Semiconductor light emitting apparatus, method for manufacturing the same, and liquid crystal display apparatus using the same

A method for manufacturing a semiconductor light emitting apparatus of side emission type includes disposing a light emitting device on a substrate having a predetermined electrode pattern. A side member is disposed on the substrate to be spaced apart from the light emitting device with a predetermined space. The light emitting device and the electrode pattern are electrically connected. A light reflecting member is disposed in the space between the side member and at least one side surface of the light emitting device so that the light reflecting member is in contact with the at least one side surface of the light emitting device. A light-transmitting sealing member is disposed to surround the light emitting device other than the at least one side surface that is in contact with the light reflecting member. A light-reflective ceiling member is disposed at least over the sealing member.

This application claims the priority benefit under 35 U.S.C. §119 of Japanese Patent Application No. 2009-219476 filed on Sep. 24, 2009, which is hereby incorporated in its entirety by reference.

TECHNICAL FIELD

The present invention relates to a semiconductor light emitting apparatus having a light emitting device (LED) installed therein, and in particular, to a semiconductor light emitting apparatus suitable for an edge-lighting type backlight for a liquid crystal display apparatus.

BACKGROUND ART

Conventionally known liquid crystal display apparatuses utilize a backlight, and for example, concrete examples thereof include a direct type backlight in which a light source unit including a light emitting device is disposed in the rear of a liquid crystal panel, and an edge-lighting type backlight in which a light source unit including light emitting devices arranged in line is disposed while facing to the end portion of a light guide plate. The present invention specifically aims to provide a semiconductor light emitting apparatus for use in the latter edge-lighting type backlight.

As the thinning of profiles of the liquid crystal display apparatus progresses, the light guide plate and the light source for an edge-lighting type backlight are also required to be thinned. For example, Japanese Patent Application Laid-Open No. 2009-105173 (US2009/0103005A1 corresponding thereto) discloses a light source module having a structure in which the upper surface of a light source device (LED chip) faces to the end of a light guide plate, thereby making its profile thinned and reducing the used amount of a sealed resin. Japanese Patent Application Laid-Open No. 2007-59612 discloses a light emitting diode of side emission type. The light emitting diode includes substrates provided above and below the components, a light emitting device interposed between the substrates and having a side facing to an end of a light guide plate, a reflector surrounding three sides of the light emitting device other than the side closer to the light guide plate, and a transparent resin with which a space defined by the substrates and the reflector is filled.

Hereinafter, a description will be given of a conventional semiconductor light emitting apparatus utilizing a light emitting diode as described in Japanese Patent Application Laid-Open No. 2007-59612 with reference toFIGS. 1A and 1B. The semiconductor light emitting apparatus of so-called side-view type includes a light emitting device102, of which a side surface faces to an end of a light guide plate, a substrate100, a side member104, and an upper substrate105. The light emitting device102is disposed within a cavity defined by the substrate100, the side member104, and the upper substrate105and having a light projecting outlet103at its one side. It should be noted that the inner surface of the cavity can also serve as a reflecting surface, and the deepest side is called as a reflector101hereinafter. The cavity is filled with a transparent sealing material106.

In the above-configured light emitting apparatus, when the light emitting device102is activated, light can be emitted from its entire peripheral surfaces. In this case, the light emitting device102can emit light toward the reflector101of the side member104(in the rearward direction) which is opposite from the light projecting outlet103. The light can be reflected by the reflector101to be directed to the light projecting outlet103. This means the light must travel a longer optical path from the light emitting device102via the reflector101to the light projecting outlet103. The sealing material106existing in the optical path can attenuate the light more.

In order to cope with this problem, a semiconductor light emitting apparatus as shown inFIGS. 2A and 2Bhas been devised. The semiconductor light emitting apparatus includes a light emitting device102that is in contact with a reflector101at the rear surface of the light emitting device102. However, when manufacturing such a semiconductor light emitting apparatus as shown inFIGS. 2A and 2B, there are the following problems.

FIG. 3Ashows a typical manufacturing step of such a semiconductor light emitting apparatus as shown inFIGS. 1A and 1B. In this case, when the light emitting device102is disposed within a cavity, the light emitting device102is sucked by a suction jig107at the tip end of the jig107to be moved for positioning. In order to manufacture the semiconductor light emitting apparatus as shown inFIGS. 2A and 2B, the light emitting device102must be precisely disposed so that it is brought into contact with a side member104. However, the control of the jig107is not so easy.

For example, as shown inFIG. 3B, if the outer diameter of the suction jig107is larger than that of the light emitting device102, when the suction jig107is lowered while sucking the light emitting device102, the suction jig107collides with the side member104. Accordingly, the light emitting device102cannot be disposed while being in contact with the side member104.

In order to cope with this problem, it is conceivable that the diameter of the suction jig107can be reduced as shown inFIG. 3C. However, also in this case, when the movement accuracy of the suction jig107is low in the direction toward the main surface of the substrate100, the light emitting device102may collide with the upper surface of the side member104. Accordingly, it is difficult to dispose the light emitting device102while being brought into contact with the side face of the side member104with high accuracy.

