U.S. patent application number 09/887405 was filed with the patent office on 2001-11-22 for semiconductor light emitting device and its manufacturing method.
This patent application is currently assigned to KABUSHIKI KAISHA TOSHIBA. Invention is credited to Komoto, Satoshi, Matsumoto, Iwao, Nagasawa, Hiroshi, Oshio, Hiroaki, Uchino, Tsuguo, Umegi, Tadashi.
Application Number | 20010042865 09/887405 |
Document ID | / |
Family ID | 11942149 |
Filed Date | 2001-11-22 |
United States Patent
Application |
20010042865 |
Kind Code |
A1 |
Oshio, Hiroaki ; et
al. |
November 22, 2001 |
Semiconductor light emitting device and its manufacturing
method
Abstract
A semiconductor light emitting device includes a semiconductor
light emitting element (1), a resin stem (10) having a recess (7),
and a projection (9) made of a light-transmissive thermosetting
resin on the resin stem so as to cover the entire upper surface and
continuous upper part of side surfaces of the resin stem to a
predetermined depth. The recess is filled with a light-transmissive
resin encapsulating element (5) to embed the semiconductor light
emitting element, one end of an externally extended first lead (21)
and one end of an externally extended second lead (22) electrically
connected to first and second electrodes of the semiconductor light
emitting element, and a bonding wires (4) connecting the second
lead to the second electrode. The projection functions as a lens
and is made by hardening a fluid-state resin in an encapsulating
case mold. Since the projection extends over the upper surface and
upper part of side surfaces continuous from the upper surface, it
is firmly bonded to the resin stem with a high adherability.
Inventors: |
Oshio, Hiroaki;
(Kitakyushu-shi, JP) ; Matsumoto, Iwao;
(Kitakyushu-shi, JP) ; Uchino, Tsuguo;
(Kitakyushu-shi, JP) ; Nagasawa, Hiroshi;
(Kitakyushu-shi, JP) ; Umegi, Tadashi;
(Kitakyushu-shi, JP) ; Komoto, Satoshi;
(Suginami-ku, JP) |
Correspondence
Address: |
HOGAN & HARTSON L.L.P.
500 S. GRAND AVENUE
SUITE 1900
LOS ANGELES
CA
90071-2611
US
|
Assignee: |
KABUSHIKI KAISHA TOSHIBA
|
Family ID: |
11942149 |
Appl. No.: |
09/887405 |
Filed: |
June 21, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09887405 |
Jun 21, 2001 |
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09006233 |
Jan 13, 1998 |
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6274890 |
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Current U.S.
Class: |
257/100 ; 257/99;
257/E33.059; 257/E33.072; 257/E33.073; 257/E33.074 |
Current CPC
Class: |
H01L 33/60 20130101;
H01L 2224/48465 20130101; H01L 2224/32245 20130101; H01L 2224/45144
20130101; H01L 33/486 20130101; H01L 33/58 20130101; H01L
2924/01025 20130101; H01L 33/62 20130101; H01L 33/52 20130101; H01L
2224/48247 20130101; H01L 2224/73265 20130101; H01L 33/54 20130101;
H01L 2224/92247 20130101; H01L 33/505 20130101; H01L 2924/01063
20130101; H01L 2924/01079 20130101; H01L 2224/48091 20130101; H01L
2924/0102 20130101; H01L 2933/0091 20130101; H01L 33/507 20130101;
H01L 2924/01012 20130101; H01L 2924/01039 20130101; H01L 2224/48091
20130101; H01L 2924/00014 20130101; H01L 2224/73265 20130101; H01L
2224/32245 20130101; H01L 2224/48247 20130101; H01L 2924/00
20130101; H01L 2224/48465 20130101; H01L 2224/48247 20130101; H01L
2924/00 20130101; H01L 2224/92247 20130101; H01L 2224/73265
20130101; H01L 2224/32245 20130101; H01L 2224/48247 20130101; H01L
2924/00 20130101; H01L 2224/48465 20130101; H01L 2224/48091
20130101; H01L 2924/00 20130101; H01L 2224/45144 20130101; H01L
2924/00 20130101; H01L 2224/73265 20130101; H01L 2224/32245
20130101; H01L 2224/48247 20130101; H01L 2924/00012 20130101 |
Class at
Publication: |
257/100 ;
257/99 |
International
Class: |
H01L 033/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 15, 1997 |
JP |
17370 |
Claims
What is claimed is:
1. A semiconductor light emitting device comprising: a
semiconductor light emitting element (1, 1', 1"); a resin stem (10)
having a first lead (21), a second lead (22) and a resin portion
(10A) partly covering said first and second leads, one end of said
first lead and one end of said second lead being externally
extended from said resin portion, and said resin portion having a
recess containing said semiconductor light emitting element, the
other end of said first lead electrically connected to a first
electrode of said semiconductor light emitting element, and the
other end of said second lead electrically connected to a second
electrode of said semiconductor light emitting element; a
light-transmissive resin (5) filling said recess of said resin
stem; and a projection (9) made of a light-transmissive resin to
cover the entire upper surface of said resin stem, said projection
being extended down onto side surfaces of said resin stem to a
predetermined distance from said upper surface to continuously
cover the upper part of the side surfaces all around.
2. The semiconductor light emitting device according to claim 1
wherein said projection (9) forms a lens having a vertical axis
aligned with a vertical axis of said resin stem (10), these center
axes being aligned with a vertical axis of said semiconductor light
emitting element (1).
3. The semiconductor light emitting device according to claim 2
wherein said resin stem (10) has at least one through hole (15) in
the bottom of said recess.
4. The semiconductor light emitting device according to claim 2
wherein said resin stem (10) has at least one through hole (14)
extending from the upper surface to the lower surface thereof.
5. The semiconductor light emitting device according to claim 2
further comprising a fluorescent element for converting light
emanating from said semiconductor light emitting element (1, 1',
1") into different wavelength light.
6. The semiconductor light emitting device according to claim 5
wherein said fluorescent element is contained in said resin portion
(10A) of said resin stem (10).
7. The semiconductor light emitting device according to claim 5
wherein said fluorescent element is applied onto inner wall
surfaces (8) of said recess of said resin stem (10).
8. The semiconductor light emitting device according to claim 5
wherein said fluorescent element is contained in a mounting
adhesive applied onto the bottom surface of said semiconductor
light emitting element (1, 1', 1").
9. The semiconductor light emitting device according to claim 5
wherein said fluorescent element is contained in said
light-transmissive resin (5) filling said recess.
10. The semiconductor light emitting device according to claim 5
wherein said fluorescent element is contained in said
light-transmissive resin forming said projection (9).
11. A semiconductor light emitting device comprising: a
semiconductor light emitting element (1, 1', 1"); a resin stem (10)
having a first lead (21), a second lead (22) and a resin portion
(10A) partly covering said first and second leads, one end of said
first lead and one end of said second lead being externally
extended from said resin portion, and said resin portion having a
recess containing said semiconductor light emitting element, the
other end of said first lead electrically connected to a first
electrode of said semiconductor light emitting element, and the
other end of said second lead electrically connected to a second
electrode of said semiconductor light emitting element; a
light-transmissive resin (5) filling said recess of said resin
stem; and a projection (9) made of a light-transmissive resin to
cover the entire upper surface of said resin stem, said projection
being extended down onto side surfaces of said resin stem to a
predetermined distance from said upper surface to continuously
cover the upper part of the side surfaces all around; wherein said
recess of said resin stem (10) is longer in a first horizontal
direction in which said first and second leads (21, 22) extend than
in a second horizontal direction normal to said first horizontal
direction.
12. The semiconductor light emitting device according to claim 11
wherein said first electrode of said semiconductor light emitting
element (1') is connected to said first lead (21) by a bonding wire
(4), and said second electrode of said semiconductor light emitting
element is connected to said second lead (22) by a bonding wire
(4).
