can be increased, and the bonding strength can be increased.

  A hole slightly larger than the shape of the hole 121b is provided so as to cover the vicinity of the hole 121b of the lead frame 121.

  A lead frame 121 provided with a notch 121a is sandwiched between an upper mold and a lower mold. At this time, the vicinity of the hole 121b is also sandwiched between the molds. Thereby, at the time of transfer molding, the thermosetting resin does not flow into the hole 121b, and it is not necessary to remove the thermosetting resin in the hole 121b.

  A resin body 124 is formed on the lead frame 121 by transfer-molding a thermosetting resin containing a light-reflective material into a mold sandwiched between the upper mold and the lower mold.

  The exposed portion of the lead frame 121 of the resin molded body 124 is plated. Plating is performed on the inner bottom surface of the recess, the outer bottom surface 120a of the resin package 120, the circular inner surface of the lead frame 121, and the upper surface extending therefrom.

  The resin molded body 124 and the lead frame 121 are cut along the notch 121a.

  The light emitting device according to the second embodiment can be provided through the above steps. Since the hole 121b is provided on the extension line of the notch 121a, when the dicing is performed using the dicing saw, the lead frame 121 to be cut can be reduced, so that the cutting time can be shortened. According to this manufacturing method, it is possible to provide a light emitting device having many portions plated on the lead frame 121 in a simple and short time.

<Third Embodiment>
A light emitting device according to a third embodiment will be described. FIG. 9 is a perspective view showing a light emitting device according to the third embodiment. FIG. 10 is a plan view showing a lead frame used in the third embodiment. A description of the configuration almost the same as that of the light emitting device according to the first embodiment may be omitted.

  In the light emitting device according to the third embodiment, the light reflectance at a wavelength of 350 nm to 800 nm after thermosetting is 70% or more, and the resin portion 225 and the lead 222 are formed on substantially the same surface on the outer surface 220b. The light emitting device has the resin package 220. The lead 222 is plated on the bottom surface and the top surface, and the outer surface has a portion that is not plated. The lead 222 has a predetermined thickness, and a step is provided near the outer surface of the resin package 220. Plating is applied to the side of the step that is deepened by one step and the bottom that slightly protrudes outward. Thus, by providing the lead 222 with a step subjected to the plating treatment, the bonding area increases, and the bonding strength with a conductive member such as solder can be improved. Moreover, since the thickness of the lead 222 at the portion to be cut using a dicing saw can be reduced, the cutting time can be shortened. Further, since dicing is performed from the outer top surface side of the resin package 220 using a dicing saw, burrs extending in the direction of the outer bottom surface are likely to occur on the cut surfaces of the leads 222. If the cut surface of the lead is the same surface as the outer bottom surface, the light emitting device may be tilted by the burr when mounting the light emitting device, but by providing a step on the lead cut surface, the burr is The light emitting device does not tilt due to burrs.

  In the lead 222 exposed from the resin package 220, the step is composed of a first surface exposed at the outer bottom surface 220a of the resin package 220, a second surface formed substantially perpendicular to the upper direction from the outer bottom surface 220a, and a second surface. A third surface formed substantially perpendicularly to the outer surface direction of the resin package 220 from the surface, and a fourth surface exposed on the outer surface of the resin package 220. The first surface, the second surface, and the third surface are plated, but the fourth surface is not plated. The second and third surfaces can be a single curved surface. By making the second surface and the third surface curved, the solder easily spreads in the stepped portion.

The resin package 220 has a substantially square shape on the outer upper surface 220 c and is covered with the resin portion 225. A substantially frustoconical concave portion is provided on the outer upper surface 220 c side of the resin package 220.
(Method for Manufacturing Light Emitting Device According to Third Embodiment)
In the method of manufacturing the light emitting device according to the third embodiment, the lead frame 221 is provided with a substantially straight groove 221c on the side corresponding to the outer bottom surface side of the light emitting device. The depth of the groove 221c is preferably about half of the thickness of the lead frame 221, but may be about 1/4 to 4/5. The width of the groove 221c is variously changed depending on the distance to the adjacent recesses, the size of the light emitting device, and the like. However, when the center of the groove is cut, it can be recognized that there is a step in the light emitting device. I just need it.

  A lead frame 221 provided with a notch 221a is sandwiched between an upper mold and a lower mold. The notch portion 221a is sandwiched between the upper die and the lower die so as not to flutter during transfer molding.