SUMMARY

The present invention was devised in view of these and other problems and features in association with the conventional art, and provides a semiconductor light emitting apparatus of side emitting type with high light emission efficiency and light utilization efficiency as well as a manufacturing method.

A first aspect of the present invention provides a method for manufacturing a semiconductor light emitting apparatus. The method can include: disposing a light emitting device on a substrate having a predetermined electrode pattern formed thereon; disposing a side member on the substrate to be spaced apart from the light emitting device with a predetermined space; electrically connecting the light emitting device with the electrode pattern; disposing a light reflecting member in a space between at least one side surface of the light emitting device and the side member so that the light reflecting member is in contact with the at least one side surface of the light emitting device; disposing a sealing member to surround the light emitting device other than the side surface thereof that is in contact with the light reflecting member, the sealing member being adapted to transmit light from the light emitting device; and disposing a ceiling member at least on or above the sealing member, the ceiling member being light reflective.

In the above configuration, the semiconductor light emitting apparatus can include a light projecting outlet. Assuming that the side surface of the light emitting device closest to the light projecting outlet is a front surface and that the side surface of the light emitting device opposite from the front surface is a rear surface, the side member can surround both the side surfaces and rear surface of the light emitting device other than the front surface while being spaced apart therefrom. In addition, in the step of disposing the light reflecting member, the light reflecting member can be disposed in a space between the side member on a rear surface side of the light emitting device and the rear surface of the light emitting device, and the light reflecting member can be brought into contact with the rear surface of the light emitting device.

In the step of disposing the light reflecting member, an uncured resin material for forming the light reflecting member can be disposed. In the step of disposing the sealing member, an uncured resin material for forming the sealing member can be disposed. The resin materials for forming the light reflecting member and for forming the sealing member can then be simultaneously cured.

The electrode pattern on the substrate can be present behind the light emitting device, and in the step of electrically connecting the device to the pattern, the light emitting device and the electrode pattern present behind the device can be connected with each other via a wire, which is buried in the light reflecting member disposed in the space between the side member on the rear surface side of the light emitting device and the rear surface of the light emitting device, with an original shape of the wire remaining.

The step of disposing the light reflecting member can include forming the light reflecting member by using a resin material having an adjusted thixotropic property and/or an adjusted viscosity so that the light reflecting member disposed in the space between the side member on the rear surface side of the light emitting device and the rear surface of the light emitting device has a raised shape having a convex surface that is higher than the top surface of the light emitting device.

A second aspect of the present invention provides a method for manufacturing a semiconductor light emitting apparatus. The method can include: disposing a light emitting device on a substrate having a predetermined electrode pattern formed thereon; electrically connecting the light emitting device with the electrode pattern; disposing a light reflecting member in a space on the substrate so that the light reflecting member is at least partly in contact with a side surface of the light emitting device; disposing a sealing member to surround the light emitting device other than a part thereof that is in contact with the light reflecting member, the sealing member being adapted to transmit light from the light emitting device; and disposing a ceiling member at least on or above the sealing member, the ceiling member being light reflective.

In the above configuration, the light reflecting member can be provided by being hardened after filling or coating a light reflective resin material.

In the above configuration, the sealing member can be provided by being hardened after filling or coating a sealing resin material.

In the above configuration, the ceiling member can be provided by being hardened after filling or coating a light reflective resin material or by providing a light reflective film.

A third aspect of the present invention provides a semiconductor light emitting apparatus. The semiconductor light emitting apparatus can include: a substrate; a light emitting device disposed on the substrate; a side member surrounding the light emitting device and spaced apart therefrom with a predetermined space, the side member having an opening at one side; a light reflecting member disposed in a space between a side surface of the light emitting device opposite from the opening and the side member so that the light reflecting member is in contact with the side surface of the light emitting device opposite from the opening; a sealing member disposed in a space between the side member and side surfaces of the light emitting device where the light reflecting member is not provided, the sealing member being adapted to transmit light from the light emitting device; and a ceiling member covering at least the sealing member, the ceiling member being light reflective.

The substrate can have an electrode formed thereon. A wire for electrically connecting the electrode on the substrate and the light emitting device can be disposed in the space between the side surface of the light emitting device opposite from the opening and the side member. The light reflecting member can be provided so as to bury the wire.

The semiconductor light emitting apparatus can further include an electronic circuit device disposed in the space between the side surface of the light emitting device opposite from the opening and the side member. The light reflecting member can be provided so as to bury the electronic circuit device.

A fourth aspect of the present invention provides a semiconductor light emitting apparatus. The semiconductor light emitting apparatus can include: a substrate; a light emitting device disposed on the substrate; a light reflecting member disposed in a space surrounding a part of the light emitting device so that the light reflecting member is in contact with at least one side surface of the light emitting device; a sealing member disposed to surround the light emitting device other than an area of the light emitting device that is in contact with the light reflecting member, the sealing member being adapted to transmit light from the light emitting device; and a ceiling member covering at least the sealing member, the ceiling member being light reflective. Furthermore, the light reflecting member can be disposed so as to be in contact with the ceiling member.