13. The semiconductor light emitting device according to claim 12
wherein said projection (9) forms a lens having a vertical axis
aligned with a vertical axis of said resin stem (10), these center
axes being aligned with a vertical axis of said semiconductor light
emitting element (1).
14. The semiconductor light emitting device according to claim 13
further comprising a fluorescent element for converting light
emanating from said semiconductor light emitting element (1, 1',
1") into different wavelength light.
15. The semiconductor light emitting device according to claim 11
wherein the center of a horizontal cross-sectional configuration of
said recess of said resin stem (10) is offset from the center of a
horizontal cross-sectional configuration of said resin stem.
16. The semiconductor light emitting device according to claim 15
wherein said second electrode of said semiconductor light emitting
element (1) is connected to said second lead (22) by a bonding wire
(4), and the center of a horizontal cross-sectional configuration
of said recess of said resin stem (10) is offset from the center of
a horizontal cross-sectional configuration of said resin stem
toward the externally extending direction of said second lead.
17. The semiconductor light emitting device according to claim 16
wherein said projection (9) forms a lens having a vertical axis
aligned with a vertical axis of said resin stem (10), these center
axes being aligned with a vertical axis of said semiconductor light
emitting element (1).
18. The semiconductor light emitting device according to claim 17
further comprising a fluorescent element for converting light
emanating from said semiconductor light emitting element (1, 1',
1") into different wavelength light.
19. A semiconductor light emitting device comprising: a
semiconductor light emitting element (1, 1', 1"); a resin stem (10)
having a first lead (21), a second lead (22) and a resin portion
(10A) partly covering said first and second leads, one end of said
first lead and one end of said second lead being externally
extended from said resin portion, and said resin portion having a
recess containing said semiconductor light emitting element, the
other end of said first lead electrically connected to a first
electrode of said semiconductor light emitting element, and the
other end of said second lead electrically connected to a second
electrode of said semiconductor light emitting element; a
light-transmissive resin (5) filling said recess of said resin
stem; and a projection (9) made of a light-transmissive resin to
cover the entire upper surface of said resin stem, said projection
being extended down onto side surfaces of said resin stem to a
predetermined distance from said upper surface to continuously
cover the upper part of the side surfaces all around; wherein inner
side surfaces (8) of said recess serve as reflective surfaces.
20. The semiconductor light emitting device according to claim 19
wherein said resin portion (10A) of said resin stem (10) is made
from a thermoplastic resin not less than 65 weight % and a filler
agent not more than 35 weight %, said filler agent being a high
reflective material containing titanium oxide, silicon oxide,
and/or aluminum oxide, and titanium oxide occupying 10 to 15 weight
%.
21. The semiconductor light emitting device according to claim 20
wherein said projection (9) forms a lens having a vertical axis
aligned with a vertical axis of said resin stem (10), these center
axes being aligned with a vertical axis of said semiconductor light
emitting element (1).
22. The semiconductor light emitting device according to claim 21
further comprising a fluorescent element for converting light
emanating from said semiconductor light emitting element (1, 1',
1") into different wavelength light.
23. A method for manufacturing a semiconductor light emitting
device comprising the steps of: forming a resin stem (10) by
integrally molding a lead frame (2) having first and second leads
(21, 22) and a resin portion (10A) such that said first and second
leads are positioned in an end-to-end alignment in a recess formed
in the upper surface of said resin portion; mounting a
semiconductor light emitting element (1, 1', 1") having first and
second electrodes in said recess, and electrically connecting said
first lead to said first electrode and said second lead to said
second electrode; injecting a fluid-state thermosetting resin (12)
into an encapsulating case mold (11); dipping the upper surface of
said resin stem and upper parts of side surfaces continuous from
the upper surface into said fluid-state resin in said encapsulating
case mold; and hardening said fluid-state resin to form a
projection (9) of a light-transmissive resin on said resin stem,
said projection covering the entire upper surface of said resin
stem, and extended down onto side surfaces of said resin stem to a
predetermined distance from said upper surface to continuously
cover the upper part of the side surfaces all around.
24. The method for manufacturing a semiconductor light emitting
device according to claim 23 wherein said resin stem (10) is
oriented upside down when dipped into said second fluid-state resin
(12) within said encapsulating case mold (11).
25. The method for manufacturing a semiconductor light emitting
device according to one of claim 24 wherein said resin stem (10) is
dipped into said second fluid-state resin (12) within said
encapsulating case mold (11) to a depth where said lead frame (2)
contacts the edge of the cavity of said encapsulating case mold
(11).
26. The method for manufacturing a semiconductor light emitting
device according to claim 24 wherein said encapsulating case mold
(11) has a stopper (13) along the edge of the cavity thereof, said
resin stem (10) being dipped into said second fluid-state resin
(12) within said encapsulating case mold (11) to a depth where said
lead frame (2) contacts said stopper.
27. The method for manufacturing a semiconductor light emitting
device according to claim 24 wherein said resin stem (10) has a
stopper, said resin stem (10) being dipped into said second
fluid-state resin (12) within said encapsulating case mold (11) to
a depth where said stopper contacts the edge of the cavity of said
encapsulating case mold (11).
28. The method for manufacturing a semiconductor light emitting
device according to claim 24 wherein said lead frame (2) includes
plural pairs of said first and second leads (21, 22).
29. The method for manufacturing a semiconductor light emitting
device according claim 24 wherein said encapsulating case mold (11)
is a part of a case mold chain which includes a plurality of said
encapsulating case molds aligned in a row.
30. The method for manufacturing a semiconductor light emitting
device according to claim 29 wherein a plurality of said resin
stems (10) are formed for individual lead pairs (21, 22) of said
lead frame (2), and are dipped into corresponding individuals of
said encapsulating case molds of said case mold chain (11).
31. A method for manufacturing a semiconductor light emitting
device comprising the steps of: forming a resin stem (10) by
integrally molding a lead frame (2) having first and second leads
(21, 22) and a resin portion (10A) such that said first and second
leads are positioned in an end-to-end alignment in a recess formed
in the upper surface of said resin portion; mounting a
semiconductor light emitting element (1, 1', 1") having first and
second electrodes in said recess, and electrically connecting said
first lead to said first electrode and said second lead to said
second electrode; injecting a first fluid-state thermosetting resin
(5) into said recess to embed said semiconductor light emitting
element and said first and second leads; injecting a second
fluid-state thermosetting resin (12) into an encapsulating case
mold (11); dipping said resin stem into said second fluid-state
resin within said encapsulating case mold by bringing said first
fluid-state resin into touch with the second fluid-state resin in
said encapsulating case mold; hardening said first and second
fluid-state resins to form a light-transmissive resin encapsulating
element (5) in said recess and a projection (9) of a
light-transmissive resin on said resin stem, said projection
covering the entire upper surface of said resin stem, and extended
down onto side surfaces of said resin stem to a predetermined
distance from said upper surface to continuously cover the upper
part of the side surfaces all around.
32. The method for manufacturing a semiconductor light emitting
device according to claim 31 wherein said resin stem (10) is
oriented upside down when dipped into said second fluid-state resin
(12) within said encapsulating case mold (11).
33. The method for manufacturing a semiconductor light emitting
device according claim 32 wherein said resin stem (10) is dipped
into said second fluid-state resin (12) within said encapsulating
case mold (11) to a depth where said lead frame (2) contacts the
edge of the cavity of said encapsulating case mold (11).
34. The method for manufacturing a semiconductor light emitting
device according to claim 32 wherein said encapsulating case mold
(11) has a stopper (13) along the edge of the cavity thereof, said
resin stem (10) being dipped into said second fluid-state resin
(12) within said encapsulating case mold (11) to a depth where said
lead frame (2) contacts said stopper.
35. The method for manufacturing a semiconductor light emitting
device according to claim 32 wherein said resin stem (10) has a
stopper, said resin stem (10) being dipped into said second
fluid-state resin (12) within said encapsulating case mold (11) to
a depth where said stopper contacts the edge of the cavity of said
encapsulating case mold (11).