  A thermosetting resin containing a light-reflective substance is transferred and molded in a mold sandwiched between an upper mold and a lower mold, and a resin molded body is formed on the lead frame 221.

  Plating is performed on the exposed portion of the lead frame 221 of the resin molded body. Plating is performed on the inner bottom surface of the recess, the outer bottom surface 220a of the lead frame 221, and the groove 221c. The plating treatment of the groove 221c corresponds to the first surface, the second surface, and the third surface of the step in the light emitting device.

  The resin molded body and the lead frame are cut along the notch 221a. Further, the resin molded body is cut along the groove 221c.

  The light emitting device according to the third embodiment can be provided through the above steps. According to this manufacturing method, it is possible to provide a light emitting device having many portions plated on the lead frame 121 in a simple and short time.

<Fourth embodiment>
A light emitting device according to a fourth embodiment will be described. FIG. 11 is a perspective view showing a light emitting device according to the fourth embodiment. A description of the configuration almost the same as that of the light emitting device according to the first embodiment may be omitted.

  In the light emitting device according to the fourth embodiment, a part of the lead 322 of the outer surface 320b of the resin package 320 has a step that is recessed from the outer surface 320b. In the lead 322 exposed from the resin package 320, the step includes a first surface provided on the outer bottom surface 320 a of the resin package 320, a second surface formed substantially perpendicular to the upper direction from the outer bottom surface 320 a, and a second surface. A third surface formed substantially perpendicular to the outer surface direction of the resin package 320 from the surface and a fourth surface of the outer surface of the resin package 320. The outer upper surface 320 c of the resin package 320 is formed in a substantially rectangular shape including the resin portion 325. The outer bottom surface 320a, the first surface, the second surface provided with a step, the third surface, and the inner bottom surface of the recess are plated. On the other hand, the outer surface 320b not provided with a step is not subjected to plating.

  The lead 322 uses an etched lead frame. On the cut surface of the resin molded body, the etched lead 322 has irregularities. This unevenness improves the adhesion between the resin part and the lead.

By providing a step in a part of the lead 322, the bonding area with the conductive member at the time of mounting can be increased, and the bonding strength can be increased. Further, since the lead frame is provided with a recess, it is easy to cut and the time required for cutting can be shortened.
<Fifth embodiment>
A light emitting device according to a fifth embodiment will be described. FIG. 12 is a perspective view showing a light emitting device according to the fifth embodiment. A description of the configuration almost the same as that of the light emitting device according to the first embodiment may be omitted.

  In the light emitting device according to the fifth embodiment, a part of the lead 422 on the outer side surface 420b of the resin package 420 has a step that is recessed from the outer side surface 420b. In the lead 422 exposed from the resin package 420, the step is formed by a first surface provided on the outer bottom surface 420a of the resin package 420, a second surface formed substantially perpendicular to the upper direction from the outer bottom surface 420a, and a second surface. A third surface formed substantially perpendicular to the outer surface direction of the resin package 420 from the surface, and a fourth surface of the outer surface of the resin package 420. The outer surface 420b of the resin package 420 has six leads 422 separated. Each of the leads 422 may be separated or connected. The lead 422 is preferably provided with a notch portion rather than a flat plate shape because the bonding strength between the resin portion 425 and the lead 422 becomes higher. An outer upper surface 420 c of the resin package 420 is formed in a substantially rectangular shape including the resin portion 425. The outer bottom surface 420a, the first surface, the second surface provided with a step, the third surface, and the inner bottom surface of the recess are plated. On the other hand, the outer side surface 420b not provided with a step is not plated.

By providing a step in part of the lead 422, the bonding area with the conductive member can be increased, and the bonding strength can be increased. Further, since the lead frame is provided with a recess, it is easy to cut and the time required for cutting can be shortened.
<Sixth Embodiment>
A resin package according to a sixth embodiment will be described. FIG. 13 is a perspective view showing a resin package according to the sixth embodiment. The description of the resin package according to the first embodiment and the resin package according to the fifth embodiment may be omitted as it adopts substantially the same configuration.

  The resin package according to the sixth embodiment has a step with a recessed corner at the lead 522 on the outer surface 520b of the resin package 520. This step has an arc shape when viewed from the outer bottom surface 520a side in the lead 522 exposed from the resin package 520. This arc shape is a circle divided into four parts. This arc shape is obtained by performing an etching process up to about half of the thickness so as not to penetrate the lead 522, and then dividing into four parts. The arc-shaped portion is plated. The plating process on the arc-shaped portion and the plating process on the outer bottom surface 520a are performed before being divided into four. On the other hand, the outer side surface 520b that is not provided with a step is not plated. The resin package 520 has a substantially square shape when viewed from the outer upper surface 520c, and the resin portion 525 is exposed.