A fifth aspect of the present invention provides a liquid crystal display apparatus. The liquid crystal display apparatus can include a liquid crystal panel having a front surface that is observed from outside and a rear surface opposite from the front surface, a light guide plate disposed to face the rear surface of the liquid crystal panel and having an end surface that serves as a light receiving surface, and a semiconductor light emitting apparatus disposed so as to face the end surface of the light guide plate. The semiconductor light emitting apparatus can include: a substrate; a light emitting device disposed on the substrate; a side member surrounding the light emitting device and spaced apart therefrom with a predetermined space, the side member having an opening at one side; a light reflecting member disposed in a space between a side surface of the light emitting device opposite from the opening and the side member so that the light reflecting member is in contact with the side surface of the light emitting device opposite from the opening; a sealing member disposed in a space between the side member and side surfaces of the light emitting device where the light reflecting member is not provided, the sealing member being adapted to transmit light from the light emitting device; and a ceiling member covering at least the sealing member, the ceiling member being light reflective.

A sixth aspect of the present invention provides a liquid crystal display apparatus. The liquid crystal display apparatus can include a liquid crystal panel having a front surface that is observed from outside and a rear surface opposite to the front surface, a light guide plate disposed to face the rear surface of the liquid crystal panel and having an end surface that serves as a light receiving surface, and a semiconductor light emitting apparatus disposed so as to face the end surface of the light guide plate. The semiconductor light emitting apparatus can include: a substrate; a light emitting device disposed on the substrate; a light reflecting member disposed in a space surrounding a part of the light emitting device so that the light reflecting member is in contact with at least one side surface of the light emitting device; a sealing member disposed to surround the light emitting device other than an area of the light emitting device that is in contact with the light reflecting member, the sealing member being adapted to transmit light from the light emitting device; and a ceiling member covering at least the sealing member, the ceiling member being light reflective. Furthermore, the light reflecting member is disposed so as to be in contact with the ceiling member.

DETAILED DESCRIPTION

A description will now be made below of semiconductor light emitting apparatuses of the presently disclosed subject matter with reference to the accompanying drawings in accordance with exemplary embodiments.

First Exemplary Embodiment

FIG. 4is a cross-sectional view illustrating a semiconductor light emitting apparatus according to the present invention andFIG. 5Eis a top plan view of the same. The semiconductor light emitting apparatus20of the present exemplary embodiment can include: a substrate1including electrodes formed on its surface (not shown inFIG. 4); a spacer4, being a side member, mounted on the substrate1and having a semi-circular opening; a light emitting device (LED chip)2disposed on the substrate1within the opening; wires8connecting the light emitting device2to the electrodes; a light reflecting member3disposed in a space between the light emitting device2and the spacer4; a ceiling member5; and a sealing member7to be filled in a cavity defined by these members.

The sealing member7can seal the light emitting device2to surround it. The sealing member7can be, in addition to a transparent material, a transparent material containing functional particles such as phosphors, light scattering materials, particles for improving thixotropic property, and the like.

The ceiling member5may be light reflective and can be disposed at the upper area of the opening of the spacer4to cover the top surfaces of the light reflecting member3and the sealing member7.

The semiconductor light emitting apparatus20is a light emitting diode of side emission type, in which a light projecting outlet6is defined at a side opposite to the spacer4where the spacer4is not provided. The light emitted from the light emitting device2can exit through the light projecting outlet6. If phosphors are contained and dispersed in the sealing member7, part of the emitted light can be wavelength-converted by the phosphors to exit through the light projecting outlet6together with the direct light from the light emitting device2to be mixed with the direct light. In this case, since the light reflecting member3is configured to be in contact with the rear surface of the light emitting device2, the light emitted toward the rear surface of the light emitting device2cannot exit therethrough, but is returned to the inside of the light emitting device2. The light emitted from the light emitting device2through the top surface and both side surfaces of the device2can be reflected by the ceiling member5, the spacer4and the light reflecting member3to be directed to the light projecting outlet6and exit therethrough.

Accordingly, the present exemplary embodiment is configured as shown inFIG. 4such that the semiconductor light emitting apparatus20of side emission type includes the light reflecting member3disposed in contact with the rear surface of the light emitting device2opposite from the light projecting outlet6with respect to the device2. Thus, the light emitted toward the rear side can be reflected by the light reflecting member3toward the inside of the light emitting device2, thereby shortening the optical path length from the light emitting device2through the sealing member7to the light projecting outlet6as a whole. This configuration can prevent the attenuation of light by the sealing member, thereby improving the light emission efficiency and the light utilization efficiency of the semiconductor light emitting apparatus20.

Next, a description will be given of a method for manufacturing the semiconductor light emitting apparatus ofFIG. 4with reference toFIGS. 5A to 5Eand6A to6E. It should be noted thatFIGS. 5A to 5Eshow the respective top surfaces of the minimum unit (including two semiconductor light emitting apparatuses) andFIGS. 6A to 6Eshows the respective cross-sectional views of three consecutive minimum units.

As shown inFIGS. 5A and 6A, a substrate1made of glass epoxy is prepared, for example. The substrate1can have electrode patterns9aand9bformed thereon by copper foil plated with Au or Ag in a predetermined shape in advance. A spacer4having a circular opening is fixed on the substrate1with an adhesive or the like. Next, a not-shown suction jig is allowed to hold a light emitting device2and place the same in position within the circular opening area. Performing die-bonding can connect the electrode of the light emitting device2with the electrodes on the substrate1with bonding wires8.