36. The method for manufacturing a semiconductor light emitting
device according to claim 32 wherein said lead frame (2) includes
plural pairs of said first and second leads (21, 22).
37. The method for manufacturing a semiconductor light emitting
device according to claim 32 wherein said encapsulating case mold
(11) is a part of a case mold chain which includes a plurality of
said encapsulating case molds aligned in a row.
38. The method for manufacturing a semiconductor light emitting
device according to claim 37 wherein a plurality of said resin
stems (10) are formed for individual lead pairs (21, 22) of said
lead frame (2), and are dipped into corresponding individuals of
said encapsulating case molds of said case mold chain (11).
39. The method for manufacturing a semiconductor light emitting
device according to claim 31 wherein said first fluid-state resin
(5) and said second fluid-state resin (12) are different resin
materials.
40. The method for manufacturing a semiconductor light emitting
device according to claim 31 wherein ultraviolet rays are
irradiated onto said resin stem before said fluid-state resin (5)
is injected into said recess (7) of said resin stem.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a semiconductor light emitting
device used in indicators, message boards, or other visual display
devices, which is improved in adherability of a resin encapsulating
element and a resin stem, and also relates to a method for
manufacturing same.
[0003] 2. Description of the Prior Art
[0004] In conventional semiconductor light emitting devices, after
a semiconductor light emitting element is mounted and bonded to a
printed board with a printed wiring, a light-transmissive resin is
injected into a cavity defined by a case mold capped onto the
printed board to form an encapsulating element having a lens
function.
[0005] These semiconductor light emitting devices are expensive,
and the injected resin often leaks. Moreover, chips, unfilled
portions or bubbles are liable to be made in the encapsulating
element, resulting that the devices are not satisfactory in their
appearances. Additionally, the use of an expensive printed board
and a slow injection speed cause a high manufacturing cost.
[0006] On the other hand, a surface-packaged semiconductor light
emitting device having no lens is as shown in FIG. 22. A resin stem
10 has formed a recess 7, and a semiconductor light emitting
element 1 is put on the bottom of the recess 7. The sloped side
walls 8 of the recess 7 functions as light reflective surfaces.
Leads 21 and 22 are embedded in the resin stem 10. The leads 21, 22
are incorporated by molding a lead frame in form of a thin Fe- or
Cu-based metal plate. The resin stem 10 is made by
injection-molding a thermoplastic resin such as polycarbonate (PC)
containing a filler agent such as silica (SiO.sub.2) together with
the lead frame. End portions of the leads 21, 22 for contact with
the semiconductor light emitting element lie on the bottom surface
of the recess 7 of the resin stem 10. The semiconductor light
element 1 is mounted on the lead 21 by conductive paste 3, or the
like, containing silver (Ag), for example. A first electrode of the
semiconductor light emitting element 1 is connected to the lead 21,
and a second electrode is electrically connected to the lead 22.
The second electrode and the lead 22 are connected by a bonding
wire 4 of gold (Au), for example. A light-transmissive resin
encapsulating element 5 of a thermosetting resin is applied onto
the resin stem 10 so as to cover these end portions of the leads
21, 22, semiconductor light emitting element 1 and bonding wire
4.
[0007] However, the surface-packaged semiconductor light emitting
device shown in FIG. 22 has not lens, and is unreliable in
adherability between the resin encapsulating element of a
thermosetting resin and a resin stem of a thermoplastic resin.
SUMMARY OF THE INVENTION
[0008] It is therefore an object of the invention to provide an
inexpensive semiconductor light emitting device and its
manufacturing method, which permits a lens to be made easily, and
is improved in adherability and humidity resistance between the
resin encapsulating element and the resin stem, and also improved
in reflecting efficiency and light take-out efficiency.
[0009] According to the invention, there is provided a
semiconductor light emitting device comprising: a semiconductor
light emitting element made by using GaP, GaAlAs, GaAsP, InGaAlP,
GaN, ZnSe, SiC, BN, for example; a resin stem having a first lead,
a second lead and a resin portion partly covering the first and
second leads, one end of the first lead and one end of the second
lead being externally extended from the resin portion, and the
resin stem having a recess containing the semiconductor light
emitting element, the other end of the first lead electrically
connected to a first electrode of the semiconductor light emitting
element, and the other end of the second lead electrically
connected to a second electrode of the semiconductor light emitting
element; a light-transmissive resin filling the recess of the resin
stem; and a projection made of a light-transmissive resin to cover
the entire upper surface of the resin stem, the projection extended
down onto side surfaces of said resin stem to a predetermined level
from the upper surface to continuously cover the upper part of the
side surfaces all around.
[0010] The resin stem may have at least one through hole in the
bottom of the recess or at least one through hole extending from
the upper surface to the lower surface. The projection may form a
lens having a vertical axis aligned with a vertical axis of the
resin stem, and these center axes may be aligned with a vertical
axis of the semiconductor light emitting element. The semiconductor
light emitting device may include a fluorescent element for
converting light emanating from the semiconductor light emitting
element into different wavelength light. The fluorescent element
may be contained in the resin portion of the resin stem, may be
applied onto inner wall surfaces of the recess of the resin stem,
or may be contained in a mounting adhesive applied onto the bottom
surface of the semiconductor light emitting element, in the
light-transmissive resin filling the recess, or in the
light-transmissive resin forming said projection.
[0011] The recess of the resin stem may be longer in a first
horizontal direction in which the first and second leads extends
than in a second horizontal direction normal to the first
direction. The first electrode of the semiconductor light emitting
element may be connected to the first lead by a bonding wire, and
the second electrode of the semiconductor light emitting element
may be connected to the second lead by another bonding wire. The
center of a horizontal cross-sectional configuration of the recess
of the resin stem may be offset from the center of a horizontal
cross-sectional configuration of the resin stem. The second
electrode of the semiconductor light emitting element may be
connected to the second lead by a bonding wire, and the center of a
horizontal cross-sectional configuration of the recess of the resin
stem may be offset from the center of a horizontal cross-sectional
configuration of the resin stem toward the externally extending
direction of the second lead. Inner side surfaces of the recess may
serve as reflective surfaces.
[0012] The resin portion of the resin stem is made from a
thermoplastic resin not less than 65 weight % and a filler agent
not more than 35 weight %, the filler agent being a high reflective
material containing titanium oxide, silicon oxide, and/or aluminum
oxide, and titanium oxide occupying 10 to 15 weight %.
[0013] There is also provided a method for manufacturing a
semiconductor light emitting device comprising the steps of:
[0014] forming a resin stem by integrally molding a lead frame
having first and second leads and a resin portion such that the
first and second leads be positioned in an end-to-end alignment in
a recess formed in the upper surface of the resin portion; mounting
a semiconductor light emitting element having first and second
electrodes in the recess, and electrically connecting the first
lead to the first electrode and the second lead to the second
electrode; injecting a fluid-state thermosetting resin into an
encapsulating case mold; dipping the upper surface of the resin
stem and upper parts of side surfaces continuous from the upper
surface into the fluid-state resin in the encapsulating case mold;
and hardening the fluid-state resin to form a projection of a
light-transmissive resin on the resin stem, in which the projection
covering the entire upper surface of the resin stem, and extended
down onto side surfaces of the resin stem to a predetermined level
from the upper surface to continuously cover the upper part of the
side surfaces all around.
[0015] According to the invention, there is provided an alternative
method for manufacturing a semiconductor light emitting device
comprising the steps of: forming a resin stem by integrally molding
a lead frame having first and second leads and a resin portion such
that the first and second leads are positioned in an end-to-end
alignment in a recess formed in the upper surface of the resin
portion; mounting a semiconductor light emitting element having
first and second electrodes in the recess, and electrically
connecting the first lead to the first electrode and the second
lead to the second electrode; injecting a first fluid-state
thermosetting resin into the recess to embed the semiconductor
light emitting element and the first and second leads; injecting a
second fluid-state thermosetting resin into an encapsulating case
mold (11); dipping the resin stem into the second fluid-state resin
within the encapsulating case mold by bringing the first
fluid-state resin into touch with the second fluid-state resin in
the encapsulating case mold; hardening the first and second
fluid-state resins to form a light-transmissive resin encapsulating
element in the recess and a projection of a light-transmissive
resin on the resin stem, in which the projection covers the entire
upper surface of the resin stem, and extends down onto side
surfaces of the resin stem to a predetermined distance from the
upper surface to continuously cover the upper part of the side
surfaces all around.