  By providing a step in part of the lead 522, the bonding area with the conductive member can be increased, and the bonding strength can be increased. Further, even when burrs are generated at the stepped portion when the resin molded body is cut, it is above the outer bottom surface 520a and therefore does not wobble at the time of joining with the conductive member. Furthermore, since the lead frame is provided with a recess, it is easy to cut, and the time required for cutting can be shortened.

  A light emitting device according to Example 1 will be described. A description overlapping with that described in the first embodiment may be omitted. FIG. 1 is a perspective view showing the light emitting device according to the first embodiment. FIG. 2 is a cross-sectional view showing the light emitting device according to the first embodiment. 2 is a cross-sectional view taken along the line II-II shown in FIG. FIG. 3 is a plan view showing the lead frame used in the first embodiment.

The light emitting device 100 includes the light emitting element 10 and a resin package 20 in which a resin portion 25 containing a light reflecting material 26 and a lead 22 are integrally formed. The light-emitting element 10 is a nitride semiconductor light-emitting element that has a light emission peak wavelength at 450 nm and emits blue light. The resin package 20 has a substantially rectangular parallelepiped shape with a mortar-shaped recess 27. The size of the resin package 20 is 35 mm in length, 35 mm in width, and 0.8 mm in height. The approximate diameter of the recess 27 on the outer upper surface 20 c side is 2.9 mm, the approximate diameter of the inner bottom surface 27 a is 2.6 mm, and the depth is 0.6 mm. The thickness of the lead 22 is 0.2 mm. Titanium oxide is used for the light reflecting material 26. An epoxy resin that is a thermosetting resin is used for the resin portion 25. Titanium oxide is contained in the epoxy resin by about 20% by weight. The resin package 20 has a light reflectance of 81% at a wavelength of 450 nm after thermosetting. The resin portion 25 and the lead 22 are formed on substantially the same surface on the outer surface 20 b of the resin package 20. The leads 22 are exposed from the four corners of the resin package 20. The lead 22 is plated on the outer bottom surface 20 a of the resin package 20 and the inner bottom surface 27 a of the recess 27. On the other hand, the lead 22 is not plated on the outer surface 20 b of the resin package 20. The recess 27 is filled with a sealing member 30 containing a fluorescent material 40 that emits yellow light. (Y, Gd) ₃ (Al, Ga) ₅ O ₁₂ : Ce is used as the fluorescent material 40. A silicone resin is used as the sealing member 30.

  This light emitting device is manufactured as follows.

  The lead frame is provided with a notch 21a by etching. Although not shown, the cutout portion 21a has an uneven surface. Ag is attached to the lead frame by electrolytic plating. A lead frame 21 provided with a notch 21a and plated is used.

  Next, the lead frame 21 having a predetermined size is sandwiched between the upper mold 61 and the lower mold 62. The lead frame 21 has a flat plate shape, and is provided with a notch 21a corresponding to the size of the light emitting device to be separated. The notches 21a are provided vertically and horizontally so that the four corners are exposed when the resin package 20 is divided into pieces, and the other corners are not exposed. Further, the notch 21 a is provided in the lateral direction so as to be electrically insulated when separated into the resin package 20, and the notch 21 a is formed by the upper mold 61 and the lower mold 62. Is sandwiched.

  The thermosetting resin 23 containing the light-reflective material 26 is transfer-molded in the mold 60 sandwiched between the upper mold 61 and the lower mold 62 to form the resin molded body 24 on the lead frame 21. To do. The thermosetting resin 23 containing the light reflecting material 26 is formed into a pellet, and heat and pressure are applied and poured into the mold 60. At this time, the notch 21a is also filled with the thermosetting resin 23. After the poured thermosetting resin 23 is temporarily cured, the upper mold 61 is removed, and further heat is applied to perform the main curing. Thus, a resin molded body 24 in which the lead frame 21 and the thermosetting resin 23 are integrally molded is manufactured.

  Next, the light emitting element 10 is mounted on the lead 22 on the inner bottom surface 27a of the recess 27 using a die bond member. After placing the light emitting element 10, the light emitting element 10 and the lead 22 are electrically connected using the wire 50. Next, the sealing member 30 containing the fluorescent material 40 is filled into the recess 27.