Next, a light reflective resin material for forming the light reflecting member3is disposed in a space between the rear surface of the light emitting device2and the spacer4. The material for the light reflecting member3can be a silicone resin including titanium oxide as a light reflecting material, and if required, particles for improving thixotropic property, dispersed in a predetermined amount. The prepared material can be filled in or coated to a predetermined space between the light emitting device2and the spacer4by a dispensing method, printing method, or the like. It should be noted that the uncured resin material can be preferably cured at the same time when the sealing member is cured at the next step. In view of this, the resin material remains uncured in this step, and the process proceeds to the next step.

Next, as shown inFIGS. 5C and 6C, a transparent resin material can be used to seal the space surrounding the light emitting device2, being the space defined by the spacer4, the light emitting device2and the light reflecting member3, to form the sealing member7. The material for forming the sealing member7can be, for example, a silicone resin containing predetermined phosphors, light scattering materials, particles for improving thixotropic property, and the like. The sealing member7can be filled by a dispensing method or a printing method.

In this case, the resin material for forming the light reflecting member3and the resin material for forming the sealing member7can be selected among resin materials that cannot be mixed with each other in an uncured state. Furthermore, it is preferred that the materials be highly thixotropic. By doing so, both materials can be raised to have predetermined shapes at respective predetermined positions without being mixed with each other.

Next, the resin materials for the light reflecting member3and the sealing member7are cured by an appropriate curing technique such as heating or UV light irradiation to form the light reflecting member3and the sealing member7. As described above, if the resin materials having high thixotropic property and being curable by the same curing treatment are used, the curing process can be carried out a single step. Since the light reflecting member3and the sealing member7can be simultaneously formed, the manufacturing efficiency can be improved. In general, heat curing requires separate heating and cooling steps, which require substantial periods of time. As in the present exemplary embodiment, the light reflecting member3and the sealing member7can be cured simultaneously in a single curing treatment. Accordingly, the time required for curing can be shortened half the total time required for separate curing steps.

Next, as shown inFIGS. 5D and 6D, a light reflective resin material for forming a ceiling member5can be filled in or coated to an upper area of the opening of the spacer4so as to cover the upper area of the light reflecting member3and the sealing member7. The resin material is cured, thereby forming the ceiling member5. The ceiling member5may be provided as a separate light reflective plate member for covering the upper surfaces of the light reflecting member3and the sealing member7. In the present exemplary embodiment, the ceiling member5can be formed by the light reflective resin material, so that the ceiling member5can have a shape following the shapes of the sealing member7and the light reflecting member3, which can provide advantageous effects in manufacturing. The material for forming the ceiling member5can be, for example, a silicone resin containing light reflective titanium oxide particles dispersed in an appropriate amount. The prepared material can be filled in or coated to a predetermined space above the light reflective member3and the sealing member7by a dispensing method, printing method, or the like. Next, the resin material is cured by an appropriate curing technique such as heating or UV light irradiation to form the ceiling member5.

Then, as shown inFIGS. 5E and 6E, the assembly of the substrate1and other components is cut at the center position of the opening of the spacer4vertically with respect to the surface of the substrate where the components are symmetrically arranged. Accordingly, the individual semiconductor light emitting apparatuses are separated. In such a way, the semiconductor light emitting apparatus of side-view type having the light reflecting member3can be manufactured.

As described above, the present exemplary embodiment can include the steps of filling or coating the respective resin materials by a dispensing method, printing method, and the like to form the light reflecting member3, the sealing member7and the ceiling member5, respectively, in-line. Therefore, there is no need to separately form these members by separate processes and then assemble these individual members. According to the present exemplary embodiment, a semiconductor light emitting apparatus having a light reflecting member that is easily and accurately provided in contact with the rear surface of a light emitting device can be manufactured with ease.

Furthermore, by adjusting the thixotropic properties or viscosity of the respective resin materials, the light reflecting member3and the sealing member7can be positioned in place without being mixed with each other even when they are uncured. This configuration can achieve simultaneous curing of these materials. Accordingly, the curing can be done by a single step, thereby improving the manufacturing efficiency. In this case, there is no need for the raw materials for the resin materials forming these members3and7to be the same. The materials should preferably have the predetermined thixotropic properties and/or viscosity, and, accordingly, they can be cured by the same process so that the manufacturing method includes a single curing process for these members.

On the other hand, the resin material for forming the ceiling member5may be a different material from the resin materials for forming the light reflecting member3and the sealing member7. Alternatively, the ceiling member5can be formed as a metal film directly formed over the top surfaces of the light reflecting member3and the sealing member7by sputtering or the like.

In the present exemplary embodiment, as shown inFIG. 4, the light reflecting member3is configured to be in contact with the rear surface of the light emitting device2. However, the present invention is not limited to this exemplary embodiment. A modification of the present exemplary embodiment will be described with reference toFIGS. 7A to 7D. In this modification, by adjusting the viscosity, thixotropic property and/or an injection amount of the resin material, the semiconductor light emitting apparatuses with various inner structures as illustrated inFIGS. 7A to 7Dcan be manufactured, thereby obtaining the advantageous effects of the present invention.