[0016] The resin stem may be oriented upside down when dipped into
the second fluid-state resin within the encapsulating case mold.
The resin stem may be dipped into the second fluid-state resin
within the encapsulating case mold to a depth where the lead frame
contacts the edge of the cavity of the encapsulating case mold. The
encapsulating case mold may have a stopper along the edge of the
cavity thereof, and the resin stem may be dipped into the second
fluid-state resin within the encapsulating case mold to a depth
where the lead frame contacts the stopper. Alternatively, the resin
stem may have a stopper, and may be dipped into the second
fluid-state resin within the encapsulating case mold to a depth
where the lead frame contacts the stopper. The lead frame may
include plural pairs of the first and second leads. The
encapsulating case mold may be a part of a case mold chain which
includes a plurality of encapsulating case molds aligned in a row.
A plurality of resin stems may be formed for individual lead pairs
of the lead frame, and they may be dipped into corresponding
individuals of the encapsulating case molds of the case mold chain.
The first fluid-state resin and the second fluid-state resin may be
different resin materials. Ultraviolet rays may be irradiated onto
the resin stem before the fluid-state resin is injected into the
recess of the resin stem.
[0017] According to the invention, there is further provided a
semiconductor light emitting device comprising: a semiconductor
light emitting element; a resin stem supporting the semiconductor
light emitting device, one end of an externally extended first lead
electrically connected to a first electrode of the semiconductor
light emitting element, one end of an externally extended second
lead electrically connected to a second electrode of the
semiconductor light emitting element, and a bonding wire connecting
the second electrode to the second lead; and a light transmissive
resin encapsulating element embedding the semiconductor light
emitting element, the ends of first and second leads connected to
the first and second electrodes, and the bonding wires, in which
the resin stem is composed of a thermoplastic resin not less than
65 weight % and a filler agent not more than 35 weight % titanium
which contains 10 to 15 weight % of titanium oxide and/or one or
more of other high reflective materials selected from silicon
oxide, aluminum oxide, and so on.
[0018] In the semiconductor light emitting device according to the
invention, since the projection of a light-transmissive resin is
formed on the resin stem to envelope its upper surface and upper
part of the side surfaces continuous from the upper surface, the
adherability between the projection and the resin stem is improved.
Ultraviolet irradiation improves the coupling force of the resin
stem of a thermoplastic resin with a thermosetting
light-transmissive resin. By aligning the semiconductor light
emitting element with vertical center lines of the projection and
the resin stem and by deviating the center of recess from the
center of the resin stem, the light emitting efficiency is
improved. The through hole formed in the resin stem facilitates
coupling of the light-transmissive resin to the resin stem. The
stopper keeps the projection distant from the lead frame
(leads).
[0019] The above-summarized constructions of the present invention
remarkably increase the adherability between the projection of a
light-transmissive thermosetting resin and the resin stem of a
thermoplastic resin, and contributes to realization of an
economical resin stem with a high reflective index. Moreover, the
invention can cope with various applications by varying the lead
forming configuration. Additionally, various semiconductor light
emitting devices with different optical characteristics can be
prepared by changing the encapsulating case mold.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a cross-sectional view of a semiconductor light
emitting device according to an embodiment of the invention (taken
along the A-A' line of FIG. 2);
[0021] FIG. 2 is a plan view of the semiconductor light emitting
device according to the invention;
[0022] FIG. 3 is a simplified plan view of a resin stem used in the
invention;
[0023] FIG. 4 is a cross-sectional view taken along the A-A' line
of FIG. 3;
[0024] FIG. 5 is a flow chart of a manufacturing process of the
semiconductor light emitting device according to the invention;
[0025] FIG. 6 is a cross-sectional view of an encapsulating case
mold and a resin stem used in the invention;
[0026] FIGS. 7A and 7B are a cross-sectional view and a plan view
of the encapsulating case mold used in the invention
respectively;
[0027] FIGS. 8A and 8B are an elevaion view and a plan view of the
resin portion of the resin stem used in the invention
respectively;
[0028] FIGS. 9A and 9B are a plan view and a cross-sectional view
of a semiconductor light emitting device according to the invention
respectively;
[0029] FIG. 10 is a cross-sectional view of an encapsulating case
mold and a resin stem used in the invention;
[0030] FIG. 11 is a cross-sectional view of the encapsulating case
mold and the resin stem used in the invention;
[0031] FIG. 12 is a cross-sectional view of the resin stem used in
the invention;
[0032] FIG. 13 is a diagram showing changes in reflective index
with composition ratio of titanium oxide;
[0033] FIG. 14 is a diagram showing changes in adherability with
ultraviolet radiation;
[0034] FIG. 15 is a cross-sectional view of a semiconductor light
emitting device according to the invention (taken along the A-A'
line of FIG. 16);
[0035] FIG. 16 is a plan view of the semiconductor light emitting
device;
[0036] FIG. 17 is a flow chart of a manufacturing process of the
semiconductor light emitting device according to the invention;
[0037] FIG. 18 is a cross-sectional view of a semiconductor light
emitting device according to the invention (taken along the A-A'
line of FIG. 19);
[0038] FIG. 19 is a plan view of the semiconductor light emitting
device;
[0039] FIG. 20 is a plan view of a lead frame used in the
invention;
[0040] FIG. 21 is a cross-sectional view of a series of case molds
and a series of resin stems used in the invention;
[0041] FIG. 22 is a cross-sectional view of a conventional
semiconductor light emitting device;
[0042] FIG. 23 is a plan view of a conventional resin stem; and
[0043] FIG. 24 is a cross-sectional view taken along the A-A' line
of FIG. 23.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] Explained below are embodiments of the present invention
with reference to the drawings. Referring to FIGS. 1 through 4
showing a first embodiment, FIG. 1 is a cross-sectional view of a
semiconductor light emitting device, and FIG. 2 is a plan view of
the same semiconductor light emitting device. FIG. 1 is taken along
the A-A' line of FIG. 2. FIG. 3 is a simplified plan view of a
resin stem for explaining the position of the resin stem in the
semiconductor light emitting device, and FIG. 4 is a
cross-sectional view taken along the A-A' line of FIG. 3.
[0045] As shown in FIG. 1, the resin stem 10 has leads 21 and 22,
made by molding a lead frame, and a resin portion 10A, which is an
integral molded product. The resin portion 10A includes a recess
which opens to the upper surface thereof with a larger area than
its bottom and has slanted side walls behaving as reflective
surfaces 8. The resin portion 10A of the resin stem 10 comprises a
generally square lower portion and a generally circular upper
portion having the recess. End portions of leads 21, 22 lie on the
bottom surface of the recess in an end-to-end confrontation.
Opposite end portions of the leads 21, 22 extend in the opposite
directions to the exterior of the resin portion 10A. These leads
21, 22 are molded in a cut-and-forming step of the lead frame. A
semiconductor light emitting element 1 made of GaP, GaAlAs, GaAsP,
InGaAlP or GaN, for example, has first and second electrodes (not
shown), and is mounted at the lead 21 on the bottom surface of the
recess by Ag paste 3, for example.
[0046] The second electrode of the semiconductor light emitting
element 1 is connected to the lead 22 by a bonding wire 4 of Au,
for example. A thermosetting resin fully fills the recess of the
resin portion 10A to form a light-transmissive resin encapsulating
element 5. A projection 9 of a light-transmissive resin
encapsulating element made of a thermosetting resin is formed on
the resin stem 10. The projection 9 is used as a lens, for example.