  Finally, the resin molded body 24 and the lead frame 21 are cut along the notch portions 21 a and separated into individual light emitting devices 100. As a result, the lead 22 is not plated at the cut portion.

  Through the above steps, a large number of light emitting devices 100 can be manufactured at a time.

  INDUSTRIAL APPLICABILITY The present invention can be used for lighting equipment, displays, mobile phone backlights, moving picture illumination auxiliary light sources, and other general consumer light sources.

It is a perspective view which shows the light-emitting device which concerns on 1st Embodiment. It is sectional drawing which shows the light-emitting device which concerns on 1st Embodiment. It is a top view which shows the lead frame used for 1st Embodiment. It is a schematic sectional drawing which shows the manufacturing method of the light-emitting device which concerns on 1st Embodiment. It is a top view which shows the resin molding which concerns on 1st Embodiment. It is a perspective view which shows the light-emitting device which concerns on 2nd Embodiment. It is a top view which shows the lead frame used for 2nd Embodiment. It is a top view which shows the resin molding which concerns on 2nd Embodiment. It is a perspective view which shows the light-emitting device which concerns on 3rd Embodiment. It is a top view which shows the lead frame used for 3rd Embodiment. It is a perspective view which shows the light-emitting device which concerns on 4th Embodiment. It is a perspective view which shows the light-emitting device which concerns on 5th Embodiment. It is a perspective view which shows the resin package which concerns on 6th Embodiment. It is a perspective view which shows the manufacturing method of the conventional light-emitting device. It is a perspective view which shows the intermediate body of the conventional light-emitting device. It is a perspective view which shows the conventional light-emitting device. It is the perspective view and sectional drawing which show the conventional light-emitting device. It is a schematic sectional drawing which shows the manufacturing method of the conventional light-emitting device. It is the schematic which shows the manufacturing process of the conventional light-emitting device.

10, 110 Light emitting element 20, 120, 220, 320, 420, 520 Resin package 20a, 120a, 220a, 320a, 420a, 520a Outer bottom surface 20b, 120b, 220b, 320b, 420b, 520b Outer side surface 20c, 120c, 220c, 320c, 420c, 520c Outer upper surface 21, 121, 221 Lead frame 21a, 121a, 221a Notch 121b Hole 221c Groove 22, 122, 222, 322, 422, 522 Lead 23 Thermosetting resin 24 Resin molded body 25, 125, 225, 325, 425, 525 Resin portion 26 Light reflecting material 27 Recessed portion 27a Inner bottom surface 27b Inner side surface 30 Sealing member 40 Fluorescent material 50 Wire 60 Die 61 Upper die 62 Lower die 70 Dicing saw 100 Light emitting device

Claims (22)