FIG. 7Ashows a modification in which the light reflecting member3is configured to be in contact with only the rear surface of the light emitting device2as inFIG. 4. In this configuration, the light can be emitted only from the front end surface of the light emitting device2closer to the light projecting outlet6. Furthermore, the ceiling member5can be formed to have a curved lower surface near the rear surface of the light emitting device2, and accordingly, there is no cavity between the rear surface of the light emitting device2and the spacer4where the sealing member7may enter. In this configuration, the light emitted toward the rear surface side can be reflected by any of the light reflecting member3and the ceiling member5, thereby effectively directing the light to the light projecting outlet.

FIG. 7Bshows a modification in which the light reflecting member3is configured to cover the light emitting device2at its side surfaces other than the side surface closer to the light projecting outlet, namely the rear surface, top surface, right and left side surfaces of the light emitting device2. In this configuration, the light can be emitted only from the front end surface of the light emitting device2closer to the light projecting outlet6.FIG. 7Cshows another modification in which the light reflecting member3and the sealing member7have the same top surface levels (are flush with each other) by adjusting the viscosity and/or thixotropic property of the respective resin materials of the light reflecting member3and the sealing member7(for example, the former has a higher viscosity and/or thixotropic property than the latter). In this case, the thickness of the ceiling member5covering the light reflecting member3and the sealing member7can be uniform.FIG. 7Dshows still another modification in which the light reflecting member3is configured to have a height the same as that of the spacer4. Accordingly, the ceiling member5is not provided on the light reflecting member3, but is provided over the sealing member7near the light projecting outlet6.

In any of the above modifications, the light emitted toward the rear surface of the light emitting device2cannot exit but can be reflected by the light reflecting member3that is provided in contact with the light emitting device2to be returned to the inside of the device2. Accordingly, the optical path length in the sealing member7through which the light travels can be shortened, thereby preventing the light from attenuating by the sealing member7. This configuration can improve the light utilization efficiency as well as the light emitting efficiency with which the light can effectively exit the light projecting outlet.

A separately prepared light emitting member3(having already been cured) may be disposed in the rear of the light emitting device.

Second Exemplary Embodiment

A second exemplary embodiment of the semiconductor light emitting apparatus of the present invention will be described with reference toFIGS. 8A and 8B.

In the second exemplary embodiment, a spacer4having a square opening is utilized instead of the spacer4having a semi-circular opening in the first exemplary embodiment. The light emitting device2and the light reflecting member3and the like are disposed within a rectangular parallelepiped cavity defined by this spacer4.

In the present exemplary embodiment, the light reflecting member3is also configured so as to be in contact with the rear surface of the light emitting device2. In this configuration, as in the first exemplary embodiment, the light cannot exit from the rear surface of the light emitting device2, thereby improving the light utilization efficiency. At the same time, the optical path length can be shortened within the cavity, thereby improving the light emitting efficiency with which the light can effectively exit the light projecting outlet6.

The semiconductor light emitting apparatus of the present exemplary embodiment can be manufactured by the same method as in the first exemplary embodiment except for utilizing the spacer4having a square opening instead of the spacer4having a semi-circular opening. Accordingly, a detailed description thereof will be omitted here.

Third Exemplary Embodiment

A third exemplary embodiment of the semiconductor light emitting apparatus of the present invention will be described with reference toFIGS. 9A to 9E.

In the third exemplary embodiment, instead of utilizing the spacer4in the first exemplary embodiment, certain thixotropic properties of the resin materials of the light emitting member and the sealing member are utilized to manufacture the semiconductor light emitting apparatus having the same advantageous effect as in the first exemplary embodiment.

As shown inFIG. 9A, a substrate1having an electrode pattern formed thereon is prepared as in the same process ofFIGS. 5A and 6Aof the first exemplary embodiment. The different point from the first exemplary embodiment is the absence of the spacer4. In this state, the light emitting device2is mounted on the substrate1at a predetermined position, and bonding wires8connect the electrode pattern with the device2.

Next, as shown inFIG. 9B, a resin material for forming the light reflecting member3is prepared as the same material used in the first exemplary embodiment in the process shown inFIGS. 5B and 6B, and is filled in or coated to a predetermined space on the substrate1by a dispensing method, printing method, or the like. In this instance, the thixotropic property and/or the viscosity of the resin material is adjusted to fill/coat the material so that the material is raised to or above the uppermost level of the light emitting device2. This process can form an upper surface the light reflecting member3is convex and is in contact with the light emitting device2. In the present exemplary embodiment, since there is no spacer4, the light reflecting member3can be formed by filling/coating the resin material not only at the originally intended area as in the first exemplary embodiment, but also at the area where the spacer4is arranged in the first exemplary embodiment. In this instance, the resin material for forming the light reflecting member3can be shaped to have an appropriate shape so that a cavity having a predetermined circular or square shape is defined.

In the processes as shown inFIGS. 9C and 9D, the same as in the processes ofFIGS. 5C and 5D, and6C and6D, the resin material for the sealing member7is filled in or coated to an appropriate area, and then cured together with the resin material for forming the light reflecting member3. Thereafter, the resin material for forming the ceiling member5is filled in or coated to an upper area of the light reflecting member3and the sealing member7, and cured to form the ceiling member5.