The projection 9 covers the entire upper surface of the resin stem
10 including the surface of the resin encapsulating element 5 and
an upper part of the side surfaces continuous from the upper
surface. The semiconductor light emitting element 1 in the recess
is located along a vertical center line O of the projection 9. The
center line O is common to the vertical center line of the resin
stem 10. However, the recess is eccentric from the center of the
upper surface of the resin stem 10, and the vertical center line O'
of the recess does not coincide with the center line O. This
construction results in locating the semiconductor light emitting
element 1 closer to the reflective surfaces 8 and in making the
reflective surfaces 8 more effective to improve the light take-out
efficiency. The projection 9 is larger than the diameter of the
upper portion of the resin stem 10 by the thickness t so as to
cover the entirety of the upper side surface of the resin stem 10
(length x). The projection 9 does not contact the lead 21 or 22,
and is distant from the leads 21 and 22 by a predetermined distance
y.
[0047] In this embodiment, the thickness t of the projection 9 on
the side surface of the resin stem is approximately 2 mm when the
length of one side of the resin portion 10A is either 2.4 mm or 4.5
mm. When manufacturing the semiconductor light emitting device,
after mounting the projection 9 on the resin stem 10, a lead frame
is cut and formed into the form of leads 21 and 22 to complete the
semiconductor light emitting device. The leads 21 and 22 may be
formed into a gull wing, J-bent or other appropriate shape.
[0048] The structure of the resin stem of the semiconductor light
emitting device shown in FIG. 1 is explained in greater detail with
reference to FIGS. 3 and 4 which are a simplified plan view and a
cross-sectional view of the resin stem supporting the semiconductor
light emitting element, removing the projection for clearly
illustrating the position of the semiconductor light emitting
element. The resin portion 10A of the resin stem 10 is generally
square or rectangular (approximately as large as 3.0.times.3.4 mm
or 5.0.times.5.4 mm, for example), and the upper portion including
the upper surface 10' is cylindrical. The B-B' line and the C-C'
line in FIG. 3 are center lines of two pairs of parallel sides. The
vertical center line O of the resin stem 10 is shown in FIG. 4. As
stated above, the upper surface 10' of the resin stem 10 is
generally circular, and the recess 7 formed therein is
substantially elliptic (with the longest diameter R and the
shortest diameter r). The leads 21 and 22 extend in opposite
directions from their confronting ends, and extend to the exterior
of the resin stem 10 through its opposite sides. The semiconductor
light emitting element 1 is located in the recess 7 to overlap all
of the center lines B-B', C-C' and O. The recess 7 is not in the
center on the upper surface of the resin stem 10 and offset toward
the lead 22 along the lead-extending direction (the distance H from
the side crossing with the lead 21 to the recess is larger than the
distance h from the side crossing with the lead 22 to the
recess).
[0049] The purpose of the offset location of the recess is to amply
reserve the region for the bonding wire. That is, this structure
decreases distances between the reflective surfaces 8 and the
semiconductor light emitting element 1 than the conventional
structure shown in FIGS. 23 and 24 while providing an ample region
for the bonding wire. Also in the conventional structure shown in
FIGS. 23 and 24, the semiconductor light emitting element 1 is
located to overlap the center lines B-B', C-C' and O. However,
since the recess 7 is formed in the center of the resin stem 10, a
the recess 7 necessarily becomes larger to provide an ample area
for the bonding wire 4. Also through comparison between FIG. 3 and
FIG. 23, the recess in FIG. 23 is apparently larger than the recess
of FIG. 3 (the size of the resin stem itself is equal as shown in
FIGS. 3 and 23). That is, the distance from the circumference of
the bottom of the recess 7 to the semiconductor light emitting
element 1 is smaller in this embodiment than that of the
conventional structure (D>d).
[0050] As explained above, the invention can locate the
semiconductor light emitting element 1 closer to the reflective
surfaces 8 than the conventional structure, and can use the
reflective surfaces 8 more effectively. That is, the invention
ensures that more light be reflected by the reflective surfaces 8
and taken out to the exterior. As a result, the light take-out
efficiency is improved.
[0051] The light-transmissive resin encapsulating element used in
the invention to form the projection 9 is made of a thermosetting
resin whereas the resin portion 10A of the resin stem 10 is made of
a thermoplastic resin. Therefore, adherability of them is generally
not good. In the present invention, however, since the
light-transmissive resin encapsulating material forming the
projection 9 and covering the upper surface of the resin portion
10A hangs down onto an upper part of the side surface, the adhering
strength between the resin stem and the light-transmissive resin
encapsulating material is improved. Therefore, the humidity
resistance of the device is improved, and thermal stress-cracking
is decreased.
[0052] Moreover, since the resin portion 10A is molded to embed the
lead frame, surfaces of the resin stem 10 can be aligned easily,
and the lead frame can be easily handled. Additionally, the
semiconductor light emitting device can be mounted easily when
incorporated into a set.
[0053] Next explained is a method for manufacturing the
semiconductor light emitting device according to the invention.
FIGS. 5 through 8B illustrate a method for manufacturing a
semiconductor light emitting device according to the first
embodiment of the invention. FIG. 5 is a flow chart of the
manufacturing process, FIGS. 6, 7A and 7B are cross-sectional views
of the device in different steps during the process for making the
projection of a light-transmissive resin, and FIG. 8A and 8B are
cross-sectional and plan views of the resin portion of the resin
stem.
[0054] The following steps are executed for manufacturing the
semiconductor light emitting device shown in FIG. 1. First of all,
the lead frame is set in a resin mold, and a thermoplastic resin is
applied into the cavity by injection molding, for example. It
results in obtaining the resin stem 10 including the resin portion
10A made of the thermoplastic resin (FIG. 5(1)). The resin stem has
formed a recess on its upper surface. Leads in the lead frame are
placed in the recess in a predetermined direction. A light emitting
element 1 (hereinafter called a chip) is mounted on one of the
leads by bonding the lead to the first electrode of the chip with
Ag paste, for example (FIG. 5(2)). Connected to the second
electrode of the chip is one end of a bonding wire, and the other
end of the bonding wire is connected to the other lead (FIG. 5(3)).
Next supplied is a thermosetting resin into the recess containing
the chip (FIG. 5(4)). On the other hand, a fluid-state resin is
injected into a encapsulating case mold (FIG. 5(5)). Then, a part
of the resin stem including its upper surface is dipped into the
encapsulating case mold (FIG. 5(6)). This step of the process is
explained with reference to FIG. 6.
[0055] The encapsulating case mold 11 contains the injected
fluid-state resin 12. The resin stem 10 oriented upside down is
progressively dipped into the fluid-state resin from its upper
surface until the leads 21 and 22, serving as a stopper, hits the
encapsulating case mold 11. The resin stem 10 is held there, with
the leads 21 and 22 contacting the encapsulating case mold 11,
until the resin sets. When the resin sets and the projection 9 is
formed, the product is removed from the encapsulating case mold
(FIG. 5(7)). Although this embodiment does not use, a parting agent
may be previously applied onto the inner surface of the
encapsulating case mold. The projection 9, thus made, may be used
as a lens, for example. After that, the lead frame is cut and
shaped into leads of a predetermined configuration (FIG. 5(8)).
Then, after a test of the semiconductor light emitting device,
additional treatment is done to complete the semiconductor light
emitting device (FIG. 5(9)).
[0056] FIGS. 7A and 7B show a second version of steps (6) and (7).
In this case, the encapsulating case mold 11 has at least one
projection 13 along the edge of its recess to serve as a stopper.
When the resin stem 10 comes down, the leads 21 and 22 engage the
projection 13. That is, since the leads do not directly hit the
encapsulating case mold, it is prevented that the fluid-state resin
flows out (leakage of resin) through between the leads and the
encapsulating case mold by capillarity. The semiconductor light
emitting device shown in FIG. 1 has been made in this process, and
the bottom surface of the projection 9 is distant from the leads by
a predetermined distance y. The distance y corresponds to the
height y of the projection 13 of the encapsulating case mold 11.