A manufacturing method of a light emitting device having a lead and a resin portion, and having an outer shape viewed from the upper side and having a substantially square shape and four outer surfaces,
A step of preparing a lead frame with a resin molded body having a lead frame and a resin molded body containing a light-reflecting substance, wherein a plurality of recesses are provided on the upper side of the lead frame with a resin molded body, The lead frame is divided and exposed by the resin molded body on the bottom surface of the recess, and the lead frame is a cut in which a part of the resin molded body has entered any of the four positions serving as the outer surfaces. A step of preparing a lead frame with a resin molded body in which a notch is provided and the lead frame is exposed at the bottom surface of the lead frame with a resin molded body;
Placing a light emitting element on the bottom surface of the recess;
Disposing a sealing member covering the light emitting element in the recess;
By cutting the lead frame and the resin molded body so that the lead and the resin portion that has entered the notch portion are substantially on the same outer surface of each light emitting device after separation, a plurality of And a step of separating the light emitting device.   The method for manufacturing a light-emitting device according to claim 1, wherein the notch is provided over a half or more of the entire surrounding circumference of the light-emitting device to be manufactured. In the step of preparing the lead frame with the resin molded body,
In the step of separating into the plurality of light emitting devices, the light emitting device after separation has a positive lead and a negative lead as the leads, and one of the two outer surfaces facing a part of the positive lead The notch is provided so that the negative lead is exposed at at least two locations, and a part of the negative lead is exposed at at least two locations on the other outer surface of the two opposing outer surfaces. A method of manufacturing a light emitting device according to claim 1 or 2. In the step of preparing the lead frame with the resin molded body,
In the step of separating the plurality of light emitting devices, the separated light emitting device has a positive lead and a negative lead as the leads, a part of the positive lead is exposed on at least two outer surfaces, and the negative lead The method for manufacturing a light emitting device according to claim 1, wherein the notch is provided so that a part of the notch is exposed to at least two outer surfaces. In the step of preparing the lead frame with the resin molded body,
In the step of separating the plurality of light emitting devices, the separated light emitting device has a positive lead and a negative lead as the leads, and a part of the positive lead is exposed on three outer surfaces, and one of the negative leads is exposed. The method for manufacturing a light emitting device according to claim 1, wherein the cutout portion is provided so that the portion is exposed on three outer surfaces. The step of preparing the lead frame with the resin molded body,
Sandwiching the lead frame provided with the notch between the upper mold and the lower mold; and
After the lead frame is inserted between the upper mold and the lower mold, a resin containing a light reflecting material is inserted into a space including the notch, and then the lead frame is inserted. Forming a resin molded body integrally with the lead frame to obtain a lead frame with a resin molded body so that a plurality of recesses exposed on the bottom surface are formed and the bottom surface of the lead frame is exposed;
The manufacturing method of the light-emitting device of any one of Claims 1-5 which has these. The lead frame with the resin molded body is:
Sandwiching the lead frame provided with the notch between the upper mold and the lower mold; and
After the lead frame is inserted between the upper mold and the lower mold, a resin containing a light reflecting material is inserted into a space including the notch, and then the lead frame is inserted. Forming a resin molded body integrally with the lead frame to obtain a lead frame with a resin molded body so that a plurality of recesses exposed on the bottom surface are formed and the bottom surface of the lead frame is exposed;
The manufacturing method of the light-emitting device of any one of Claims 1-5 manufactured through this.   The method for manufacturing a light-emitting device according to claim 1, wherein in the step of preparing the lead frame with a resin molded body, the lead frame is subjected to silver plating on the entire surface.   The light emitting device according to any one of claims 1 to 8, wherein in the step of preparing the lead frame with a resin molded body, the lead frame has a step or an unevenness in all of the portions that define the notch portion. Manufacturing method.   The light emitting device according to claim 1, wherein in the step of preparing the lead frame with a resin molded body, the lead frame has a portion etched from one side so as not to penetrate the lead frame. Manufacturing method.   The said resin molding is a manufacturing method of the light-emitting device of any one of Claims 1-10 containing a triazine derivative epoxy resin.   The method for manufacturing a light emitting device according to claim 1, wherein a sealing member containing a fluorescent material is used as the sealing member in the step of arranging the sealing member. A resin package having a lead having a positive lead and a negative lead and a resin portion, and having a recess having a bottom surface where a part of the positive lead and a part of the negative lead are exposed, and a bottom surface of the recess A light-emitting device mounted on the light-emitting device and a sealing member that covers the light-emitting device in the recess, the light-emitting device having an outer shape viewed from above and having four outer surfaces,
The lead is exposed on the bottom surface of the light emitting device, and has a notch on any of the four outer surfaces,
A part of the resin part has entered each of the notch parts,
In each of the four outer surfaces, a part of the lead is exposed from the resin portion, and the resin portion and the lead entering the notch portion are substantially flush with each other.   The light-emitting device according to claim 13, wherein the cutout portion is provided over a half or more of the entire surrounding circumference of the light-emitting device. A portion of the positive lead is exposed at at least two locations on one outer surface of two opposing outer surfaces,
The light-emitting device according to claim 13 or 14, wherein a part of the negative lead is exposed at at least two locations on the other outer surface of the two opposing outer surfaces. A portion of the positive lead is exposed on at least two outer sides;
The light emitting device according to claim 13 or 14, wherein a part of the negative lead is exposed on at least two outer surfaces. A portion of the positive lead is exposed on three outer sides;
The light emitting device according to claim 13 or 14, wherein a part of the negative lead is exposed on three outer surfaces.   The light emitting device according to any one of claims 13 to 17, wherein the lead is subjected to silver plating on the entire surface except the outer surface.   The light emitting device according to any one of claims 13 to 18, wherein the lead has a step or an unevenness in all portions defining the notch.   The light-emitting device according to claim 13, wherein the lead has a portion that is thinned from one side so as not to penetrate the lead.   The light emitting device according to claim 13, wherein the resin portion includes a triazine derivative epoxy resin.   The light emitting device according to any one of claims 13 to 21, wherein the sealing member contains a fluorescent material.

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