Finally, in the process as shown inFIG. 9E, the assembly of these components is cut at the center position of the cavity defined by the light reflecting member3vertically with respect to the surface of the substrate1where the components are symmetrically arranged. Accordingly, the individual semiconductor light emitting apparatuses are separated.

In this case, the third exemplary embodiment does not use a spacer4, thereby reducing the number of the components. In the third exemplary embodiment, since the light reflecting member3is adjusted in its viscosity and/or thixotropic property and the amount used for filling/coating, a desired cavity shape can be formed. Accordingly, in addition to the advantageous effects of the previous first and second exemplary embodiments, the third exemplary embodiment can control the improved light emitting efficiency by the desired cavity shape.

Fourth Exemplary Embodiment

Next, a fourth exemplary embodiment of the semiconductor light emitting apparatus of the present invention will be described with reference toFIGS. 10A to 10Eand11A to11E.

In the fourth exemplary embodiment, a plurality of light emitting devices are arranged within the semicircular cavity so that the light emitted from the plurality of light emitting devices is mixed together to be emitted through the light projecting outlet.

First, a method for manufacturing a semiconductor light emitting apparatus having two light emitting devices2aand2binstalled therein will be described with reference to the top plan views ofFIGS. 10A to 10E. It should be noted that the same processes in the manufacturing processes of the present exemplary embodiment as in the first exemplary embodiment will be omitted in some cases.

First, as shown inFIG. 10A, a substrate1having predetermined electrode patterns9aand9bformed thereon is prepared. A spacer4having a circular opening is mounted thereon and fixed by an adhesive or the like. Within the opening, two pairs of light emitting devices2aand2bare mounted at predetermined positions. Then, electrodes formed on the light emitting devices2aand2bare connected to the electrode patterns9aand9bby bonding wires8, respectively.

During the bonding process, there is no light reflecting member3disposed within the circular opening area of the spacer4. In this instance, the light emitting devices2aand2bare disposed near the center area of the circular opening, namely near the position where the light projecting outlet will be formed, and then the wires8can be bonded toward the electrode pattern9ain the rear of the light emitting devices2aand2b.

Next, as shown inFIG. 10B, the resin material for forming the light reflecting member3is filled in or coated to a predetermined space between the spacer4and the rear surfaces of the light emitting devices2aand2bby a dispensing method, printing method, or the like. In this instance, the spaces in the rear of the light emitting devices2aand2bcontain the curved wires8. Accordingly, the uncured resin material is filled in the spaces so as to bury the curved wires8with the uncured resin material therearound. In this manner, the shapes and electric characteristics of the wires8are not adversely affected.

Then, as shown inFIGS. 10C and 10D, the resin material for forming the sealing member7is filled in or coated to an appropriate area, and then cured together with the resin material for forming the light reflecting member3. Thereafter, the resin material for forming the ceiling member5is filled in or coated to an upper area of the light reflecting member3and the sealing member7, and cured to form the ceiling member5.

Finally, in the process as shown inFIG. 10E, the assembly of these components is cut at the center position of the cavity defined by the spacer4vertically with respect to the surface of the substrate where the components are symmetrically arranged. Accordingly, the individual semiconductor light emitting apparatuses are separated.

As described above, the uncured resin material is filled in the space in the rear of the light emitting device and then cured. Accordingly, the wires can be arranged in the rear of the light emitting devices in advance. This can achieve a high degree of freedom for arranging the wires and the electrode patterns. Furthermore, even if the cavity is narrow, the light emitting devices can be arranged side by side near the position where the light projecting outlet will be formed after separation. Accordingly, even when the apparatus is designed to be compact, the two light emitting devices can emit light near the light projecting outlet while mixing their light, thereby providing a semiconductor light emitting apparatus with high light intensity.

As in the previous exemplary embodiments, the light reflecting member is arranged to be in contact with the rear surface of the light emitting device. Accordingly, the optical path length through the sealing member7with respect to any of the light emitting devices can be shortened, thereby effectively preventing the light from attenuating due to the sealing member. This can increase the light intensity as a whole.

As a modification of the present exemplary embodiment, a method for manufacturing a semiconductor light emitting apparatus having three light emitting devices2a,2b, and2cinstalled therein will be described with reference to the top plan views ofFIGS. 11A to 11E.

First, as shown inFIG. 11A, a substrate1having predetermined electrode patterns9a,9b,9c, and9dformed thereon is prepared. A spacer4having a circular opening is mounted thereon and fixed by an adhesive or the like. Within the opening, two sets of light emitting devices2a,2b, and2care mounted at predetermined positions. Then, electrodes formed on the light emitting devices2a,2b, and2care connected to the electrode patterns9a,9b,9c, and9dby bonding wires8, respectively. The illustrated exemplary embodiment utilizes the light emitting device2bhaving a backside electrode, and the backside electrode is connected to the electrode pattern where the device2cis mounted via a solder bump or the like during die bonding. The top electrode of the light emitting device2bis connected to the electrode pattern9bby the wire8.