The spacer between the leads and the encapsulating case mold may be
formed on the resin stem instead of the encapsulating case mold as
illustrated. Particular consideration must be taken on the position
of the projection 13 relative to the encapsulating case mold in
order to ensure that the leads (lead frame) do not contact with the
fluid-state resin when the resin stem 10 is dipped into it.
[0057] FIGS. 8A and 8B show a third version of steps (6) and (7).
In this process, at least one through hole 14 is formed in the
resin stem 10 excepting the region of the recess. In the example
illustrated in FIGS. 8A and 8B, one through hole 14 for each corner
of the resin stem 10, namely four through holes in total, are
formed. The through holes serve as escape holes for an excessive
amount of the injected fluid-state resin to escape from the
encapsulating case mold when the resin stem is dipped into the
resin.
[0058] Next explained is a semiconductor light emitting device
taken as the second embodiment of the invention.
[0059] FIGS. 9A and 9B are plan and cross-sectional views of the
semiconductor light emitting device, and FIG. 10 is a
cross-sectional view of the semiconductor light emitting device for
explaining its manufacturing method. The semiconductor light
emitting device shown in FIGS. 9A and 9B is similar to that of FIG.
1 in construction. Namely, a semiconductor light emitting element 1
is mounted on the resin stem 10, a resin encapsulating element 5 of
a light-transmissive resin packs it, and a lens-shaped projection 9
of a light-transmissive resin is formed on the upper surface of the
resin stem 10 containing the resin encapsulating element 5. Since
the projection 9 covers the upper surface of the resin stem 10 and
the side surface continuous from the upper surface, the
adherability of the resin stem 10 and the projection 9 is high. The
semiconductor light emitting element 1 is aligned with the vertical
center axis of the projection 9 and the resin stem 10. In order to
increase the light take-out efficiency, the recess of the resin
stem 10 is eccentric from the center in a direction closer to the
edge from which the lead 22 extends to the exterior (in a direction
remoter from the edge from which the lead 21 extends to the
exterior). That is, the structure provides an ample area for the
bonding wire while shortening distances between the semiconductor
light emitting element 1 and the reflective surfaces 8.
[0060] To form the projection 9, a thermosetting resin is injected
into both a encapsulating case mold 11 and the recess 7 of the
resin stem 10. Before the thermosetting resin sets, the resin stem
10 is dipped into the fluid-state resin 12 in the encapsulating
case mold 11 from its upper surface. In this manner, even if the
resin contracts while it sets, part of the resin existing between
the encapsulating case mold 11 and the resin stem 10 (at regions A
and B in FIG. 10) compensates or absorbs it. Therefore, the
projection 9 can holds its shape of a lens also after setting of
the resin, and shortage of resin does not occur at the bonding area
with the resin stem 10.
[0061] Moreover, the resin stem 10 need not be intentionally hit to
the encapsulating case mold to prevent leakage of the resin to the
exterior before it sets. Therefore, this embodiment does not
require particular attention on the pressure for hitting the resin
stem 10 to the encapsulating case mold 11, and permits a low
accuracy in relative dimension between the encapsulating case mold
11 and the resin stem 10. That is, the embodiment permits a low
relative dimensional accuracy between different parts, and makes
the manufacturing process easier.
[0062] Next explained is another method for manufacturing the
semiconductor light emitting device according to the invention with
reference to FIG. 11 which is a cross-sectional view of the
semiconductor light emitting device shown in FIG. 9 in a step of
the manufacturing process. When the resin stem 10 is brought onto
the fluid-state resin 12 in the encapsulating case mold 11, air may
enter between them in form of bubbles. This embodiment intends to
prevent such bubbles and can make a high-quality resin
encapsulating element. Namely, a fluid-state thermosetting resin is
injected into both the encapsulating case mold 11 and the recess 7
of the resin stem 10. Amounts of the resin are adjusted to form
convex liquid surfaces. In this status, the resin stem 10 is
inserted from its upper surface into the fluid-state resin 12 in
the encapsulating case mold 11. Contact of both fluid-state resins
begins from their convex centers and progressively extends toward
their radially outward regions. Therefore, it is prevented that air
is confined in form of bubbles between both resins. In this case,
it is not necessary that both liquid surfaces be convex. Even when
one of the liquid surfaces is convex and the other is flat or
slightly concave, the same effect will be obtained. Also when a
through hole 15 is formed in the recess of the resins stem 10 to
release bubbles, a similar result is obtained.
[0063] Next explained is a semiconductor light emitting device
taken as the third embodiment of the invention. Heretofore, the
following technical problems have been recognized and desired to
overcome in the field of surface-packed semiconductor light
emitting devices. (1) Due to a structure making it difficult to
form a lens, the device has a low luminance. Moreover, due to
variance in amount of resin, setting contraction of epoxy resin,
etc., the resin surface becomes convex, and the luminance varies
largely. (2) The distance between the semiconductor light emitting
element and the stem reflective surface is long, in general, and
the effect of the reflective plate is small especially in a InGaAlP
compound semiconductor light emitting device where the active layer
is close to the surface of the element. (3) Since an epoxy resin of
a low Tg(glass transition temperature) is used, the epoxy resin
used as the resin encapsulating element applies a resin stress to
the bonding wire (Au wire) upon changes in ambient temperature, and
accelerates breakage of the wire. (4) Low Tg epoxy resins have low
crosslinking densities after being set, and are weak in humidity
resistance.
[0064] On account of the conventional semiconductor light emitting
device, the semiconductor light emitting device according to the
embodiment can remarkably alleviate the resin stress to the
semiconductor light emitting element and the Au wire upon changes
in ambient temperature by forming the projection of a
light-transmissive resin on the resin stem 10 in the same manner as
the embodiment of FIG. 1 and by additionally applying a silicone
resin into the recess of the resin stem 10. Moreover, the
reflective plate 8 of the resin stem 10 is positioned higher and
closer to the semiconductor light emitting element 1 to reflect
light from the side surface of the element upward and to improve
the optical output. Further, the embodiment provides a high-output
high-quality semiconductor light emitting device having a parabolic
reflective plate.
[0065] With reference to FIG. 12, a method for manufacturing the
semiconductor light emitting device is explained below. First of
all, the resin stem 10 is made by injection-molding a high
heat-resistant thermoplastic resin, such as liquid crystal polymer
(LCP), SPS, PPS, onto leads 21 and 22 prepared in form of a iron
(Fe)- or copper (Cu)-based lead frame. After that, the resin stem
10 is treated by ultraviolet radiation, and the semiconductor light
emitting element 1 is bonded to the resin stem 10 with Ag paste 3
by heating it to 200.degree. C. for two hours, approximately. Then,
the semiconductor light emitting element is connected to the lead
22 with a Au wire 4 of a diameter of 25 to 30 .mu.m. After that, a
light-transmissive silicone resin is poured onto the resin stem 10
to cover the entirety of the semiconductor light emitting element 1
and the Au wire 4, and it heated at 150.degree. C. for five hours,
approximately, to form the encapsulating element 5. Next, although
not shown, a projection of a light-transmissive resin for use as a
lens is formed on the resin stem 10 in the same manner as the first
embodiment, and it is heated and set at 125.degree. C. for six
hours, approximately. Then, appropriate coverage is made onto outer
parts of leads 21 and 22 by solder, Sn or Au, and they are cut to
remove excessive portions to complete the device.
[0066] FIG. 12 is a cross-sectional view of the resin stem having
mounted the semiconductor light emitting element. As shown, the
reflective surface is made closer to the semiconductor light
emitting element 1 and higher than in the conventional device (see
FIG. 22) to use the light emitted from the side surface of the
light emitting element as part of the externally emitted light (in
case of the side-surface emitted light, since the intensity
distribution of the light emitted from the side of the element 1
according to the Lambert's law originating from the active layer is
localized, the take-out efficiency of the light increases as the
reflective surface becomes higher and nearer to the light emitting
element). Although the illustrated reflective surface is
cone-shaped, a parabolic reflective surface exhibits a higher
reflective effect.
[0067] The material used in the embodiment for encapsulating the
recess of the resin stem 10 is a light-transmissive silicone resin.
The use of a silicone resin remarkably decreases the resin stress.
That is, since a conventional low-Tg epoxy resin applies a stress
to the Aug wire 4 upon thermal expansion or contraction of the
epoxy resin caused by changes in ambience temperature, the Au wire
4 is liable to break by fatigue in long-term temperature cycles
(approximately 100 cycles). In contrast, in this embodiment where
the semiconductor light emitting element 1 and the Au wire 4 are
entirely covered by the silicone resin 5, the resin stress of the
encapsulating element 5 is remarkably reduced, and the stress from
the projection 9 (see FIG. 1) is substantially removed (although
the silicone resin thermally expands and contracts, its stress is
negligibly small).
[0068] Further, in the conventional device, a low-Tg epoxy resin
has been used on account of a low adherability of the epoxy resin
to the stem of a thermoplastic resin. In the embodiment, however,
irradiation of ultraviolet rays onto the resin stem as explained
above activates the resin surface, improves the adherability even
of a high-Tg epoxy resin, and can significantly improve the
humidity resistance of the semiconductor light emitting device.
[0069] Moreover, a Fe- or Cu-based lead frame used in the
embodiment contributes to a reduction of the cost, and also the
in-line step of forming the resin stem integrally with the lead
frame contributes to providing an economical semiconductor light
emitting device.
[0070] Additionally, since the embodiment uses a lens-shaped case
mold, the light emitted from the light emitting element is
converged, and hence improves the luminance remarkably. Further,
the structure is usable to various applications by varying the lead
forming configuration, and semiconductor light emitting devices
having various optical characteristics can be prepared by changing
the encapsulating case mold.
[0071] Next explained is another embodiment of the invention with
reference to FIGS. 13 and 14. A typical filler agent contained in
the thermoplastic resin forming the conventional resin stem is
silica (SiO.sub.2). It results in a low reflective index and a low
optical output. Moreover, epoxy resins and other thermosetting
resins, in general, have no chemical bonds with thermoplastic
resins, and their adherability is weak. Moreover, since a low-Tg
epoxy resin is used, the humidity resistance is not good.
[0072] This embodiment, however, improves the composition of the
resin portion 10A of the resin stem 10 used in the semiconductor
light emitting device shown in FIG. 1. That is, in this embodiment,
(1) the resin stem having a reflective plate made of a
thermoplastic resin and a filler agent contains the thermoplastic
resin not less than 65 wt. % and the filler agent less than 35 wt.%
, and the filler agent contains titanium oxide not more than 20 wt.
% and aluminum oxide. (2) Used as the thermoplastic resin is a high
heat-resistant resin such as liquid crystal polymer (LCP). (3)
Ultraviolet rays are irradiated onto the molded resin stem.
[0073] A method for manufacturing the device is summarized below.
First prepared is a Fe-based or Cu-based metal plate-shaped lead
frame, such as NSD, as thin as 0.1 to 0.2 mm. Next, the resin stem
10 is injection-molded on the lead frame by using a high
heat-resistant thermoplastic resin such as LCP, PPS, SPg containing
TiO.sub.2, as the major component, and a filler agent. After the
semiconductor light emitting element 1, made of GaP, for example,
is mounted on the resin stem 10 with conductive paste 3 (at
200.degree. C. for two hours, approximately), wire bonding is done
using a bonding wire (Au wire) 4 with a very small diameter (25 to
30 .mu.m). After that, a light-transmissive epoxy resin is injected
into the recess 7 of the resin stem 10 (the vertical wall of the
recess serves as the reflective surface), and is held under
120.degree. C. for eight hours, approximately, to thermally harden
it. Thus, the encapsulating element 5 is obtained (see FIG. 12).
After that, the projection 9 of the same material as the
encapsulating element 5 is formed on the resin stem 10 by any one
of the methods explained before. Then, appropriate coverage is made
onto externally extended portions of the leads frame by solder or
Age, and it is cut and shaped into predetermined configurations for
the leads 21 and 22 to complete the semiconductor light emitting
device (see FIG. 1).
[0074] The semiconductor light emitting element 1 emits light not
only from its upper surface but also from its four side surfaces.
In order to improve the reflective index of four reflective plates
(reflective surface of the recess 7), a high reflective filler
agent, such as TiO.sub.2, is used. FIG. 13 shows changes in
reflective index (in %) with amount of TiO.sub.2 (in wt. %). It is
known that the reflective index tends to saturate when the amount
of TiO.sub.2 (titanium oxide) 10% or more). TiO.sub.2, however, is
expensive, and it usually makes it difficult to mold the resin
containing 30% or more TiO.sub.2. On account of this, by limiting
the amount of TiO.sub.2 within 10 to 15%, and one or more of
SiO.sub.2 (silica), Al.sub.2O.sub.3 (alumina), and so on, are used
to compensate the desired amount of the filler agent. Thus, an
inexpensive resin stem with a high reflective index can be
made.
[0075] On the other hand, thermosetting resins and thermoplastic
resins, in general, have no chemical bonds. Therefore, the
adherability is bad, and becomes worse when the temperature
increases. To cope with it, after the resin stem is formed by
injection-molding the thermoplastic resin, ultraviolet rays are
radiated onto the surface. After that, by injecting a thermosetting
resin, such as epoxy resin, and heating it, the adherability is
improved as shown in FIG. 14. The adhesivity (N/cm.sup.2) increases
and occurrence of the peel mode (%) decreases with radiation of
ultraviolet rays (mJ/cm.sup.2). These values apparently show
effects of irradiation of ultraviolet rays.
[0076] Presumably, irradiation of ultraviolet rays results in
breaking C-C' and C-H coupling on the surface of the resin stem and
in making dangling bonds, and the dangling bonds of the
thermoplastic resin, when heated, contributes to chemical bonding
with the thermosetting resin injected later. As a result, the
adherability between them can be doubled. The conventional device
uses a low-Tg thermosetting resin with an affinity with
thermoplastic resins in order to improve their adherability.
However, it gives only a small margin for the humidity resistance,
and this results in providing a small margin for reliability. The
present invention, however, makes it possible to use a high-Tg
thermoplastic resin with a high margin in humidity resistance, and
hence can remarkably improve the margin for reliability.
[0077] Next explained is another embodiment of the invention with
reference to FIGS. 15 and 16. This embodiment uses a blue light
emitting element or a ultraviolet light emitting element made of a
GaN compound material, for example, as its semiconductor light
emitting element. FIG. 15 is a cross-sectional view of the
semiconductor light emitting device according to the embodiment,
and FIG. 16 is its plan view. FIG. 15 is taken along the A-A' line
of FIG. 16.
[0078] In the semiconductor light emitting device shown here, the
semiconductor light emitting element 1' has formed the n-side
electrode and the p-side electrode on its upper surface, and they
are connected to the leads 21, 22 by bonding wires 4. The bottom
surface of the light emitting element 1' is typically an exposed
surface of an insulating substrate (such as sapphire substrate).
Therefore, short-circuiting does not occur even when the light
emitting element 1 is mounted on any one of the leads 21 and 22. In
the illustrated example, the semiconductor light emitting element
1' is mounted with its respective edges angled by approximately 45
degrees relative to the length-wise direction of the leads 21 and
22. The invention, however, is not limited to this. For example,
the semiconductor light emitting element 1' may be mounted with a
slanting angle other than 45 degrees or with no slanting angle like
the embodiment shown in FIG. 1.