During the bonding process, there is no light reflecting member3disposed within the circular opening area of the spacer4. Accordingly, the wires8can be freely arranged within this area. Namely, the wires8can be bonded toward the electrode patterns9aand9bin the rear of the light emitting devices2aand2b. In this configuration, the light emitting devices2a,2b, and2care disposed near the center area of the circular opening, namely near the position where the light projecting outlet will be formed.

Next, as shown inFIG. 11B, the resin material for forming the light reflecting member3is filled in or coated to predetermined spaces between the spacer4and the rear surfaces of the light emitting devices2a,2b, and2cby a dispensing method, printing method, or the like. In this instance, the spaces in the rear of the light emitting devices2a,2b, and2ccontain the curved wires8. Accordingly, the uncured resin material is filled so as to bury the curved wires8with the uncured resin material therearound. In this manner, the shapes and electric characteristics of the wires8are not adversely affected.

Then, as shown inFIGS. 11C and 11D, the resin material for forming the sealing member7is filled in or coated to an appropriate area, and then cured together with the resin material for forming the light reflecting member3. Then, as in the previous exemplary embodiment, the ceiling member5is formed. Finally, in the process as shown inFIG. 11E, the assembly of these components is cut at the center position of the cavity defined by the spacer4vertically with respect to the surface of the substrate1where the components are symmetrically arranged. Accordingly, the individual semiconductor light emitting apparatuses are separated.

As described above, the modification of the present exemplary embodiment can manufacture the semiconductor light emitting apparatus including three light emitting devices arranged near the position of the light projecting outlet.

Namely, in the present exemplary embodiment, a plurality of light emitting devices each having different emission wavelengths can be disposed side by side near the position where the light projecting outlet will be formed. The side-by-side arrangement can prevent the absorption of light by adjacent light emitting devices, thereby preventing light attenuation. Accordingly, even when the apparatus is designed to be compact, three light emitting devices can emit desired light while mixing their light to, for example, white light, thereby providing a semiconductor light emitting apparatus enabling to emit white light.

Fifth Exemplary Embodiment

Next, a fifth exemplary embodiment of the semiconductor light emitting apparatus of the present invention will be described with reference toFIGS. 12A and 12B.

In the fifth exemplary embodiment, a spacer4having a square opening as in the second exemplary embodiment is utilized instead of the spacer4having a semi-circular opening in the first exemplary embodiment. In addition, a plurality of light emitting devices, a light reflecting member, and the like are arranged within the square-shaped cavity defined by the spacer4. It should be noted thatFIGS. 12A and 12Billustrate the semiconductor light emitting apparatus where the ceiling member5and the sealing member7are omitted in the drawing for facilitating understanding.

The method for manufacturing the semiconductor light emitting apparatus of the present exemplary embodiment is the same as the fourth exemplary embodiment except for the spacer4having a square opening. Accordingly, the description for the other features will be omitted here.

The present exemplary embodiment ofFIG. 12Aincludes two light emitting devices2aand2bwhileFIG. 12Bshows its modification where three light emitting devices2a,2b, and2care arranged. When compared with the case where the spacer4having a circular opening is used as in the fourth exemplary embodiment, the cavity opening of the semiconductor light emitting apparatuses ofFIGS. 12A and 12Bis wider. This configuration can simplify the shape and arrangement of the electrode pattern. In other words, the wiring accuracy of bonding wires8can be alleviated, thereby improving the process yield of the production.

Sixth Exemplary Embodiment

A sixth exemplary embodiment of the semiconductor light emitting apparatus of the present invention will be described with reference toFIGS. 13A and 13B.

The semiconductor light emitting apparatus according to the present exemplary embodiment as illustrated inFIGS. 13A and 13Bis configured to have another electronic circuit device such as a protection diode10arranged in the space where the light reflecting member3is to be arranged between the rear surface of the light emitting device2and the spacer4. The protection diode10can be connected to an electrode pattern9avia a wire11.

The semiconductor light emitting apparatus of the present exemplary embodiment and the method for manufacturing the same are the same as the second exemplary embodiment. Accordingly, the description for the other features will be omitted here. The protection diode10and the wire11can be arranged at the same process at which the light emitting device2and the wire8are arranged, and then a wire bonding operation is performed.

After the wire bonding operation, the resin material for forming the light reflecting member3is filled in or coated to a predetermined space between the spacer4and the rear surface of the light emitting device2. In this instance, the space in the rear of the light emitting device2contains the protection diode10, so that the light reflecting member3can bury the protection diode10. This configuration can facilitate the effective space utilization within the cavity, thereby achieving the production of compact semiconductor light emitting apparatuses.

Seventh Exemplary Embodiment

In the previous first, second, and fourth to sixth exemplary embodiments, the light reflecting member3is arranged to be in contact with the light emitting device2and the spacer4. In the seventh exemplary embodiment, as shown inFIG. 14, there is a space12between the light reflecting member3and the spacer4.

Even when there is the space12as shown inFIG. 14, the light reflecting member3is in contact with the rear surface of the light emitting device2, and accordingly, the light reflecting member3can reflect the direct light at the rear surface to the inside of the light emitting device2.

The light reflecting member3forming the space12inFIG. 14can be formed by filling or coating the resin material having been adjusted in thixotropic property and/or viscosity by a dispensing method, a printing method, or the like. InFIG. 14, the light reflecting member3is illustrated to have a square cross section, but the present invention is not limited thereto. As inFIG. 1, the cross section of the light reflecting member3may include a raised surface.

A light source apparatus for an edge-lighting type backlight can be configured by utilizing the semiconductor light emitting apparatus according to any of the foregoing first to seventh exemplary embodiments as described above.FIG. 15illustrates a liquid crystal display apparatus50according to the present invention. The liquid crystal display apparatus50can include a liquid crystal panel30, a light guide plate40disposed in the rear of the liquid crystal panel30, and a semiconductor light emitting apparatus20according to the present invention disposed near the end face40aof the light guide plate40. In this configuration, the semiconductor light emitting apparatus20can be disposed so that the light projecting outlet6faces the end face40aof the light guide plate40. It should be noted thatFIG. 15does not illustrate required wirings, controlling devices, and the like but only the optical system for facilitating the understanding of the present invention.

As described above, the semiconductor light emitting apparatuses20of the exemplary embodiments have the shortened optical path length passing through the sealing member7, thereby enabling them to emit light with high intensity. The high intensity light can enter the end face40aof the light guide plate40, and propagate therethrough to illuminate the liquid crystal display panel30, thereby providing a bright liquid crystal display apparatus50.

In the above-described exemplary embodiment, it is described that the spacer or side member is configured to surround the light emitting device so as to have a single light projecting outlet. However, the present invention is not limited thereto. For example, instead of the spacer4having a semi-circular or square opening, two planar side members can be disposed both sides of the light emitting device spaced apart therefrom, and a resin material for forming a light reflecting member is filled in or coated to spaces between the light emitting device and the respective side members. Then, a resin material for a sealing member is filled in or coated to the remaining areas, and a resin material for a ceiling member is covered to the top of these members. Thereby, the semiconductor light emitting apparatus can emit light from both sides of the light emitting devices where the side members are not provided. In this configuration, the optical path length passing through the sealing member can be from the front and rear surfaces of the light emitting device to the respective light projecting outlet, thereby preventing the light from attenuating due to the sealing member.

In the above-described exemplary embodiments, one, two, or three light emitting devices2are arranged with respect to a single light projecting outlet6. However, the present invention is not limited to these features. The semiconductor light emitting apparatus can include an elongated slit-shaped opening in one direction, along which four or more light emitting devices are aligned in line to face the opening.

EXAMPLE

A description will be given of an exemplary semiconductor light emitting apparatus of the present invention.

As the example, the semiconductor light emitting apparatus ofFIG. 4in accordance with the first exemplary embodiment was manufactured. First, electrode patterns9aand9bmade of copper foil were formed on a glass epoxy substrate1. A spacer4having a circular opening with a diameter of 1.7 mm and made of glass epoxy was fixed on the substrate1by an adhesive as shown inFIG. 6A. In this spacer4, an Al film had been formed on an inner wall of the opening. Light emitting devices2were disposed at predetermined positions within the opening area and die-bonded. It should be noted that the distance between the rear surface of the light emitting device2and the spacer4was set to 0.4 mm.

The top electrodes of the light emitting devices2were connected to the electrodes on the electrode pattern of the substrate1by bonding wires8.

A resin material for forming the light reflecting member3was prepared by dispersing titanium oxide particles having a particle diameter of 200 to 300 μm in an amount of 50 wt % in a silicone resin. The resin material was filled in a space defined by the light emitting device2and the spacer4by a dispensing method. In this manner, an uncured light reflecting member3was formed as shown inFIG. 6B.

Next, a resin material for forming the sealing member7was prepared by dispersing YAG phosphor in an amount of 10 to 20 wt % in a silicone resin. Then, as shown inFIG. 6C, the resin material was filled in a space around the light emitting device2.

Thereafter, the assembly was heated in a furnace to cure the resin materials for the light reflecting member3and the sealing member7.

Then, a resin material for forming the ceiling member5was prepared by dispersing titanium oxide particles in an amount of 30 to 60 wt % in a silicone resin. The resin material was coated over the top surfaces of the light reflecting member3and the sealing member7, and heat treated to cure the resin, thereby forming the ceiling member5as shown inFIG. 6D. Finally, as shown inFIG. 6E, the assembly of these components was cut at the center position of the cavity defined by the spacer4vertically with respect to the surface of the substrate1where the components are symmetrically arranged. Accordingly, the individual semiconductor light emitting apparatuses were separated. In this way, the semiconductor light emitting apparatus of side-view type having the light reflecting member3was manufactured.

As a comparative example, a semiconductor light emitting apparatus was manufactured in the same manner as the previous example, except that the light reflecting member3was not provided and the sealing member7surrounded around the light emitting device2entirely.

The obtained semiconductor light emitting apparatuses of the example and comparative example were determined in light intensity measured at the light projecting opening. The measurement revealed that the light intensity of the example was increased by approx. 20% higher than that of the comparative example.

It will be apparent to those skilled in the art that various modifications and variations can be made in the presently disclosed subject matter without departing from the spirit or scope of the presently disclosed subject matter. Thus, it is intended that the presently disclosed subject matter cover the modifications and variations of the presently disclosed subject matter provided they come within the scope of the appended claims and their equivalents. All related art references described above are hereby incorporated in their entirety by reference.