[0079] In the embodiment shown here, the light emitting element 1'
has formed the first electrode and the second electrode on its
surface, and wires 4 are connected to these electrodes. Therefore,
the recess of the resin portion 10A has a configuration elongated
in the direction for connecting the wires 4. That is, the recess is
made longer in one direction to provide ample bonding areas for
individual wires 4 and shorter in the other direction to decrease
distances from the light emitting element 1 to reflective surfaces
8. In this manner, the reflective surfaces 8 can more effectively
reflect light emanating from side surfaces of the light emitting
element 1', and the light can be taken out with a high
efficiency.
[0080] In case of a structure different from the illustrated
example, where the light emitting element 1 has the p-side or
n-side electrode on its bottom surface as one of the preceding
embodiments, mounting and bonding of the light emitting element 1
may follow the same embodiment. An example of this type may use a
light emitting element made of a SiC compound material, ZnSe
compound material or BN compound material, for example. That is, in
these cases, an n-type semiconductor substrate is normally used,
and wiring is done as illustrated in FIG. 1.
[0081] In the embodiment, a fluorescent material may be added to
realize a semiconductor light emitting device with a novel
structure configured to convert light from the semiconductor light
emitting element 1' into different wavelength light before
extracting it to the exterior. For example, if an appropriate
fluorescent material is mixed when the resin portion 10A is molded,
incident light from the light emitting element 1' to the reflective
surface 8 of the resin stem is wavelength-converted and extracted
to the exterior of the light emitting device as different
wavelength light through the encapsulating element 5 and the lens
9.
[0082] Usable as the fluorescent material in the embodiment are
YAG:Ce compound materials (emitting yellow light) excited by
blue-light wavelengths, Y.sub.2O.sub.2S:Eu (emitting red light)
excited by ultraviolet rays, (Sr, Ca, Ba,
Eu).sub.10(PO.sub.4).sub.6.Cl.sub.2(emitti- ng blue light) and
3(Ba, Mg, Eu, Mn)O.8Al.sub.2O.sub.3 (emitting green light), for
example.
[0083] When a YAG:Ce fluorescent material is combined with a blue
light emitting element, white light can be taken out by mixing
yellow light from the fluorescent material and blue light from the
light emitting element. While light can be obtained also by mixing
ultraviolet-excited red, green, blue light emitting fluorescent
materials by an appropriate ratio.
[0084] Usable as the light emitting element used in the invention
is a blue light emitting element made of a GaN compound material or
an ultraviolet light emitting element introduced above. It is also
possible to use a light emitting element made of a SiC, ZnSe or BN
compound material.
[0085] Also when a fluorescent material is applied onto the surface
(reflective surfaces) of the resin portion 10A, substantially the
same effect is obtained. In this case, especially when appropriate
amounts of materials such as titanium oxide and zinc oxide, for
example, which reflects ultraviolet to blue light well, are mixed
into the stem 10, part of the light from light emitting element
passing through the fluorescent material layer is reflected by the
reflective surfaces 8 with a high reflective index, and is
wavelength-converted when again passing through the fluorescent
material layer. Therefore, a semiconductor light emitting device
with a high wavelength-converting efficiency and a high light
take-out efficiency can be realized.
[0086] Further, the same effect is obtained even by mixing a
fluorescent material into the adhesive (silver paste) for mounting
the light emitting element 1. That is, when light emitted to or
toward the bottom surface of the element 1 enters into the adhesive
3 containing the fluorescent material, it is wavelength-converted,
and taken out as different wavelength light to the exterior of the
light emitting device through the encapsulating material 5 and the
lens 9.
[0087] The same effect is obtained also by mixing the fluorescent
material into the encapsulating element 5. FIG. 17 is a flow chart
of a process therefor (FIG. 17(3")). By previously mixing an
appropriate ratio of a predetermined fluorescent material into the
encapsulating material (silicone resin, epoxy resin, etc.) and by
molding and thermally setting the encapsulating material, an
encapsulating element 5 containing the fluorescent material can be
obtained. In this case, by previously setting the encapsulating
material prior to forming the lens 9, the fluorescent material
mixed into the encapsulating material 5 is held within the
encapsulating 5 without dispersing it into the lens when the lens 9
is made. When the encapsulating element 5 is molded and set, the
grain size of the fluorescent material and the viscosity of the
encapsulating resin before setting may be adjusted such that, due
to precipitation of the fluorescent material after injection of the
resin, the fluorescent material be localized along the surface of
the encapsulating element 5 or along the surface for mounting the
light emitting element 1'. By causing precipitation to make the
fluorescent material layer in form of a high-density thin film and
by optimizing the thickness of the thin film, the wavelength
converting efficiency and the light take-out efficiency can be
optimized.
[0088] Since substantially all of light from the light emitting
element 1' enters into the encapsulating element 5 containing the
fluorescent material, more effective wavelength conversion is
promised than mixture thereof into the resin portion 10A or the
adhesive 3. Even when the lens 9 contains the fluorescent material,
the same effect can be obtained. Similarly to the encapsulating
element, a lens 9 containing a fluorescent material can be made by
previously mixing an appropriate ratio of a predetermined
fluorescent material into a lens material (epoxy resin, for
example) and by molding and thermally setting the lens
material.
[0089] Alternatively, prior to injection of the resin for molding
the encapsulating element 5, the fluorescent material may be
applied (coating) onto the surface of the light emitting element
1', or the semi-product may be pre-dipped into a solvent or
dispersing medium containing the fluorescent material to immerse
the light emitting element 1. Coating of the light emitting element
1' by the fluorescent material may be done either before or after
mounting the light emitting element 1'.
[0090] Next explained is a further embodiment of the invention with
reference to FIGS. 18 and 19. This embodiment uses a flip chip type
element as the semiconductor light emitting element. FIG. 18 is a
cross-sectional of the semiconductor light emitting device, and
FIG. 19 is a plan view. FIG. 18 is taken along the A-A' line of
FIG. 19.
[0091] In the semiconductor light emitting device shown here, a
semiconductor light emitting element 1" has formed an n-side
electrode and a p-side electrode directly connected to leads 21 and
22. The light emitted from the element 1" is taken out through the
projection 9. Since no wire is used to connect the semiconductor
light emitting element 1" to leads 21 and 22, this embodiment
requires no bonding region around the light emitting element 1". As
a result, the distance from the light emitting element 1" to the
reflective surfaces 8 can be minimized in all directions. That is,
since all of the reflective surfaces 8 effectively reflects light
emanating from any side surface of the light emitting element 1",
light can be taken out with a remarkably high efficiency.
[0092] The light emitting element 1, 1', 1" may be a semiconductor
light emitting element made of, for example, GaP, GaAlAs, GaAsP,
InGaAlP, GaN, or the like. Especially when a GaN, SiC, ZnSe or BN
compound material is used to make the light emitting element, light
can be taken out in a wavelength-converted form by using one or
more fluorescent materials which may be mixed into one of the resin
portion 10A of the resin stem 10, encapsulating element 5 or lens
9, or may be applied as a coating onto the inner wall surfaces of
the recess of the resin portion 10A or the surface of the
semiconductor light emitting element 1".
[0093] Embodiments of the invention have been described above as
manufacturing a single semiconductor light emitting device.
Actually, however, a plurality of semiconductor light emitting
devices can be fabricated simultaneously as shown in FIGS. 20 and
21. That is, semiconductor light emitting devices can be
mass-produced by attaching resin portions 10A to individual pairs
of leads 21 and 22 of the lead frame 2 (FIG. 20) and by molding
projections of a light-transmissive resin on resin stems, using a
case mold chain having a number of encapsulating case molds 11
continuously aligned in a row in intervals equal to intervals of
the lead pairs or the resin portions 10A (FIG. 21). The lead frame
used in the above-explained embodiments has the width (the full
length of a pair of leads, including the frame portions at opposite
ends of the leads) of approximately 55 mm. Projections can be
precisely aligned with resin stems 10 by properly positioning the
case mold chain relative to the lead frame.
[0094] Reference signs in the claims are intended for better
understandanig and shall not limit the scope.
* * * * *